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Whitfield
11-25-2008, 03:58 PM
Bought my daughter an 04 Sportsman 90. Bike has a bad Pirmary shaft and outer (Clutch side) bearing. The bearing failed and took out the shaft. (This is on the rear most clutch assembly)

Clutch Diagram from Hetrick below:

#1 Shaft

#9 Bearing

http://www.hetrickracing.com/CVTbreakdown.htm.jpg

Looks like Polaris wants close to $150 for just the shaft

Is anyone offering a better deal on the shaft or a better shaft?

I'm considering giving it to a machinist to see if he can repair it?
Good ideia or not ???

Unfortunatly the previous owner did alot of mud and water, the kick start is frozen up and other pieces will require attention too.

Tomorrow I'll be pulling down the trans and removing the shaft.
Tonight I'm picking up a Denli parts bike.... Maybe I'lll get lucky and it will be the same shaft ???

11-25-2008, 05:27 PM
Would you sell me the gas tank cover and the hood off of that Dinli? I really need those items . Or if any one has these items please let me know? Thank you Toby

Whitfield
11-26-2008, 06:21 PM
Bike was salvaged (Saved from the dump) as a frame engine and rear. If I find any other parts I'll let you know.

Turns out the transmissions are very different. Ordered my parts new from Babbits today.

Got the front clutch and starter all put back together, fired the bike and it runs great. :)

Whitfield
12-10-2008, 11:56 PM
Ordered my new shaft from Polaris (Driven Clutch shaft) based on the Microfiche. Got my part and It is wrong. :(

Double checked my part # and application checked on different Polaris 90cc modles ~ Predator ~ Scrambler, different years, down to 02 and up to 06. All require the same part#... :ermm:


This shaft is about 3/8" shorter and the gear on the transmission side is much smaller.

12-11-2008, 05:13 AM
HEY Whitfiel what kind of quad and year I have several motors with the gears in it let me know. i will see if i have the part. and no im no dealer im just Toby who has bought alot of stuff in the last 3 years lol. i think the more the better. let me know

Whitfield
12-11-2008, 05:52 AM
Thanks!

PM Sent...

20 / 07 / 2004 Polaris Sportsman 90cc

Driven Clutch shaft

10th character of my Vin says it is a 2005 year modle bike.

Whitfield
12-11-2008, 07:17 AM
http://i9.photobucket.com/albums/a53/whitfimb/Polaris%20Sportsman/PC110423.jpg

Engine case # TR18002525

My Shaft is .5" Longer then the Polaris part # 0450195 and MY gear on the right is about 4-5 time bigger (longer & wider)

Whitfield
12-11-2008, 08:58 AM
Looks like a microfishe error. They have the secondary shaft pictured (part #25) but call it the primary shaft.

http://webservices.motorsportdealers.com/parts/partImages/POL/2/IMAGES/9506/9506A12.Gif


The primary shaft is pictured in another slide (part #16) and is also called the primary shaft, but is a different part #....

http://webservices.motorsportdealers.com/parts/partImages/POL/3/IMAGES/9506/9506A10.Gif

Whitfield
12-12-2008, 11:47 AM
R E T U R N of part from Order # 179937


(1) Part Returned : Drive ASM PRIMARY #0450195

Reason: Incorrect part due to Polaris Microfiche part numbering error.


I scanned the Microfiche for DRIVE PULLEY –A05FA09CA/CB/CC and ordered the shaft in the picture (part #25) Receiving this part, the number matched my order but the part is incorrect. In speaking with your service representatives on the morning of Thursday December 11th, they offered to accept return of my part, but gave no resolution to provide me with the correct part. I then contacted Eric at Snow's Polaris. Eric then contacted Polaris PARTS. Polaris PARTS notified him that there is a Microfiche error (incorrect part number). The error actually matches the Primary shaft part number to the Secondary shaft picture.



BIG Thanks to Eric at Snow's Polaris

Whitfield
01-10-2009, 10:37 PM
The Sportsman 90 (Bike in a box) turned out great once I got thru the transmission Microfiche error. (Thaks again to Snows Polaris for the help and factory contact). That snag put me reassembeling everything late Dec 23rd... And at 5am on the 24th it was done. I've that smile on my little girls face made it all worth wild.

http://i9.photobucket.com/albums/a53/whitfimb/ATV/PC250533.jpg

http://i9.photobucket.com/albums/a53/whitfimb/ATV/PC250537.jpg

http://i9.photobucket.com/albums/a53/whitfimb/ATV/PC250542.jpg

We rode it today for the first time and it performed great. [/B][/