[Fuelfather]

2019 850HL, 2024miles and 221hrs. Applied 1/2-3/4 throttle while moving and get a popping noise, not every time. Same noise is occasionally hear when decelerating at low speed using only the engine and no brakes.

I can’t tell for sure if it’s coming from back end or from the transmission. I did kind of feel it in my boot, but was going down into a dry creek bed when it happened and may have pressed it tighter to the frame at the same time.

I did look at the rear shaft into the rear diff and it seems a decent bit of movement before engaging the driveshaft when I roll it, at least to me. Not sure how much backlash is considered normal. I am the second owner, so not sure what it was when new.

Not a ton of info I know, but all I have right now as I’m in the woods with no lift. It still runs and drives fine as long I roll into the throttle, and watch how I decelerate.

 

[FPD218]

Make sure the rear diff mounting bolts are NOT loose.

 

[Fuelfather]

All four bolts are tight, no sign of movement around them. Don’t ask me how I managed to have 2 15mm wrenches in my travel box, but I did.

 

[Polaris754]

sounds like a chain or spline gone bad

 

[Polaris754]

start draining fluids go there first sparkle's

 

[polman500]

Sounds like normal Polaris drive train play to me.

 

[Fuelfather]

I got under it out here at my deer lease, the play I thought I saw in rear drove shaft isn’t much. It does sound more like it’s coming from mid bike unfortunately. Was really hoping for rear diff as it’s much easier to access and remove.
Would I be better off with new drive chain sets, or transmission? Knowing me, I’m gonna replace all chains while I have it open anyways.

 

[crazyflyboy30]

I got under it out here at my deer lease, the play I thought I saw in rear drove shaft isn’t much. It does sound more like it’s coming from mid bike unfortunately. Was really hoping for rear diff as it’s much easier to access and remove.
Would I be better off with new drive chain sets, or transmission? Knowing me, I’m gonna replace all chains while I have it open anyways.

Replacing the chains is not a big deal and can be done without removing the transmission.
Check out Mud puppy videos on YouTube .
I answer any questions you might have because I replacing the gears , shaft ,sprockets and chains and bearings to SKF to make my Sportsman XP 1000 transmission same as a 2022 Highlifter .
And I did it with the transmission still in the frame.

 

[Fuelfather]

Given the hours and miles on the bike, would y’all recommend replacing bearings in the transmission? If so, would the transmission have to be removed to do so?

 

[crazyflyboy30]

Given the hours and miles on the bike, would y’all recommend replacing bearings in the transmission? If so, would the transmission have to be removed to do so?

How many miles do you have?
I don't think that the OEM bearings are bad and seen others posting having 8000 miles with no problem but the are China and I like SKF and think that they are the best so replacing all my bearings with SKF when I in there replacing everything else.
And the transmission is easy to work on with it in the frame and no doubt a lot quicker than complete removal then taking it apart.
Just need a bearing separator to pull the bearings off tht shafts and it also works fine to push them back on with to just need something to push on the inside race so you don't damage the bearing .
I modified one of the old bearings of each different size.
If you need to part numbers Partszilla shows the size of the bearing so that you can get them in a different brand like SKF.
And unless you're just getting OEM bearings the other brands come with or without seals so get the ones with no seals is better to start with than having to remove them .

 

[Fuelfather]

Ok, so I finally had a little bit of time to start the removal of plastics.

I then removed the rubber vent hose from the clutch cover and look at the rear drive shaft checking for play in the u-joints and rear diff input. The question I have now is, is there supposed to be a bolt or pin in the drive shaft yoke going to the transmission output shaft? There is a little play between the yoke and output shaft.

Will post more as I get further into it. Still kind of hope it’s the rear differential, still seems odd, to me anyway, that both forward and reverse chains would start to slip at the same time. Only my second ATV, and the first one I’ve ever owned with this many miles.

 

[crazyflyboy30]

Ok, so I finally had a little bit of time to start the removal of plastics. View attachment 176327

I then removed the rubber vent hose from the clutch cover and look at the rear drive shaft checking for play in the u-joints and rear diff input. The question I have now is, is there supposed to be a bolt or pin in the drive shaft yoke going to the transmission output shaft? There is a little play between the yoke and output shaft.

View attachment 176328

Will post more as I get further into it. Still kind of hope it’s the rear differential, still seems odd, to me anyway, that both forward and reverse chains would start to slip at the same time. Only my second ATV, and the first one I’ve ever owned with this many miles.

No pin in rear output shaft and a little play is normal.
The main chain is used for forward and reverse and is known for problems and if you have a problem with the reverse chain is just breaks and doesn't do anything.

 

[Fuelfather]

Any links for a clutch removal tool?

 

[crazyflyboy30]

Any links for a clutch removal tool?

POLARIS SPORTSMAN 850 & 1000 SCRAMBLER PRIMARY CLUTCH PULLER drive TOOL 550 | eBay

 

[crazyflyboy30]

Polaris years ago put a chain tensioner in some transmissions.

 

[Fuelfather]

Well, the chains came in today, I don’t know why, but I kind of expected them to be bigger than they were.

The clutch removal tool package came in, sadly the tool wasn’t in the package, not their fault as the packaging looks like it was damaged in transit. I reached out to the seller, after hours as that was when I got home from work, and they said they would have a new one sent out Monday when they open.

 

[crazyflyboy30]

Well, the chains came in today, I don’t know why, but I kind of expected them to be bigger than they were.

The clutch removal tool package came in, sadly the tool wasn’t in the package, not their fault as the packaging looks like it was damaged in transit. I reached out to the seller, after hours as that was when I got home from work, and they said they would have a new one sent out Monday when they open.

Did you get the bigger RZR reverse chain?
I put one in my Sportsman XP1000 and it cost like $290 and partnumber .3235633

 

[Fuelfather]

No, I almost never use reverse where I ride. Usually only to get out of the garage or off the trailer. I thought about it though.

If I do decide to do so in the future I’ll probably get one from Dirty3rd.

 

[crazyflyboy30]

No, I almost never use reverse where I ride. Usually only to get out of the garage or off the trailer. I thought about it though.

If I do decide to do so in the future I’ll probably get one from Dirty3rd.

With me it's a safety issue because I ride the hardest trails but sometimes it gets to ruff and one day messed up and when down a insane steep hill and got about half way down and it was dugout so bad where SXS couldn't climb it so I had to back up the hill and I was so scared of not only flipping but also my reverse chain breaking.
I guess you don't use your Highlifter for mudding or you would need to back out of a bad hole from time to time.

 

[crazyflyboy30]

No, I almost never use reverse where I ride. Usually only to get out of the garage or off the trailer. I thought about it though.

If I do decide to do so in the future I’ll probably get one from Dirty3rd.

Yes I checked out the Dirty3rd customs and a good deal on the bigger reverse chain if it's has good has OEM but the main chain they are $25 more than Partzilla.