04.5 SP700 EFI Rear Driveline Clunking Help?
 

A friend of mine brought his 2004.5 Sportsman 700 EFI over last night with what feels like a bad U-Joint coming from the left rear of the machine. He stated he had changed Boot on that side about 3 months prior but swears he cleaned it out completely. Had a stick drive itself through the boot. It only does it on the low end: when taking off or traveling 5mph or less.. You add some speed and it goes away. It worsens when turning left on the machine... I tore both hubs off and could not see any damage there... Took both drive axles off... and can not feel any damage within the bearings.... Tonight I will take the boots off and check the bearings on the left side first to check them...

I have never had a CV bearing go out... but someone must have had a similar experience?
Things I should have checked prior are the Belt and Clutches... but told myself it has to be in the driveline. Like I said... It feels like a U-joint going out the way it clunks at slow speeds.

What should I look for on the CV knuckle as far as damage?

Jon

04.5 SP700 EFI Rear Driveline Clunking Help?
 

Are you sure you are not hearing just normal drive line slack? Polaris's are natorious for these type of noises as they do use conventional U-joint instead of CV joints in the drive line?

04.5 SP700 EFI Rear Driveline Clunking Help?
 

Positive it's not the normal drive-line noise...
I will be pulling it apart in 2 hours and will post back what I find...
Thanks for the Reply...

04.5 SP700 EFI Rear Driveline Clunking Help?
 

That's odd I will quirious as to what you find.

04.5 SP700 EFI Rear Driveline Clunking Help?
 

Well after changing the outer CV Joint for $150.00 I put it all back together just to find out that it didn't take care of the whole problem... Going to go after the inside CV Joint tonight... unless my Polaris Mechanic can find something else... I gave it to him today to diagnose the problem through another set of ears... After cleaning the outer CV joint... I did find 2 ball bearings that seemed to be locked into place... so I am hoping that it is all wrapped into that axle shaft and not something out of the ordinary... Like the otherside or something.

Keep You Posted!

04.5 SP700 EFI Rear Driveline Clunking Help?
 

My Polaris mechanic just called... seems I was on the right path... but strayed from the trail... I changed the outer CV Joint and should have changed the Inner one... He told me it was a mistake they make a couple of times a year too... I guess it was an honost mistake... Anyway... it's back to the shop tonight to change out the inner CV joint and have a few beers with the guys... and this story will continue tommorrow.....

Jon

04.5 SP700 EFI Rear Driveline Clunking Help?
 

Got IT!
Replaced the inner left hand CV Joint and the problem is gone...
I will diagnose the parts and try to find the cause of the failure when I get time...
For now my friends wheeler is up and running strong...
I have about $450.00 into both CV Joints and 1 Boot and CV grease....
More in labor....
The dealer did say that you can buy the whole drive shaft complete for around $350.00 but I was 1 CV joint into already!

Something to think about?