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Hi

I have an 04 ac 500 4x4. When turning I can hear a loud clicking noise coming from the diff area. I had the axles out and check all the cv's for play and wear then regreased them. Didn't fix it so i was thinking the pinion bearing. So today i removed the diff from the bike and opened it up... no play in any bearings, clean oil, perfect wear pattern on the gears, just no noticeable problems. The noise is driving me nuts and I'm stumped. Has anyone here had similar problems or an idea of where to look next? Any help would be appreciated thanks.
 

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Noise

I would check the spline that goes into motor, I have had to change mine twice now........3500 miles........
Good Luck
 
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