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Old 08-18-2012, 12:43 PM
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'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!!
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Old 08-18-2012, 03:28 PM
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Hey man, I am up in Nova Scotia, and have one in excellent shape. Let me know if your interested. 250.00
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Old 08-18-2012, 05:51 PM
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Welcome to the board!
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Old 11-30-2012, 06:04 PM
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i had the same problem with my 2007 800. i found "hot rods" crankshaft to be the the cheapest and best quality crankshaft, purchased on ebay store.

after talking with the dealer tech, he said that the number one side(clutch side) of the crankshaft will develop this play if the motor is run low on oil.
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Old 12-27-2012, 10:57 AM
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Thanks to everyone for their help. A special thanks to Corey850XP for shipping me a used crank which worked perfectly.

It was the clutch side that went out. I'm thinking the last gut never primed the oil pump when he rebuilt the engine.
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Old 12-27-2012, 10:59 AM
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Awesome!!!!!!!
Always happy to help!!!!
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Old 08-13-2013, 12:22 PM
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02 sportsman 700 new crank bad

Hello I recently purchased a brand new crank assembly from Polaris and installed it into my 02 sportster 700 and ran it for about 5 hours total time and started to hear a knock. tore engine down to find connecting rod bearing bad on crank, but only one rod. Oil looked ok, could I have a bad oil pump or what distributes oil? not sure what else to check, any help would be great.
Contacted Polaris but no help. Does anyone have a good used crankshaft assembly I can purchase to put this back together with, Thanks.
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Old 08-13-2013, 12:37 PM
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Quote:
Originally Posted by JRANDA45 View Post
Hello I recently purchased a brand new crank assembly from Polaris and installed it into my 02 sportster 700 and ran it for about 5 hours total time and started to hear a knock. tore engine down to find connecting rod bearing bad on crank, but only one rod. Oil looked ok, could I have a bad oil pump or what distributes oil? not sure what else to check, any help would be great.
Contacted Polaris but no help. Does anyone have a good used crankshaft assembly I can purchase to put this back together with, Thanks.
your crankshaft will always be in contact with oil as the crankcase is always full of oil, assuming you have the correct amount of oil in it. the oil pump draws the oil from the crankcase and pumps it through different channels is the motor to lube the bearings and the rocker arms and other components from the valve assembly on down.
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Old 08-13-2013, 01:32 PM
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oil appeared to be full and clean when I took engine apart, anything else that would cause only 1 crank rod bearing to go bad with in 5 hours other than defective parts?
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Old 08-13-2013, 05:08 PM
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I would at this point summize to say defective parts, I'd be calling Polaris and getting money back on that.
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