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Discussion Starter #1
Hi there,

My 2008 Sportsman 800 EFI has a clacking noise from the rear recently, about twice a second depending on speed, and in reverse it's louder than going forward.

I took a look underneath; there's a leak from the rear gearbox right axle, and it appears the axle is a bit further from the gearbox than the other side:

136045


Compared to this side:

136046


Is it the axle seal and it's just making noise because it's low on fluid? Something more serious? Any suggestions on where to begin?

Thank you!
 

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Unless the case is broken, the only thing there that could leak is the axle seal. Noise could be due to another issue inside that causes the seal to leak though. I would check the level and depending on what it looks like drain the old out and check for filings. No matter what, you should probably replace the seal.
 

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Time for a rebuild!! Bearings and seals!!
 

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Discussion Starter #4
Thanks guys.

I found two kits that say they work, it looks like the boss bearings don't have the needle bearing. Which one do you guys suggest I jump on? Perhaps it's been replaced with the teflon ones. Thanks

Ebay:

Boss Bearings:
 
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