[RedZ1K]

For the last while I've had a clunk from somewhere in my drivetrain.  I originally thought for sure it was from the rear diff, but now I'm not sure if it's the diff, the transmission, or maybe even the secondary clutch.  It does it upon engagement when I'm taking off if I don't ease into it super carefully, but also does it pretty bad when I'm coasting on a rough hill, and not using engine braking.  If I keep the clutch engaged to use engine braking it seems fine.  It's almost like there's too much play somewhere in the driveline.  If I rock it back and forth by hand while in park there is a bit of a clunk but not as bad as when I'm driving it.  It works fine when moving at any speeds, it's just the initial point of take off (and the coasting down hills).  All diff bolts are tight, and it doesn't move.  I feel like it started after I had some gears and the shift forks replaced by dealer (known problem with some 2018 1000s, causing it to not engage in gear properly and grind), but I can't really recall. 

Also, as of yesterday I sometimes get a single chirp out of the belt on take off, it has never done this before.  Is the chirp a sign I need a belt, or something else?  I just rolled over 3000kms yesterday and I have not touched anything in the clutches, dealer has probably been in there when doing the mentioned repair but never changed a belt.  I should probably pull the CVT cover to check things out and clean it up, but I'm kinda curious if any of you fine folks have an idea of what I have going on with the clunking, or if I should just send it back in to the dealer (not what I really want to do yet, because I'm afraid they'd have it for weeks possibly and I'm running out of time to use it before the snow flies and the trails around here become groomed sled trails).  Thanks

[NMKawierider]

Being that it's a 1000 and the dealer has been in it..deep, I would first pull the clutch cover and the clutches, do a complete inspection and cleaning cause if they didn't get the primary on correctly, not only can that be the source for the clunk but it also could be destroying your crank shaft. Heck even a loose secondary could be doing that and destroying it's shaft.

The other thing I wanted to mention was the I and most other 800 owners have a loud clunking when starting off but it usually stops after warned up. Part of this is the loose coupling mechanism they use between the rubber mounted engine and the solid mounted rear gear case. Mine is very loose and always has been. My rear gear case is also slowly chewing up aluminum which I assume is the case from a spinning bearing race or something but I am going to let it go until it breaks, then replace the complete unit.

Anyway if your clutches are all good and there isn't any leaking seals tossing oil onto the belt, then the squeel is a sign of glazing and my need replacing if a good rub-down with a scotchbrite pad won't clear it off or it's warn down below the minimum width.

Might also check the front driveline and all it's bolts as well as the rear yoke and parts. 

[ctdls]

Follow NMK's advice, when your dealer goes that deep into a repair unfortunately new problems may be created. Most manufactures have learned doing it right the first time is the least expensive way to build......this one hasn't figured it out. Then they chisel the dealer so you may not have the best tech's on the repair & working on a time constraint.

If I remember correctly the 2018's had recall on the drive clutch retaining nut. When you have the clutch cover removed, elevate the unit off the ground & run it so you watch & listen.

[RedZ1K]

Thanks for the ideas guys.  I'll pull the belt cover off and check things out this week, and go from there.  Any tips for doing it, like do I have to (or should I) remove the inner plastics to ease access to it?  Any secrets to pulling the clutches if I go that far, or can they be cleaned/inspected while in the machine? I've looked over that rubber driveshaft coupler already and it seems like it's fine, good and tight.  I don't think it's anything in the front end, I can hear it from somewhere behind me and most of the time I'm in 2wd anyway.  I'm hoping it's nothing internal in the transmission or diff, but if I can't find anything I'll take it in and let them sort it out.  Just don't want to be without it for an extended period of time, at least not until winter hits. 

[NMKawierider]

Thanks for the ideas guys.  I'll pull the belt cover off and check things out this week, and go from there.  Any tips for doing it, like do I have to (or should I) remove the inner plastics to ease access to it?  Any secrets to pulling the clutches if I go that far, or can they be cleaned/inspected while in the machine? I've looked over that rubber driveshaft coupler already and it seems like it's fine, good and tight.  I don't think it's anything in the front end, I can hear it from somewhere behind me and most of the time I'm in 2wd anyway.  I'm hoping it's nothing internal in the transmission or diff, but if I can't find anything I'll take it in and let them sort it out.  Just don't want to be without it for an extended period of time, at least not until winter hits. 

Don't know the 1000 but I'm pretty sure taking the interior plastics off will be the way to go....but if you don't have the tools or equipment to do the job completely, then don't. Let them do it.

