2004.5 sportsman 500 ho grinds at low idle
 

its idle is set to 1000rpm
it makes no noise in low or reverse
when high gear is selected the quad will roll a bit nothing major, at this time there is a sound that comes and goes seems from front of transmission that sounds terrible....
for example shift into high gear and give some gas to roll take off throttle and roll and then this sounds happens (clanking like gears not messed or chain rattle)
take off and drive normal all is well smooth as can be....slow down to a creep or almost stop and clunking noise again
primary,secondary, belt all new (well not new the originals have been swapped out to trouble shoot with my buddys 04.5 clutches) spline on output shaft looks and is tight as well as front u joint.....any idea from all you experts I really don't want to take out transmission yet
also I can duplicate it easy while on jack stands with quad running in gear and hold onto driven clutch at idle lowest speed tires barely turning any ideas or thoughts I have read a lot on here as well

the ebs bushing is getting worn out most likely. this causes the bike to grind in gear and creep forward. need to have the clutch removed and have the bushing replaced.

are you thinking the 1 way bearing? it spins free if turned by hand I tried some wd40 in it as well to see if that may help

See if the belt drifts over and touches the inner front clutch sheath. If it does it can keep the rear clutch spinning and have a load on it. Worn fiber and brass washers in front and rear of the one way bearing are the primary cause for this.

I will give those a try can they be replaced on the machine or does the clutch need to be removed?

Look at these posts on this and see if it helps.Clutch belt creeping - ATVConnection.com ATV Enthusiast Community

clutch needs to be removed and use special tools to take apart the clutch.

changed the bushings and installed a brand new belt, so far its working great thanks for tips guys

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