Ya'll have put my worries to rest. I wish the dealership would have given me a heads up on the noise. I'll pull the oil drain plug this evening just to be sure.
Thanks for all the info.

 

Wow, Stendori, you beat me to the punch. I was JUST ABOUT to post the same post you just did. I was going to say that I have a theory about where the noise comes from. My oil plug look EXACTLY like yours. And if you reach your pinky up in the hole, you can feel the slack chain right above the hole. If you reach your pinky in there and roll your ATV back and forth slighty to take the lash out of the drivetrain, you will feel the chain loosen, then tighten as you go back and forth. I think the noise is a combination of the chain going tite then loose, and of the chain hitting the oil plug. I wonder if a. there is an internal adjustment to tighten that chain, and b. if Polaris purposely wants that much slack in the chain to make it shift/operate properly. I guess what I'm saying is, with as many first time 700/800 owners that complain about this noise, if it were as simple as tightening the chain, wouldnt Polaris have done it about three years ago? There MUST be a reason why the chain is that loose. Now, that being siad.......What the hell are they thinking letting the chain take all that metal off the oil plug?? i don't want that crap swirling around in my tranny.

 

Can I ask the million dollar question?

What do you do know? Leave it alone after
you change the oil? Shave the bottom of the plug
down to eliminate more metal shavings in the transmission?
Tighten the chain yourself or have a Polaris tech
do it? What do you do?

Regards,

R'

 

I drilled out a washer that fits just around the plug and spaced it out a little.

 

Had a customer come over with a bad clunking noise, thought at first it was the secondary clutch. Put it up on stands and removed the belt took off the secondary clutch just to isolate it.

Spun rear wheels and sound was still there. Pulled the transmission and split the cases. Found bad wearing on the chain drive on the main shaft as well as the countershaft. Really nothing to do at this point. Got a used tranny and installed. Exact same problem.

To me its a terrible design, if you look at the oil check plug that is where the level is. There is no pump to push oil up to the top gears Just a horrible design on Polaris. I will post some pics of internals soon.