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Discussion Starter #1
A recent issue has surfaced. A buddy of mine and I went out on a short run the other day. We are both big guys so the RZR was loaded down pretty well.

Midway through the ride, I noticed a fairly loud popping sound coming form the rear left side when we were articulating over some of the terrain. It wasn't anything terribly difficult. Then after a few more turns, the sound started coming from the right side too!

The sound is not continuous - just a single POP when the chassis is flexed slightly. I've seen mention about brake calipers loose, so I may look at that, but this situation doesn't sound like what other people are describing.

Ever since then, whenever we are slowly creeping over uneven terrain and flexing the suspension, the popping will be persistent - first one side, then perhaps the other depending on the angles.

I'm not an expert with the RZR's mechanical functionality, but this sound is very similar to what my old truck sounded when a ball joint failed and was popping in and out of place.

Any suggestions?
 

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De Oppresso Liber
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I had a similar problem when I installed WER shocks on my stock RZR and had the front sway bar connector rods attached. While I was trying to figure out what the sound was caused by, one of the front sway bar connector rods snapped just under the top eyelet. I believe the problem or the sound is caused by quickly unloading the suspension during articulation and the result is the noise you hear as the spring extends and the sway bar connector rod catches/stops the A arm from further downward movement.
 
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You described the exact same problem I had this weekend. I have all new ball joints, wheel bearings, a arms, axles/cv joints, diff seals. I dont have the sway bars on. Its still a mystery to me but I did notice one thing that I thought might could be happening but dont know if it would make that popping sound:

My rear right side is starting to leak again and having new seals...got me to thinking that maybe the axle is popping in and out of the diff when it flexes, but every time I check it is in......Its kind of like that little guy that turns the light on when I open the fridge---I never see him.
 

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This may sound silly, but give it a try. I found that the rear sway bar was loose. It took less than a half turn on each of the 4 bolts that hold the sway bar to the frame. Don't forget to pump some grease into each of the saddle fittings. I think that if the fittings are a little dry or loaded with dust the sound is worse.
 
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Mine RZR4 started doing the fairly loud popping when going over obstacles yesterday....haven't had time to try to narrow down exactly where it is coming from..definitely in the rear suspension. I can rock it side to side by hand and make it pop..doesn't seem like it is coming from the sway bar but can't say for sure just yet.
 

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I get the same sort of pop out of mine, but I experience the problem from the front end. It's done it since new, been checked by the dealer a couple times for it, and continued to do it after I installed the lift, and front anti sway bar disconnects in the front. It pops whether in all wheel drive or not when I get the thing all twisted and tweaked on the trails. On the plus side, it's gone from quite common to only once or twice per ride over time, and nothing has let loose yet so I quit worrying about it..
 

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Is it the CV joints?
I have few vehicles in the past with popping sounds.
Suzuki Samurai front axle before the burfield(like a CV joint) goes. Pop, pop, BLAM!
Arctic Cat 650 H1 under hard rock crawling. Pop, pop, pop, as we go along.
Just throwing it out there.
 
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Mine was the sway bar links...the bolts apparently have to be TIGHT. They felt tight but one of was just loose enough to let the bushing walk under a load causing a popping noise. I cranked down the 4 end link bolts/nuts and the noise is gone. Guess I should look up the TQ and actually torque them...but the noise is gone so I guess they are tight enough lol.
 

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I've got a single pop when in a hole or somewhat flexing... My rzr is too loud tell where it's coming from.
 

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Discussion Starter #10
Great analysis and suggestions guys! I'm going to start pulling it apart this coming weekend to see if I can narrow it down using the suggestions given - starting with the sway bar.

Feel free to keep the conversation going because the more things mentioned to try, the better off we'll be! Thanks!
 

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Mine was the sway bar links...the bolts apparently have to be TIGHT. They felt tight but one of was just loose enough to let the bushing walk under a load causing a popping noise. I cranked down the 4 end link bolts/nuts and the noise is gone. Guess I should look up the TQ and actually torque them...but the noise is gone so I guess they are tight enough lol.
i 3RD this. Mine was popping any time i went over any kind of uneven terrain. Sway bar bolts where it bolts to frame looked tight, but i got about 1/4-1/2 turn out of 3 of the 4. No more popping!
 

