Question about Polaris ATV

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I have a 2003 Polaris trail boss, when new at idle it would clatter, as it warmed up it would go away, Polaris dealership said this was normal, as time went on it took longer and longer for the clatter to quiet down finally it clatters all the time at idle, I took it to 2 different dealerships they agreed it sounded bad but had no clue as to the problem, I pulled the top end apart and found everything perfect as it only has about 600 mi. on it. one thing I found was that the timing sprocket on the crankshaft would move back and forth about a eight'h of an inch, polaris mechanic said this was normal! I put back the top end with new rings and the sound was still there. I decided to pull the motor for a full tear down because the noise was down low. when I took off stator the large nut that holds the timing gear to crankshaft was loose and the key in the gear was loose, could this be my clatter? as I metioned earlier the gear would rock back and forth, this seemed odd to me as I have worked on many cycles and never seen a loose timing gear before! any help would be appreciated, thank's Pat

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  • chopperthurm Jan 03, 2011

    I guess what I need is a answer as to if the nut holding the crankshaft sprocket on needs to be torqued down or should be loose? this seems to be a likely suspect as to the rattle or clatter. thanks Pat

  • chopperthurm Jan 09, 2011

    I'am not sure what well ok means but the second tec answered my question, your answer was not even helpful!



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All nuts on the crank shaft are supposed to be torqued and pat i noticed one other thing while i was reading your post you pretty much have answered you own questions what size is the engine on the polaris that you have and any numbers that you happen to have off the engine would also be of benefit in turn i can look up the exact torque ratio on the crankshaft or you can call an engine shop and they will also give you the specs and heres another hint whoever the dealer is that keeps coming up with the dear in the headlights look to your questions needs to go out of business hopefully theres a different dealer near you that you can also go see the next time you have a problem message me back with engine size and any further questions I await your reply Thanks again

Posted on Jan 04, 2011


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