Broken crank stub - 900 fusion

[dfloen]

Hi guys, I broke the PTO stub on my 05 900 fusion. I was told that the PTO stub is replaceable, so i bought a crank out of the US with a boken mag side to use for parts. I haven't got it yet.

Today, somebody tells me that you can't replace the PTO stub because its part of the crank. This would mean the crank would need to be pressed apart at the crankpin, the whole journal replaced and the crank would need to be balanced and trued. Is this correct?

I'm looking for a quick and easy fix here. I have way more money in this sled than what its worth, and need to sell it soon. I don't want to spend more than a few hundred, if possible.

Thanks for any help guys.

 

[Z-Man]

new crank time. Don't think you are fixing it for a few hundred.

 

[dfloen]

The crank can't be pressed apart at the crankpin journal of the pto side connecting rod?

 

[guidoxpress]

talk to indydan on the forums (his info is in here)

if you lost a crank stub, you may have also damaged your cases..so you might be looking at new cases as well...

sorry to hear that...

most imp is if you had all the preventive items done to the sled to prevent this, belt, motor mounts, shimmed clutch, balanced primary, venting...

 

[markoo]

you can get a new crank complete from polaris. comes with everything you need including bearings, clutch, bolt and belt. It's about $1000.

 

[dfloen]

I looked into Indy Dans setup and 2800 is way more than I can spend on this sled. The next option would be the Polaris factory kit, but even that is more than i can spend right now. If i was going to keep it then that would be a good option of course. Times are tight and the toys gotta go...

 

[guidoxpress]

he has many different crank options...he can build you a motor with the stock crank, or repair yours...he doesnt just do custom cranks...he is a guru and can do anything you need...

 

[dfloen]

oh, i didnt know that about Indy Dan. I thought he was all high end stuff. I will look into it. Thanks.

Also, i hope i don't come across here like i am not willing to accept advise. I just want to get rid of it without pouring a ton more money into it. This sled has been a nightmare since day one. After buying it a year ago for $5000, the top end of the engine melted down on the first ride, requiring new jugs, pistons and cylinder head. Then a new belt every ride. Then a new drive clutch, etc etc etc. Worst sled ever.

 

[SnowScooter]

+1

most imp is if you had all the preventive items done to the sled to prevent this, belt, motor mounts, shimmed clutch, balanced primary, venting...[/QUOTE]

 

[dfloen]

It does have all the updates, but i'm not sure when they were added

 

[mountainhorse]

Pics of the Cranks ... this may help.

The PTO end, as said above, does not come apart.

Also, you will need to find someone that knows how to work on this... it takes a BIG press and holding fixtures to do this correctly.

 

[dfloen]

Thanks for the crank pics. So as long as the crank can be seperated to service the big end con rod bearing, I should be able to built one good crank from two broken ones. Even if I have to send the parts that i have to someone like Indy dan (assuming he would do it), thats going to be a lot less expensive than a new crank.

 

[zx800x]

Should be no big deal for someone capable of that kind of work. Make one good one from 2. Find a good crank shop and get it done.

 

[triple650]

im starting to see more and more, that the sleds who have had the worse rep, is from owners who have done nothing to fix the problem. im not saying you didnt do nothing, but if it blew the first ride you took with it, whaat was the problem? and blowing belts every ride? why wouldnt you check to see whats wrong instead of building a money pit?

it just seems odd to me, when you buy a high hp, high performance sled, you have to expect high maintenance. ya know? just my thoughts.

as for the crank i dunno what to tell you, both cranks might be bad for all you know, guranteed your cases are poopoo. how bout you ship me the sled for free?

 

[dfloen]

On the first ride when the engine blew, a coolant hose failed and blew all the coolant out while ripping accross the lake. By the time i saw the steam it was too late and the damage was done... In addition to rebuilding the engine (new cylinders, pistons, head, etc) it got new hoses and clamps.

Second ride it lunched a belt. Previous owner claimed to have never blown a belt, so i put a new Ultimax belt on it.

Third ride that belt blew up. Rebuilt the clutch, reshimmed it. Rollers were flat spotted. Checked secondary as well. Installed anothe Ultimax belt

Fourth ride blew 2 more belts. Rechecked everything, found nothing. Installed SLP cold air vent kit. Installed a factory Polaris belt and bout another Ultimax for a spare.

Fifth and last ride the crank stub broke.

What more could i have done in 300kms? Like i said, it has all the updates.

 

[Z-Man]

wow, if you were blowing ultimax belts everyride you had some kind of serious problem. Ultimax lasted 600 miles on my sled.

 

[Z-Man]

new motor mounts needed!!!!!!! Does it have an SLP torque arm on it and pusher?

 

[guidoxpress]

yeh your front motor mounts are long gone...and your rear i bet too...sad deal on a real power house sled

 

[sks rider]

Something else is def wrong.....

 

[Z-Man]

Something else is def wrong.....

You got that right, Ultimax XS belts are almost as indestructible as the 1115