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Mine was the sway bar links...the bolts apparently have to be TIGHT. They felt tight but one of was just loose enough to let the bushing walk under a load causing a popping noise. I cranked down the 4 end link bolts/nuts and the noise is gone. Guess I should look up the TQ and actually torque them...but the noise is gone so I guess they are tight enough lol.
i 3RD this. Mine was popping any time i went over any kind of uneven terrain. Sway bar bolts where it bolts to frame looked tight, but i got about 1/4-1/2 turn out of 3 of the 4. No more popping!
Mine did this too on the second ride out. Tightened up the sway bar bolts and good to go.
 

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Discussion Starter #15
Well, somehow I missed the last 4 posts on this thread - I must have dismissed the e-mail notification without visiting here.

So you people are correct. It was indeed the sway bar bolts! Took it to the dealer twice to figure it out. Now I'm kicking myself cause I could have just checked this thread again and saved a lot of headache.

Gave it a good test today at our local OHV park. So much more pleasant!

Thanks guys!
 

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Mine was front sprague...
 

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Well, somehow I missed the last 4 posts on this thread - I must have dismissed the e-mail notification without visiting here.

So you people are correct. It was indeed the sway bar bolts! Took it to the dealer twice to figure it out. Now I'm kicking myself cause I could have just checked this thread again and saved a lot of headache.

Gave it a good test today at our local OHV park. So much more pleasant!

Thanks guys!
Rob - Take the swaybars off. Trust me your ride, especially at low speed, will improve alot. Articulation is way better. Don't worry about body roll. with the progressives you won't have body roll.

Steve
 

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Discussion Starter #18
Well, somehow I missed the last 4 posts on this thread - I must have dismissed the e-mail notification without visiting here.

So you people are correct. It was indeed the sway bar bolts! Took it to the dealer twice to figure it out. Now I'm kicking myself cause I could have just checked this thread again and saved a lot of headache.

Gave it a good test today at our local OHV park. So much more pleasant!

Thanks guys!
Rob - Take the swaybars off. Trust me your ride, especially at low speed, will improve alot. Articulation is way better. Don't worry about body roll. with the progressives you won't have body roll.

Steve
Hmm.... Interesting. Will that make it more tippy? I think thats my biggest fear on the trail but unsure how the swaybar will effect it.

BTW, those progressives are working fantastic! That was the other thing I was testing while I was out this weekend.
 

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Well, somehow I missed the last 4 posts on this thread - I must have dismissed the e-mail notification without visiting here.

So you people are correct. It was indeed the sway bar bolts! Took it to the dealer twice to figure it out. Now I'm kicking myself cause I could have just checked this thread again and saved a lot of headache.

Gave it a good test today at our local OHV park. So much more pleasant!

Thanks guys!
Rob - Take the swaybars off. Trust me your ride, especially at low speed, will improve alot. Articulation is way better. Don't worry about body roll. with the progressives you won't have body roll.

Steve
Hmm.... Interesting. Will that make it more tippy? I think thats my biggest fear on the trail but unsure how the swaybar will effect it.

BTW, those progressives are working fantastic! That was the other thing I was testing while I was out this weekend.
Great! Look Rob you took the leap of faith and got the springs, now trust me again, remove the front for sure. Then disconnect one side on the rear and go ride. If you don't like it, I can't imagine why, reconnect and no harm done. Otherwise I have a feeling you'll be removing it like everyone else with the progressives.
 

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Discussion Starter #20
Rob - Take the swaybars off. Trust me your ride, especially at low speed, will improve alot. Articulation is way better. Don't worry about body roll. with the progressives you won't have body roll.

Steve
Hmm.... Interesting. Will that make it more tippy? I think thats my biggest fear on the trail but unsure how the swaybar will effect it.

BTW, those progressives are working fantastic! That was the other thing I was testing while I was out this weekend.
Great! Look Rob you took the leap of faith and got the springs, now trust me again, remove the front for sure. Then disconnect one side on the rear and go ride. If you don't like it, I can't imagine why, reconnect and no harm done. Otherwise I have a feeling you'll be removing it like everyone else with the progressives.
Ok, cool. I'll give it a shot. Guess I know what I'm doing this weekend! :ride:
 
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