I have a 2009 Polaris Outlaw 450 that I have now had a few years. A couple summers ago I was going about 60mph down a highway and it suddenly died. It didn't lock up or anything, it died as if it was out of fuel, yet that wasn't the case and it wouldn't start. After getting home I got it to start and then from that day on it had an awful rattle/clatter/almost knock sound to it. I then was scared to ride it and it either lock up going that fast or just make the issue even worst. So its sat in shop for the past couple years, until today. I decided to hell with it and got it running and then ripped around in the yard and the noise got much worse (I knew it was a bad idea). So I did some research and found out about the loose crankshaft bolt on these KTM motors and how their generally clatterly motors. So I went ahead and pulled both sides of the crank covers off after draining the oil, which pulled a huge amount of ground metal for such a little motor. I have quite a collection of metal on the flywheel and whatever that stator looking thing does. (not a fourwheeler mechanic) I believe its the stator and armature to the starter but what do I know. Anyways I believe my metal and noise is coming from somewhere around the timing chain area or the crank. I would guess I've got a bearing out, but I thought I would try you guys before tearing it apart farther without knowing the tricks of the trade. Again any help would be much appreciated. I also am going to try to attach a video of the motor running before I took it all apart. Nevermind, it wont let me post the video.
