Anybody know if the front shafts on the 05's will fit the 04's, they look identical in size as far as I can see.

 

I looked on the www.parts.polarisind.com and they show the 2005 models use an inner cv joint and the 2004 uses a u-joint on the inner. I would say "no". However they may interchange since the splines look to be the same. The following is a list of the vehicles Polaris shows use that same axle number:
Year Product Model Assembly
2005 ATV SPORTSMAN MV7 DRIVE SHAFT, FRONT - A05MH68AP
2005 ATV SPORTSMAN 800 EFI DRIVE SHAFT, FRONT - A05MH76AC/AU/AW
2005 ATV SPORTSMAN 400 FRONT DRIVE SHAFT - A05MH42AB/AG/AH
2005 ATV SPORTSMAN 500 HO/INT'L FRONT DRIVE SHAFT - A05MH50AB/AC/AG/AH/FB
2005 ATV SPORTSMAN 600 FRONT DRIVE SHAFT - A05MH59AK/AN
2005 ATV SPORTSMAN 700 EFI FRONT DRIVE SHAFT - A05MH68AC/AS/AU/AW
2005 ATV SPORTSMAN 700 FRONT DRIVE SHAFT - A05MH68AK/AN
I hope this helps.
Danny
thecvman

 

yes, I knew they had different part #'s, polaris has already told me that and would not say if they could be interchanged, don't know why they wouldn't say yes or no. The mechanic at the dealer I go to says that the shafts are slightly longer on the 05 with dual cv's to allow more travel, I think this would be a good thing because it is what's needed to stop the 04' cv's from breaking, the u-joint doesn't allow any extra travel when turning in 4wd and puts alot of pressure on the outside of the cv causing it to break the casing. Anyway if polaris doesn't want my cash I think I will get the gorilla cv's and be done with it.
Also for you guy's that do break a cv you should also get them to check the diff. as well, because when I opened mine up the roller cage was broken, this could have been part of the problem to start with, I had the left side go under warranty and the dealer did the work the first time and I'll guarntee the diff was not touched, only pop out the bad cv and re-install the new!! so this time I have no warranty and no way to prove if the roller cage was broken the first time and caused the second one to break, second one was on the right side but the roller cage was broken on the left side of it, so it would cause uneven power to the wheels, know what I mean.