[chiaj144]

My 1000 has clunked when trying to take of since it was brand new. Especially when going from reverse to forward or visa versa. I also have a clunk when the rear suspension unloads. I think it's the design. As others have said, get the clutches looked at and cleaned at the minimum.

[Almoto]

have you tried using your hand brake when you stop. Try to keep load off the drivetrain when its stopped then when you resume and change gears its will be a smoother shift.

[chiaj144]

Hand brake wouldn't make any difference as I always use the foot brake. It's louder when it's cold. Seems to simmer down when I've been riding for a while.

[NMKawierider]

Hand brake wouldn't make any difference as I always use the foot brake. It's louder when it's cold. Seems to simmer down when I've been riding for a while.

Run it hard while under warranty until it breaks. Then you will know for sure.

[TJDJERRY]

My 1000 has clunked when trying to take of since it was brand new. Especially when going from reverse to forward or visa versa. I also have a clunk when the rear suspension unloads. I think it's the design. As others have said, get the clutches looked at and cleaned at the minimum.

Mine too.  I got it in May of 2018 and it's got about 2,500 miles on it now.  Little clunk if I ease into the throttle and big clunk if I nail it from stop.  Happens in both high range and low range.

[RedZ1K]

My 1000 has clunked when trying to take of since it was brand new. Especially when going from reverse to forward or visa versa. I also have a clunk when the rear suspension unloads. I think it's the design. As others have said, get the clutches looked at and cleaned at the minimum.

Mine too.  I got it in May of 2018 and it's got about 2,500 miles on it now.  Little clunk if I ease into the throttle and big clunk if I nail it from stop.  Happens in both high range and low range.

  Do you guys notice it when coasting down hill at all?  If I'm coasting down hills with any amount of bumps and I don't have it revved up enough to have the clutch engaged and engine braking I get it pretty bad.  Worse than the takeoff clunk.  It sounds and feels to me like theres too much play somewhere, like gear lash in the rear diff or something else.  It's kinda hard to explain.  It's better if I give it a shot to engage the clutch, it's just the play i can hear/feel when there isn't a load on the drivetrain.  Like a clank clank clank noise like something is loose somewhere (but nothing I've found yet).  It hasn't always done it, but it has for the last while now. 

[chiaj144]

I will try to copy what you are describing but I haven't really had mine on many hills yet and get back to you.

[TJDJERRY]

My 1000 has clunked when trying to take of since it was brand new. Especially when going from reverse to forward or visa versa. I also have a clunk when the rear suspension unloads. I think it's the design. As others have said, get the clutches looked at and cleaned at the minimum.

Mine too.  I got it in May of 2018 and it's got about 2,500 miles on it now.  Little clunk if I ease into the throttle and big clunk if I nail it from stop.  Happens in both high range and low range.

  Do you guys notice it when coasting down hill at all?  If I'm coasting down hills with any amount of bumps and I don't have it revved up enough to have the clutch engaged and engine braking I get it pretty bad.  Worse than the takeoff clunk.  It sounds and feels to me like theres too much play somewhere, like gear lash in the rear diff or something else.  It's kinda hard to explain.  It's better if I give it a shot to engage the clutch, it's just the play i can hear/feel when there isn't a load on the drivetrain.  Like a clank clank clank noise like something is loose somewhere (but nothing I've found yet).  It hasn't always done it, but it has for the last while now.

I try really hard to not coast down hill.  I keep a little throttle to keep the revs up so that it doesn't freewheel down the hill.  If it does take off on me, I give it more throttle rather than hit the brake.  Engine braking seems to work well.  I have no idea if it's bad for the machine or not.

[NMKawierider]

I try really hard to not coast down hill.  I keep a little throttle to keep the revs up so that it doesn't freewheel down the hill.  If it does take off on me, I give it more throttle rather than hit the brake.  Engine braking seems to work well.  I have no idea if it's bad for the machine or not.

Not bad for the machine at all. Keep it up and the brakes will last much longer.

[RedZ1K]

I usually do the same thing when going down hill.  It's a little weird giving it a shot of gas to slow down, and it scares my wife often, but it does work good and the engine braking holds on until a fairly low speed.  There are times when it just isn't really feasible though.  The coasting downhill is when I notice the noise the most because that's when I'm not usually on the gas, and chances are on a flat surface I'm either revved up enough not to freewheel, or going slow enough that it isn't really noticeable.  It's only rough surfaces too, if I were coasting down a paved hill I don't think I'd hear it but on an old wheeler trail, definitely.  I'm gonna go at it tomorrow and see if I can find anything.  Might even change my diff oil too just to see what it looks like.