Tighten the castle nut on the hub....Passenger side started on mine first after about 100 hrs....The drivers side came in about 25 hrs later....It has been probably 50 hrs since, and no problems.....It feels tight, but go ahead and put a little more on it and re-install the cotter pin....It will fix it....
Hoodlum

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3 1989 Honda pilots
1985 350 odyssey
2008 Polaris rzr

Tightened mine up. My torque wrench only goes to 80lbs. Can you tighten them any more than 80lbs. My problem seems to be gone after tightening to 80lbs. Thanks. Hopefully it will not start again

Mine goes into the Dealer on the 24th to look at the Right Front wheel for the same noise. I jacked it up spun the wheel and no noise. Pulled the wheel off and looked everything over, can't find anything loose. Axel and CV seem tight and fine. Sounds like a bearing issue to be as it only makes the noise when rolling under a load.

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Thanks,
Will
My 1953 Dodge M37
My Dodge Power Wagons

I just turned 400 hours and the clicking started in the front passenger side wheel on right turns. I also get a lopping up and down motion on the right front when going straight. I have taken apart the right front and can't see anything bent and the cv looks good. Any ideas.
Fast Eddie

I've noticed that I can also get it to click by lifting up on the front end (almost off the ground), and then pushing down on it. sure seems to be a bearing issue to me, but I hope to know more after the Dealer looks at it.

Just got word from the dealer. The CV that he ordered was supposed to be here today but now its out until the 21st. I don't think the dealer knows what the problem is and now it will sit in his yard for three weeks. Might just need that spacer or tighten the end nut.

i have some clicking/bad cv noises on my rzr with 4 hours on it! can one of you nice fellas check to see if there is play on the inner shafts were they go into the diff. mine has a little slop there and i was wondering if it is normal thanks.

Some people consider movement a little play when the cv is actually doing it's job. When I fixed the clicking in the cv, the axle nut was tight, but just not tight enough. Seriously, just pull your wheel and hub off (cotter pin and castle nut), regrease and tighten axle nut to aprox 80 ft lbs. While you're at it, check how tight your ball joints are. You might be surprised, because it seems to be working for the rest of us that thought we had bad cv's.

A buddy of mine had the same clicking in the rear end of his. We simply tightened the spindle nut to fix it. the dealers seem too quick to diagnose the problem as a failed bearing. his front end did the same thing two days later. same thing fixed it. mine now has the clicking after 1000 miles of really hard abuse. tried to tighten the nut, but it was no use. the damage appears to have been done. these are, all in all, some baddass machines, though. wouldn't get too discouraged, guys. the fix usually is something minor.

mines clicking too, 300 miles, jacked it up and no wiggle in the front tires but the shafts coming out of the front diff seem to be loose

i took mine to the dealer and had them torque it to 80 lbs but it didnt fix the clicking/poping. the fix from polaris is a shim and to locktite the bearing in place. they say the bearing walking/moving is the cause of the noise and the shim will stop it. the cause they said is big tires and abuse but i had 4 hours on mine and didnt abuse it. all in all i love the hell out of it and i will drive it like i stole it as soon as the break in period is over. i will also keep you posted on the shim loctite thing as soon as the shim comes in bla bla thanks for the previous information from all you guys!

Thanks for the info chuck. What bearing did they locktite. Where and w did the extra shim go and what does it look like. Is the shim the round washers under the wheel bearing lock nut.

yes they are the same washer that is under the locknut however it is not done, the parts are on order ill let you know if it fixes it.

Have the same clicking noise, Torqued the castle nut to 80lbs and regreased everything from the a-arms to the wheels, and still had a clicking noise. Went back thru and had a lot of play at the wheels. The wheel bearings were shot, waiting for parts, keep ya posted if that stopped the noise. Just turned 400 miles (90% of miles rough XC riding)
Thanks for all the good info!

mine is making rattling noise after only 5 hrs, does it when wheel is turned to right, seems to be coming from underneath, cant tell if its left or right though, wtf