Went duning last night, was in 2 wheel drive most of the time. Noticed a clicking sound from front end, maybe left front? It makes the noise with the wheels straight, and pushing it with engine off it makes the clicking sound?

I ride mine in the Sierra Navada mtns and I have the same clicking especially in tight turning CLICK CLICK CLICK CLICK

Jack it up and check to see if there is alot of play in the wheel.It might be a broken hub.Just a guess.It could also be a cv joint.

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I have heard the same noise in mine and i have been told that it sould be the bearing carrier in the front differential. The stock one is made of plastic.

I jacked up the front end today and spun the tires, couldn't hear the clicking sound from either side. I put it back on the ground and moved it and the clicking sound is gone. Maybe lifting it moved a cv joint position and that stopped the noise? I don't know, but atleast the noise is gone

It can also be something simple like the castle nut needing to be tightened. Or the cone washers under the castle nut are sometimes installed backwards...

Another cause could be a bad or broken bearing...

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Yea I had 6 hrs and 180 miles and click click, bad inner cv joint, only showed in turns with load on it.

Pull the hub off and put some never seize on the splines that will cure it most of the time

18 hours and 130 miles with that clicking, popping sound from front pass. side wheel..has a slight amount of play in it
at the dealer now for that issue and first service

ok i have had this noise on 3 of my rzr's there is an update for the front hub a simple spacer washer


7555939 polaris oem part number

my dealer replaced hubs and cvjoints noise was still there, anyhow, this tightens the hub and removes the play you get if you jack the front tire up and rock it in and out from the top of wheel.

also look for a worn lose lower ball joint bolt.....

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I am having the same issue on my 2008 with the 3" Xtreme lift kit. Notice more on the right side that the left. Started with the right side and pulled the wheel and spacers. The castle bolt was extremely loose on it. Service Manual says it should have 80lbs of torque. Broke off one of the wheel stud on the spacer so that just came in and going to test tonight. Hoping that was the issue.
One questions, I see about the coned like washers just inside the Castle bolt. Should there be 2 or 3. Looks like the wheel should have 3 cause the cotter pin is just inside the castle bolt. Anyone have any idea?

Update 10/15/09 -- Took apart all wheels and spacers. Noticed that on trhe front where the 2 coned washers are that the castle bolts were defintaley loose. Could use 1 more cone washer behond the castle bolt. Put all back together and tested and no more popping. Drove around and all seems well. Checked the rear also and they are much better than the front. Seems like this is another maintenance item to add to the checklist. Next item on the agenda is investigating for a long travel conversion.

HI. I have the RZR at the Dealer and we'll see what they come up with and I will follow
up. thanks for your imput. Ned.

Cone washers not being installed properly is a know problem. I would check the washers, and the torque on the castle nuts. All bolts with torque specs should be checked after break in period. All owners of a motorized vehicle should have a small collection of tools, and a multimeter...not to mention the service manual. Many of the repairs you can do yourself and learn more about your machine. A service manual is just cheap insurance.

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well it turned out to be a loose brake caliper and hub nut..dealer added a dab of locktite..