Ok her goes. I have been given the same answers by different dealers. The problem is when I am riding my sp in 2 wheel drive in high gear I hear a clank when I go over a few bumps in the road. I is when I back off the throttle a little. If I give it gas it goes away. It appears it is the clutch and the transmissions. The only thing is that it has a noise that sounds like gears clashing and I can hear it. My warranty ran out and now I am concerned that my transmission is going to fail. I have been told by Polaris that it is normal. Is there anything I can do to get rid of the noise. possibly shim the transmission or replace the rear drive line from the transmission to the rear differential. Does anyone know what to do..thanks

 

Mines always done it. You think it sounds bad now, let it coast down a steepish hill with a bunch of rocks on it, or get off the gas on a rocky terrain at decent clip...

*edit*
Coming up on 65 hours and 600 miles, been doing it since I got it.

 

Mine has also done it since I bought it now it has 1400 miles on it. How can we get rid of that terrible noise..

 

Dunno, to be perfectly honest it's part of why I'm getting rid of it. Sounds way to narly trying to slow down a hill and its making a clapping noise whole time.

I do not think it's a bad thing for the machine, getting rid of it for other reasons (trading for a spots quad+ cash on his end), but that was actually one of them.

My only guess is whatever does the actually engine braking for the clutch is what's making the noise.

 

I had an 08 800 too and just recently traded for an 08 Outlaw 525 IRS. Mine made the same noises and I had 950 miles on it when I got rid of it. It is normal, even though it sounds terrible..

 

My 07 Sportsman 800 does the same thing. Lots of noise and clanking going on. Seems like they are just inherently noisy machines.

 

What kind of deal did you get on that? Straight trade, get cash, paid cash?

 

Straight trade. Only paid for the dnr licensing. :-)

 

i have had an 06' and now an 08' 800 and can tell you part of if not most of the noise is drive line back lash( which for polaris is normal) and part of the noise is from the transmission drain plug being too long and rubbing on the chain inside the tranny case.
as you can see by the picture the side is worn alot so i had to grind it down some to stop it from hitting. took some of the noise away put still has some.

 

Pretty decent. We have a couple 08 525 IRS's at couple dealers. Wanted 4k or so for them and was gonna straight trade me but wanted money to get a cheap older 4x4. Ended up finding a 06 pred cross country limited edition with under 7 hours +2k cash. Comeing to my door from 4 hours away week from tomorrow. LONGEST WEEK AND HALF EVER lol. Just want something lighter, fast, and want the shifting responsibility to make it more interesting.