2004 Sportsman 700
 

i have a 2004 Sportsman 700 twin that had a motor knock. it sounded more like on the flywheel side of the engine but was a solid knock and would not go away with RPMs like a lifter or something.
i checked the rockers to make sure they were not broke and didnt find anything wrong there
last night i had it running and it was still knocking and made a louder knock and the motor shut off and it will not crank over at all. when trying to push it back to the porch i noticed the rear wheel on the right side didnt seem to want to turn as free as the left rear. not sure that has anything to do with it or not.

this motor just throw a rod you think?
talked to a tech in the area and he said the noise at first sounded like a rod bearing but wasnt sure.
anyone have any advise how i should proceed..im no dummy when it comes to mechanical stuff but have never worked on one of the big twins like this one before.
any advise is appriciated.

Sounds like a rod,but could possibly be a shattered piston that has locked up the engine also. 700s were the worst and a few 800s had this rod throwing problem.Problem is finding good places that can rebuild the 700 crank shaft as many of the places concentrate on the 800 only. Here's a partial listing from one of the more notable places that can rebuild one. "Some machines are known for crankshaft issues and failures, most notably Polaris 800cc liberty twin and Ski Doo 800cc cranks, Honda 450cc crankshafts and Polaris Sportsman 700 cranks. We have the specialized equipment and experience to rebuild several model crankshafts. We have access to billet steel PTO ends, larger quality bearings, lightweight heavy duty connecting rod kits, and more..." Here's their website if it is the crank shaft and you would like to have it rebuilt (probably cheaper) rather than buying another $800 oem crank. Crankshaft Rebuilding for Motorcycle ATV and Snowmobiles LaBaron's Power Sports Almont, MI (810) 798-2035

thank you for the reply
are there any specialty tools i would have to have for tear down to be able to check and see what has happened such as tools for clutch removal, flywheel and so on

Mainly the drive clutch tool that you can find online or a 3/4 fine thread bolt(along with a small old socket or bar stock if the large bolt is too short) at any good hardware store that a lot of people have used. Air and hand tools for the most part on the rest of the machine. Plus a good steering wheel/harmonic balancer puller to pull the flywheel which is usually tough to get off. This cheap manual can pay for itself in the first use..2004 Polaris Sportsman 700 Service Manual PDF Download If you have the efi model they have it also.2004 Polaris Sportsman 700 EFI Service Manual PDF Download

thank you very much for the info.
any tips or advise for me in what all to check or look at or look for or shortcuts
does the whole clutch system have to be removed to be able to get the crankcase cover off?

On the 700 the engine has to be removed from the frame. The manual again shows this step by step. You should be able to find out pretty quick once you get the head off. First thing to do is remove the flywheel and stator plate and tie it up out of the way.Then the clutches and exhaust system.

ok another question for you Old Polaris Tech.
i see on Ebay there is a Hot rods rebuild kit for about $1200
comes with
(2) std. bore 80mm Namura pistons 10.2:1 compression, Hot Rods Crankshaft, complete gasket set, counter shaft bearings, water pump rebuild kit, seal kit ,crankshaft bearings & new cylinder for Polaris 800 EFI engines 2005-2015

would i be able to use this kit on my 700 and just swap parts in to my cases?
i have done a little reading and they say it can be done but would also need an ECM from an 800 also...is this correct?

I suppose people have done that,but being a mechanic I put em back the way they were...Polaris Sportsman RZR Ranger 800 Engine Rebuild Kit 2005 2015 | eBay Here's the other option,get your crank repaired and try one of these kits.Polaris Ranger Sportsman 700 Top End Rebuild Kit Engine Cylinder Pistons Gaskets | eBay ALL depends on what you find when you tear it down. You may not need a new cylinder. Repaired crank(if needed) new piston kit and gasket kit would be a lot cheaper if you could get by with it. Again several ways to go on this.