I have a 1995 300 4x4 which I bought in August and don't know too much about it's history. Tonight while riding it in my back yard I noticed a random clunk which seems to be coming from the transmission / chain area. It occurs only seldom and seems to happen when the rig has to work hard such as going up hill. Since it was dark I couldn't see whether it is chain or sprocket related or if it is related to the transmission. I will take a closer look tomorrow but my question is does anybody have any ideas as to the possible problem. Thanks!!

 

sounds like the silent chain in the gear case is stretched and slipping. if your drive chain/sprockets all look good and your carrier bearings are nice and tight i would tear into the gearcase to replace that chain. not a hard job to do but you have to remove the gearcase from the frame to do the work

 

Thanks very much. It was my impression from the sound that it was a chain slipping. When I have daylight tomorrow I will look and see if there are any chain or sprocket issues externally or not. It could very well be that my rear chain which appears quite old could be streached and under tensioned (I hope) and that is what is causing the noise. But your suggestion seems pretty plausable too. I'll let you know what I find out. Thanks again!!

 

check out both sprockets on the rear chain for missing teeth, if you have to replace anything do the chain and both sprockets so everything will mesh and wear correctly.

 

You have a '95 300. What model is it?

 

According to everything I have been able to find, including the owners manual it is a Polaris 1995 300 4X4. No specific model name listed.

 

I checked my rear chain and it is very loose. I had replaced the other two chains several weeks ago and didn't get to the back chain yet. I had adjusted my rear shock stiffer and don't know if that has any impact on the rear chain tension or not. By the slack in the rear chain I am guessing that the clunk is in fact the rear slipping. Without taking the chain off I can't be sure about my sprockets but they seem intact the best I can tell. I'll replace the rear in the next few days and will adjust the tension accordingly. Thanks for all the help and I'll post how I made out.

 

I have a question regarding my 95 Polaris 300 4x4. Is the hole on the frame under the bearing plate on the transmission output shaft (right side) big enough to allow the rear chain's forward sprocket to be removed? Any help would be greatly appreciated!!

 

POLARIS in their infinite wisdom sometimes makes the hole slightly small to get sprocket in! When first built,trans is placed in frame with inner sprocket on,then bearing,then outer sprocket. I usually encountered this on older machines such as the 89-92 models,BUT you may have clearance! IF NOT,just ream out hole enough to allow sprocket in,DOESNT take much!

 

OPT,

Thanks for your reply. I was able to get the 13T sprocket through the hole without too much trouble but couldn't get by the bushing on the swing arm so I had to take the bushing off which wasn't too much trouble. The sprocket fits fine and I adjusted the rear eccentric to get the new chain connected. As I mentioned earlier in this post the initial problem was a loose chain. For some reason the chain I took off had a connecting link attached to the master link. I'm not sure why that was done especially in conjuntion with the 12 tooth sprocket that was installed. I can only guess whoever installed the chain thought it was easier to add a link then it was to adjust the eccentric to join the chain. In any event I will adjust the chains today to the specifications as listed, my understanding 1/4 to 1/2" deflection, the rear 1 1/4 to 1 1/2 uncollapsed, 1/4 to 1/2 fully collapsed. If you have any advice or other opinions regarding chain tension please reply. Thanks very much!!!