It says dont start it with the cover off. I guess there is alot hanging out unsupported when the bearing is not in place.

Powerslider- How would you describe the noise before you used the shim? Sounds like we found the same culprit. Did you try many shims and stuff in the largest you could?? I will measuere the one I put in out of curiousity. Your shim only touched the outer staitionary part of the bearing- right? Thats how mine is.

 

I forgot.
Even though the clutch isn't engaged the shaft still spins in the bearnig so yes it can be the clutch side making the noise. Next time I might try a large o-ring instead of a steel shim to help dampen the sound resonating against/from the case.

 

The noise to me was like a loose bearing ball rattling around at idle and slightly above. I made a shim to remove all the endplay from the bearing in the cover so it's snug. The shim only contacts the outter bearing race, it's outside diameter is the same as the bearing and I bored a hole in the center larger than the shaft. Hopefully the shim will stay rigid and not flex or wear. A wave washer would be the ticket but I don't readily have one that size. I thought about the o-ring too but I didn't think it would stay in place and it might be a chore to get the snap ring back in place. My shim ended up 20 or 21 thou (bad memory) anything more and the snap ring wouldn't seat in the groove. My brother-in-laws with half the miles of mine is starting to make the same noise so I think it will be pretty common. I ask my dealer to check with Polaris for a fix but they don't aknowledge the problem yet. I did get the new reinforced subframe at no charge....
The clutch or shaft doesn't spin until the internal clutch engages but it must vibrate enough to cause the noise. I had my primary apart and talk about a simple design, there isn't much to it. No spring just 8 rollers and the ramps, that little "T" tool that comes in the tool kit threads into the primary to hold the pressure plate and rollers together when you pull the outter clutch shieve assy. There is probably a special tool to separate the pressure plate from the splined shaft but I threaded the two holes in the plate and used a bar type puller to pop it off. To change the belt the secondary has three threaded (metric) holes that you can screw bolts into to spread the secondary clutch shieves then the belt comes off easily.....

 

Great info!!

I guess I stand corrected about the shaft turning at idle. When my cover was off and we were searching for the problem, my brother was watching while I started it and he said to shut it off quickly as soon as i started it because he saw it wobbling? Not sure what he saw if it doesn't turn in nuetral?

Did your bearing have a copper film inside where the shaft rests? Mine only has about 12 hours and it has what looks like the shaft wearing against the bearing.
The reason that I like the o-ring idea is that it should remain flexible and keep constant pressure. This should eliminate any wear issue. In additon it should allow you to squish it and get the clip to seat. I dont think it will move. A wave washer is a good idea but I am thinking the o-ring will absorb noise too.

If I find a good o-ring I can send you one if you like. I am pretty sure I can find one. I will also measure my shim and let you know the size.

I am just thrilled to know someone else fixed the problem the same way I did. Hopefully Polaris will admit to their poor tolerances in the future and make a proper fix themselves. My dealer wont even acknowledge their is a noise.

P.S. You described the noise better than I did. Very good explanation because thats how mine sounded. I thought the belt had came apart after my wife ran through some water. I tore into her about shredding the belt and when I opened it up (because i knew it wouldnt be covered under warranty) there was nothing even wrong with the belt.

 

With the shaft unsupported on the outside it may create a support/misalignment issue in the centrifugal clutch assy so that is maybe what you saw. The clutch spins with the shaft so if that were spinning all the time you couldn't shift the trans.
If you can keep the o-ring from shifting and possibly damaging the bearing seals it should work but I'm a bit leary on that. A rubber disc might be a better solution like my shim it shouldn't shift or collapse. I didn't have any discoloration on the end of the shaft where the bearing rides, I did lube it on reassy though....

 

Powerslider- I ordered the wave springs today and i should have them tomorrow. They have a thickness of of .017", which means they will be quite compressed, but the diameters were nearly perfect. I still want to buy a new bearing so it will be a little more time before I can install and test.

More to follow.

 

Cool. let me know how that works out.....

 

Well I got my wifes Hawkeye back from dealer. They put 8 miles on it and scratched the fender all up. Said nothing was wrong with it, thats how the PVT system sounds. I was hot, but just told the guy to get it the hell outside so I can take it home. I asked if the sound was normal then why didnt it make it all the time? All they said was 3 mechanics rode it and and they are all certified mechanics. I said I hope they didnt pay much for their training because I think they got ripped off.

Well I got it home and pulled the aluminum cover back off. I bought a new bearing just to be safe because I didnt want to take it apart for awhile.

I lubed the case with a light coat of bearing grease and placed in the wave washer. Then I placed the new bearing into the bore. I gave the bearing a push down into the bore and released it. The bearing pushed back out forcefully with a smooth action.
I placed the snap-ring down into the groove, but it would not seat completely, so I took the old bearing and placed it over the new one (with the snap-ring in between), and tapped around the old bearing with a hammer. I removed the old bearing and the snap-ring was completely in the groove.
I wanted to check my work so I squeezed the snap-ring. The wave spring did as intended and push the bearing out. Then I put it back together one last time.
I lubed the inside of the bearing and the shaft and put the cover back on. I fired it up and it sounded better than it ever has. My wife put about 5 miles on it and it still sounded great. I think it is fixed for good this time.

I did notice that the clutch will make a sound when you spin it by hand. Whatever was making a sound in the clutch might continue to make a minor sound, but the terrible rattle noise is gone.

 

It is very unfortunate that the dealer and Polaris think this noise is acceptable and normal when the fix is so simple, just doesn't make sense. Things of this nature surely don't build customer confidence or future sales.
Glad you got it corrected, I have 50 or so miles on mine since the shim install and all is still quiet.
Where did you get the wave washer from?

 

Powerslider-


Industrial Supply catalogue from work. I had to buy 25 pieces, but they are under $15 per pack. I can send you two in the mail if you want.

I noticed my Hawkeye has leaking oil on the cooling fins and its dripping onto the oil filter. Unit has 140 miles on it. I found a post on here about it, and now I can see that the problem was a defective or poorly designed cover plate on the engine. Yours leaking oil yet??