My 2001 500 HO just started making a loud clicking like noise in the transmisson area, it only does it when coasting slowly in gear, I can also make it do it if I jack up the rear and let it idle in gear and let the wheels spin then slowly apply the brakes, if anyone has any ideas please let me know, thanks in advance.

 

i've seen where the side of the silent chain rubs against the cases.
the one i did had a bad casting causing the chain to touch.

 

Sounds like a loose chain in the tranny to me but its not that hard to fix just a pain to get the tranny out.It could be the buttons in your primary clutch too.Try checking for the noise with the belt cover off.

 

Doesn't the Sportsman have a self-adjusting tranny chain???

 

the long rear chain has a tensioner, the small front one does not.
and the polaris's with ebs don't use platic buttons, they use plastic rollers, with are way less prone to wear or damage.

 

The machine has 2100 miles on it and the original belt, do you guys think that the belt could be slipping and grabbing at low speed coasting causing this noise ? I will check the secondary first as that will be easier than pulling the tranny, thanks for the info too.

 

Have you checked the belt? because if the belt is old some of the teeth may have broke off and the broken teeth could be getting in the way.
Check out the belt first, also if it is the belt, make sure that you get all the little chunks of belt from the tubes that come out of clutch cover.

 

I may have found the problem, I think the primary is sticking, there seems to be alot of slop in the movable sheave bushing, does anyone know how tight that bushing should fit ? also does anyone have the tourqe specs for all the different bolts on the clutches ? and how long are these clutches generally good for until a rebuild is needed ? hope I'm not being a pain with all my qestions, thanks in advance.