new '07 500, clunk clunk clunk

[tlcasper]

I have a new '07 500EFI, it makes a clunk on most take offs and when going at a crawl it often goes clunk, clunk, clunk as it moves along, not always but sometimes. When backing into the garage as soon as it hits the pavement, it does a steady clunking at crawl speeds, if I go a little faster it stops. Forward or back on pavement at a crawl it clunks. Kind of the same clunk as when you put it in park. The dealer says that it's just the normal sound of the clutch on this model, but I think it sounds closer to the transmission.
I also have a '01 Sportsman 500HO it has never made any sounds like this.

Anyone else get this? Or any suggestions would be appreciated.

Thanks Dave

[MrBill]

You will get a clunk when you get on the gas and you will get a clunk when you let off the gas. It is the driven clutch shifting from drive to EBS.
Did your 01 500 have EBS? if not this is why it didn't clunk.

[tlcasper]

The '01 has EBS, and has never made this clunk.
So other people have this too?

Dave

[MrBill]

If you look at item 17. Those two little dog ears shift forward and backward. When they shift it will clunk as it hits the stop.
Some clunk louder than others. I don't even hear mine anymore.

If you jack up the rear end and put it in gear you can spin the rear wheels back and forth and hear that clunk.

Most all Sportsman do it. The 06 and up 700 and 800's don't do to a newer driven clutch. As you can see below very different. Item #8 is rubber thus the clunk is dampened from the drive to the back shift.

[MrBill]

One other thing is with the 500's your trans. and rear diff. are all in one and you will get alot of back lash in that also. it's just a 500 thing. No problems.

[Ken]

One other thing is with the 500's your trans. and rear diff. are all in one and you will get alot of back lash in that also. it's just a 500 thing. No problems.

The godfather has spoken.

I actually had the shop in Moab call me to the back..."I think there's another problem"....I started to move, and CLUNK. "THAT"S IT!". Uh....that's normal.

[tlcasper]

Thanks guys that make what is happening clear. I still don't think it should make a noise like that, Maybe I'll raise the roof a little an see it they will extend the warranty for me.

With that said I'm liking the new bike, the EFI and better mud protection really help. Lots of mud where I ride and those cold damp Canadian mornings, no more playing with the choke .

This is the third Sportsman 500 I have owned, the first was a '97, I think that was the second year out for the 500 4 stroke, I traded it for the '01 witch was a big change, EBS, HO it just had so much more power, Although back in '97 that 500 sure turned heads. Now I have kept the '01 and added the '07, the wife and kids get the '01 .

Thanks again for the help.

Dave

[Ken]

Really...don't worry about. That's exactly how it works.

It's like worrying about a whine in your turbo.....

[tlcasper]

Sometimes I need a little "WINE" for my turbo.

Dave