'02 Sportsman 700 Engine Rebuild - Crankshaft Parts
Hi all, this is my first time on here and it seems to be a good place to be!
I recently bought an '02 Sportsman 700 that I was told it had some knocking in the lower end. Once I got it started, that was definitely confirmed. The previous owner had rebuilt the top end to some extent. He said it was running fine for about an hour until the noise started.
Armed with the service manual, I tore into it and replaced all of the crank and balance shaft bearings. I put everything back together, started it up, and STILL KNOCKING as loud as ever!!
Frustrated, I tore apart the top end thinking it must've been something he put together wrong. When I got down to the pistons I found that the left connecting rod was really loose on the crankshaft when I pulled up and down on it. In any normal engine, this would be a cheap and easy fix but, those of you who know anything about these engines know that the connecting rods are permanently attached to the crank and are non-replaceable. Who ever though that was a good idea?
The dealer couldn't believe that I had to rebuild the engine in the first place and told me "those engines never break". I still haven't told them my latest findings. Online, Polaris wants ~$700 for a new crank assembly and that's just not going to happen so, I'm SOL unless I can find a used one. Anybody have any suggestions on where I should start?
Thank you for your help!!