06 sportsman 800 timing

Ga.Sportsman800 · #1 (**permalink**) 01-26-2012, 05:06 PM

Hello, I have 2006 sportsman 800 that seems to have developed a bit of a knock. Some background:
I bought this quad new and have had no issues until now. Back in September i rolled it over on its side and got water in the intake and therefore the engine and the crankcase also. I brought the quad home, changed the plugs, changed the oil about 10 times (literally), cleaned everything and put it all back together. Started it up, GOLDEN... or so i thought. Now the oil pressure relief dowel was stuck and causing the oil filter seal to blow out and leak oil everywhere. After i finally got all that corrected, and got it running, it was making a "knocking" or "clanking" noise on the right side of the bike. Its been about 4 months since I have had it running and I remember the engine being a little noisy, but not like this. I have a video of the noise posted on youtube so that you can hear it also.
Is there something to be worried about, or am I just being paranoid?

2006 Sportsman 800 idling. - YouTube

chopper89 · #2 (**permalink**) 01-26-2012, 05:16 PM

im guessing if you havent already check your exhaust bolts and heat deflectors mine 06 had the deflector come loose sounded bad just like yours. coming from the right side im thinking that what it might be plus its real sharp and tinning like its on the outside hard to tell by video

Ga.Sportsman800 · #3 (**permalink**) 01-26-2012, 05:55 PM

I'm pretty sure that its not something on the outside. I had all of the plastic and the racks off and it still made the noise.
If I try to listen through a long screwdriver or something, It really sounds like its coming from the engine. I just cant distinguish what noise is coming from the clutch and whats coming from the engine.

kcaves · #4 (**permalink**) 01-26-2012, 07:03 PM

sounds like a lifter to me

cdgoodling · #5 (**permalink**) 01-27-2012, 04:22 AM

being an 06 they have dual head pipes coming off the motor. and then come together into one pipe. let me tell you the problem i had.... if the pipes are not on perfect the lower pipe will come in contact with the side case on the right side. there is very little clearance there about an 1/8" or less. may want to check this. hope everything works out ok.

Diesel man 03 · #6 (**permalink**) 01-27-2012, 12:55 PM

When the relief valve stuck did the engine run with out oil for a while?

Ga.Sportsman800 · #7 (**permalink**) 01-27-2012, 01:48 PM

No, I did not run the engine without oil. I didnt allow the engine to run for more than a few seconds after the oil filter blew.

ATVDOC · #8 (**permalink**) 01-27-2012, 05:15 PM

A few things to check. First, remove your magneto housing & verify nothing is loose under there(flywheel nut, pieces of stator, etc.). Next, if you can, kill the spark one cylinder at a time & note if the noise changes. Finally, pull your valve cover & check for a loose rocker arm against the pushrod indicating a collapsed lifter. Hope this helps.

Ga.Sportsman800 · #9 (**permalink**) 01-27-2012, 06:15 PM

Just a side note, I rode it around the yard for a few minutes to see how it does and I didn't notice any loss in power or responsiveness. I cant really hear the noise unless its at an idle. Doesn't seem to get much louder when the engine is revved. Feels like its running okay, except for that awful racket its making.

Well, I got around to checking a couple of things tonight. I double checked to make sure that the noise wasn't coming from a loose header pipe or anything like that. I removed the clutch primary to eliminate any noise from the clutch. Still makes the knocking sound...

Thanks for the advise ATVDOC, I guess that I'll start trying some of your suggestions tomorrow and report back the findings.

Ga.Sportsman800 · #10 (**permalink**) 01-31-2012, 07:14 PM

Okay, so I finally got around to pulling the cover off of the stator and checking that out... everything looks fine, except it did have a little water in there. Not too much, just enough to soak up with the end of a paper towel.

I also started the bike up and and let it warm up and (with the clutch still removed) pulled one plug wire at a time to check for any noticeable change - no change really. It ran a little rough, but the knocking was still there.

I guess the next step is to pull the valve cover and check the rockers and look for a collapsed lifter, as ATVDOC suggested. Anyone have any advice, tips, or tricks that I should be aware of? Any other things that I should look for as I open the engine up?