2005 sporstman 800
Hi guys,
I just bought a '05 sportsman 800 blown-up. I rebuilt the entire motor basicly, new case, crank, cylinders, cam, lifters, bearings, bushings, and pistons. I put all together going by the polaris service manual for the wheeler last weekend. I finished it and started it up and there was some knocking that i had expected due to the lifters needing to get pumped up with oil. Long be hold the knocking never really went away. I talk to the prevous owner and another guy that has rode these 800's and they both said that it is normal to make the knocking noise. Has anyone else heard of this? Is it normal for the noise? It sounds like a lose rocker arm, but i rember torqureing all the rocker arms. If it suppose to be quiet running egine then im going to have to tear it apart. Any help would be much appreciated.

Thanks

 

seems like i recall several folx sayin there is a slight tickin in the right side of the machine when running. might have that confused with the 500's tho

 

neither of my (06,08) 800's knocked.

 

Recheck the rocker/valve lash clearance.

 

I went to the dealer today and listen to an 800 run and it was much quieter then mine. The mechanic wasn't there etheir so i couldn't pick his brain. I came back home and listen to mine run and I'm thinking the rocker/valve lash is out of adjustment. But i have no idea how to adjust them. The head is orginal with 800 miles on it. I guess I'll have to take the valve cover off and investgate it while its running.

 

Does it sound like this?


YouTube - '07 Polaris Sportsman 800 engine noise

 

As mentioned above a little ticking noise is normal for these engines,but if you have a deeper knocking noise then may need to check into it. Were you able to align the cam gears and springs properly mark to mark(takes the tool kit to keep aligned and held together while installing???

 

Has hydraulic lifters so should not need adjustment. Depending on why engine went may have a blocked oil passage restricting proper lubrication. Did you prime the oil system?

 

they all tick, but no way would you be calling it a knock as you should barely notice it. imo

 

Hello, I've got the same problem! I bought a brand new 2010 polaris ranger 800 6x6 back in sept 2010. I used it every saturday hunting for about three months. I only have 18 hours on it so I haven'nt changed the oil untill the 25 hour mark. I had no problems at all and it ran and sounded smooth. Just last week I started noticing that it would hesitate starting but would start. Also I started hearing a clicking noise coming from the valve cover. I took the valve cover off and found that the rocker arms were not adjustable , but they were all tight. One thing I can'nt understand is that with the cover off I cranked the engine but there is no oil any were , should'nt there be oil coming out into the valve cover area? Also , if there is a oil presure problem could the clicking be coming from the hydraulic lifters due to the lack of oil pressure? Also how can I install a after market oil pressure gauge to see exactly how much presure I'm getting? I would greatly appreciate any help!!!!! God bless to all , and if you haven'nt thanked a soilder lately , please do , because there the reason we are free.