I have an 05 sportsman 800 that had new rear axles put on not too long ago due to an occasional click. The axles were put on under extended warranty. I believed the clicking was a cv joint. The clicking still exists after the new axles. Dealer told me the axles were fine but replaced them anyway. It is only noticable when you get on or off the machine. If you rock the machine side to side both sides click at he back. I assume it is somewhere in the suspension, but where? It does not click that I can hear while moving ( accelerating/slowing). I washed it today and it sounds like it got worse. What is it?

 

did they check the wheel bearings when they replaced the alexs? sometimes a bad bearing going will actually make some what the same kind of sound. did you try pushing grease intothe suspenion parts to rule out certain areas? just a couple of ideas

 

It could just be something somewhere rubbing or binding just a hair. You say that it got worse after you washed it is what makes me think this. If it is axles,cv's,or bearings it should click faster/slower with a change in speed. I'd grease everything good like Stendori mentioned....I'm bettin' you're guess is right,prolly suspension. If grease doesn't do the trick maybe spraying the springs etc. with some kind of dry lube would do the trick.
My machine makes weird noises sometimes just by shaking it or climbing on/off.

 

check rear sway bar bushings. Had it happen to mine, although I heard the click when riding. Just a thought

 

you should be able to pin point it fairly easy if its the suspenion just by doing some move ments sitting still.

 

My 06 Hawkeye does exactly the same thing. Haven't found it yet, but goes away for a bit when I tighten all the frame/sub frame bolts. Comes back after a few hours of riding.

 

Today the noise is gone. Simple fix. I did not do anything. I am guessing it will be a temporary fix though.

 

take a beater and tap down on the coils just a tad. mine come unseated and do the same thing if i get too crazy jumping fieldplugs. not sure how to permanently fix it, but this seems to work for me until i go nuts again.

 

Thanks. I bet thats it. I keep mine on a stand with the tires off the floor.