So I just got a 02 sportsman 700 and it's got a knock somewhere. I pulled the clutch and it's not that. Checked the valves there all good. The noise is really loud where the starter bendix is. Any body have any ideas what it might be

 

This is my bike

 

Noisy engine to begin with because of the hydraulic lifters and push rods. A deep knocking noise cold be more serious such as a piston, lower rod bearing or crank bearing. Sound can radiate through out the engine. A good engine stethoscope can help narrow down where the noise is coming from.

 

I used a stethoscope and the noise is the loudest over the starter bendix. Is it possibly that would sound like a rod knock

 

Starter bendixes are pretty strong on the 700/800 engines,a lot stronger than the ones on the 500,ect. Plus the bendix should kick back once started. Just pull the cover and check it out and see if it spins out and retracts back ok. Could still be a rod bearing or crank bearing transferring noise through the engine case.

 

Without the side case on the bendix comes about and gets stuck on the fly wheel I then have to spin the flywheel by hand for it to retract

 

Yes it will only come out so far and hit the flywheel by hand. Even if you turn the flywheel and the bendix retracts back,sounds like it's working ok.Behind the stator and flywheel and cover are the crank sprocket,cam and counter balancer sprocket along with the oil pump sprocket.If they are ok,the clutch has been eliminated as the knocking noise also,then still could be a rod or crank bearing.700s were sort of noted for that happening.

 

Ok thanks I guess I'm gonna have to tear it apart and put bearings in it

 

When you have the bendix out check to see if the gear that engages the flywheel rotates easily in both directions, clockwise and counter clockwise. Often when these fail they will only rotate clockwise.

 

That was over a year and a half ago. My guess is they got it fixed by now. It would be nice to know what the problem actually was and how they fixed it, in case someone else has the same problem.