[Gregor]

The wife and I went to a ride yesterday and not even a mile into the trip we started having issues. It sounded like metal hitting metal when we started up a hill and didn't make it to the top because the machine stopped. Its like the drive shaft is slipping and not getting power to the wheels.  We had it towed back and it is currently at the dealer where I bought it from.  Has anyone else had an issue like this? We have only put 31 miles on it and got it new, I was told at the dealer that what ever the issue is it definitely was not anything we did and it will be covered under warranty.

[NMKawierider]

Not much in the way of reports from 500 owners on driveline issues but some 800 owners reported some carrier bearing and/or retainer issues..but not so soon.

[Gregor]

The mechanic said he hasn't heard of any issues and couldn't really find any posts on here. I am just glad that it happened while we were on a group ride where there were other people to help tow it out.  The other time we took it out it was just us and that could have made for a long night walking home to get the other 4-wheeler to tow it home.

[NMKawierider]

The mechanic said he hasn't heard of any issues and couldn't really find any posts on here. I am just glad that it happened while we were on a group ride where there were other people to help tow it out.  The other time we took it out it was just us and that could have made for a long night walking home to get the other 4-wheeler to tow it home.

Oh I know the feeling. I go out by myself sometimes but only as far as I care to walk back...but lately I'm getting where I trust it more and more and worry about it having an issue less. It's actually been consistently reliable on every trip so..that's starting to count for something...lol. Hope they get it all sorted out..probably forgot to tighten something at the plant...

[Gregor]

Thats what we are thinking, just really frustrating since it was the first time taking it somewhere and we didn't get to ride.  I am just hoping that they get it figured out/fixed quick. I want to get some miles put on it so if there are any other issues we find them now.  We usually take about 5 or 6 trips throughout the summer for long weekends and whatnot and don't want to be running into issues.

[Wheels]

I'm gonna go out on a limb as say the cv primary clutch hat came off the splines. Or stripped them out.

[Gregor]

I am guessing this is not a normal problem for them? Sounds like you have some knowledge on the internals of these, how bad could the damage be?

[Wheels]

The 500HO/550 has a known problem with the nut tightness on the primary clutch. Thou this was on earlier models.
Dealers where told to remove the nut lock tight it and re-torque.
If not done correctly the hat has a chance of misalignment and the hat and washer would not lock on to the clutch spline.
Or it could be the output shaft
Or it could be the Rear Diff.
Were you in 4x4 or 2x4?
Could you move it while in gear?
Really without seeing it is hard to say, but I am leaning to the Primary clutch hat, Next would be Outputshaft, then rear Diff.
I did see a rear Driveshaft strip out the splines. So anything is possible.
Keep us posted.

[Gregor]

It did it in both 2x4 and 4x4.  4x4 seemed to work better than 2 wheel but slowly got worse. It looked like the driveshaft was being pushed out towards the rear wheels when giving it gas. As soon as I hear what the issue is I will post it.

[Wheels]

That said, I'd be looking at the output shaft.
But very hard to diagnose online.
I have a few hundred hrs working on this model.
seen some funny things

[Gregor]

It has been a crazy week but the dealer called me monday around lunch time and they have found the problem.  They said there is a retention spring in the rear end that is supposed to hold pressure on the drive shaft to keep it in place, it was missing.  They are pretty sure that it was never installed when it was assembled because they could not find it.