I have had an issue with my 2015 RZR 1000 XP4 where a sever engine knocking noise can be heard occasionally.
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I am convinced that the timing chain tensioner is the issue. My dealer sent the video to Polaris who also responded that it was the tensioner. I also took the valve cover off and observed the timing chain slacking up. When rotating the engine, there is a moment that the tension direction of the exhaust cam gear actually reverses... The chain is pulling the cam in the direction necessary to open the valve. Once the second set of valves have passed full open, spring pressure pushes on the back side of the cam and causes a reversal in the loading on the cam gear and allows the chain to slack up. This is the noise that we hear but isn't the problem... The tensioner is hydraulically actuated and is supposed to hold tension for at least a few days. However over time, it will bleed off. Typically within the first few revolutions of starting the motor, the oil pump re-pressurizes the tensioner and it's good to go. However occasionally, SOMETHING prevents this from happening and therefore the issue persists through a full engine warm up and light reving. It's not until the engine is ran hard that the tensioner frees to resume normal function.

Polaris responded to my dealer that this is a "NORMAL OPERATING CHARACTERISTIC OF THE ENGINE" and that no further action should be taken. Not happy with that answer, I called Polaris and after some investigation on their part and a couple calls later...they did give me a 1 year warranty. This helps, but still doesn't make me very happy. This is nearly a brand new machine with 900 miles on it. If anyone were to hear that noise on the showroom floor, Polaris would never sell that machine. Now I'm stuck with it and will always question its integrity. So far, the issue has happened 3 times. If I hear it again, I will install a manual tensioner or perhaps one of the aftermarket automatic tensioners from Boondockers or Weller Racing.

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