My 2004 Sportsman 600 has only been used for work around my place in the country. Mostly for pulling a mower and the Swisher dump bucket for removing manure and moving dirt and gravel. I always run it in low range, usually 4x4. It has about 110 hours on it.

The last time I used it, it was running great with no problems. When I went to use it a few days ago, I'm getting a knocking under acceleration in the area around the back of the engine and near the rear drive shaft. If I accelerate real slow, it doesn't do it, but the least bit of pressure will make it knock. I am hoping to get some ideas on what to look for before I start taking it apart.

 

I have a 2004 500 sports witht he same issue.
I took it too the dealer and he mentioned this is normal. I don't understand how it is normal but i checked with a few toerh people that also have 2004 500 and they say the same thing. I guess it is the way the engine was built.

 

I think I know the noise you're speaking of, but this is different. This problem definately causes power loss and performance problems.

 

If you have been pulling heavy loads there is a good chance you have burnt a flat spot on your belt.

Everytime this worn spot on the belt rolls around the rear clutch it will make a knocking sound.

Remove the belt and look closely for uneven wear or flat spots burnt in the side of the belt.

This only takes a few minutes and it is a good place to start.

 

sorry about your luck. My dad had the exact problem with his and it ended up being the drive saft where it connects to the diff. Two dealers said it would be 1700$$ to fix so we got rid of the machine. He too only used it around the yard for plowing and pulling in wood loads.

Good Luck I hope it is something else

 

if its only a noise when you 1st hit the throttle, its either the driveshaft, or the clutching.
ive heard where the clutches can make a bit of noise when engaging.

 

Thanks for the replys.....except CrashinIt. He had the one thing I didn't want to here. [img]i/expressions/face-icon-small-frown.gif[/img]

Hopefully I'll have time to take the belt cover off this weekend and see what's going on in there. I've been going to buy a spare belt anyway.

TJ700, the noise continues when you give it more throttle, and feels kinda like an engine miss..

 

Probably the belt, I will be checking mine too, as I
seem to be loosing power/performance (only 100 miles)
learned from other threads.

Whatever it turns out to be, I hope it is the
least of the issues mentioned and of your
worries, take care!

R'

 

Thanks, luck to you also.

 

i heard it all,how rediculos,where do you all come up with this stuff,go figure, a belt will make your ATV rattle,and knock, I've heard it all........