I was out riding with a buddy of mine a few weeks ago and I was trying to clean the thick red clay off my tires by powerbraking and all of a sudden I hear a pop from under the seat. I got off checked the chain and had him watch the sprockets thinking maybe the chain had somehow gotten out of adjustment, but it wasn't and he said it looked like it came from the front sprocket. So I replaced the front sprocket(which was fine btw) checked for output shaft to sprocket play and there is none. It only makes the sound in forward and has got me irritated I've checked the shifter linkage from front to back and it rotates back and forth fully on the tranny. I drained the trans oil and there was quite a bit of stuff stuck to the drain plug and the fluid looked fairly dark. I ran out of daylight tonight to fill it back up and go for a ride to make sure it's still doing it. Does it sound like time to go through the tranny? or is there something I might be missing? ANY (almost ) ideas will be entertained....

 

it might be the silent chain in the tranny having slack and jumping the sprocket?

 

would it only do it in one direction tho? I can back up to a tree and gas it in reverse and not the first noise from the trans.

 

Could be as simple as a frozen,worn link on the drive chain or drive chain is too loose also if you didn't change it out. Just jack up the atv and while turn the back wheel see if the chain tightens up slack and then loosens up in the middle as it turns around. Lot of people overlook the drive chain itself. To check the silent chain out do as you've done,but run the front end up to a post and give it gas along with doing the same in reverse.Should grind if the silent chain is loose,plus have someone look at the drive chain itself while you're doing this to see if it jump on the sprockets. OPT

 

Will the silent chain make that "pop" sound in only forwards? Or will it do it in forwards and reverse? I'm not all together sure how exactly this type of tranny works as I've never been inside one(yet). I know when I try to take off(in fwd) with anything above a nice calm slow start it pops atleast once. I will check the drive chain in a few minutes and make sure it's not like you say.

 

Usually in forward because the gear teeth and silent chain links are used to going forward most the time,but I've see chains so worn out it didn't matter which way,would just go in gear(forward or reverse) and just grind. This is the worst case scenario. Just put a heavy load on it or against a post forward and reverse and you should be able to tell pretty quick. OPT

 

Also check to see if any rollers are broke off of the chain. My friend had that happen on his Sport 400.

 

well I'm not missing any rollers or any teeth from either sprocket.... I pulled up to a tree and hit the gas and pop pop pop pop..... I got off so I could watch the chain and sprockets and hit the gas and pop pop pop.... there was no slip from the drive chain or the front or rear sprockets..... how much damage could possibly occur from me going on a ride tomorrow?

 

Silent chain damage is usually progressive and gets worse over time as most owners told me that brought em in for repair,but I wouldn't ride alone or without a winch or rope! As far as actual damage the chain takes the brunt of it, but if the gear case is taken apart, inspect the small drive gear the chain rides on and the slider gear(dog gear) engagement dogs for any wear and sharp edges,replace if you have any doubt. The big drive gear run by the chain is tough,shouldn't be any problem there. Always replace circlips,don't reuse them on the gear shafts, replace case seals and check the bearings out for any rough play or noise. It's not that hard to replace a chain,just takes awhile to remove all the stuff to get the gear case out. OPT

 

Well the ride went well but the noise does get quite a bit worse with time. I was able to make it out and back under my own power but I'm going to be taking it apart this week so I can see what all I need to order. I haven't really looked at what i need to do to get the trans out but is there anything special that I'll need along the way or any hard-to-reach places during this process?