I have a 1996 Polaris 500 sportsman, I need to change out the rear universal joints. I have a shop manual and have followed the directions. I have the bolt backed out as far as possible that holds the joint to the transmission. My problem is that the shaft (joint) will not let go of the transmission. I have sprayed it and let it soak over night, and I tried to pull it by hand, but it will not release.
Any suggestions on how to remove the joint (shaft) ?

thanks
rust

 

There is a roll pin in the yoke on the tranny side of the shaft. Make sure that is knocked out. You will also have to unbolt the rear differential and slide it back to get the shaft off.

 

I do not see a pin? There is a bolt that holds the yoke onto the tranny. I have backed the bolt off as far as i can, I have attached a 3/8 rope in through the universal, and hooked it onto a come along and put strain on the rope to try and pull it away from the transmission. ( I have another rope on the opposite side to prevent bike from sliding sideways).
I have sprayed the yoke area with PB Blaster, and have let it soak. Tapping on the yoke with a rubber tipped hammer, but it is not moving, any suggestions???
thanks
rust

 

My manual does not show a pin? Is there suppose to be a pin in the 1996 500 sportsman??
rust

 

My bad on the pin. Thought the older one's were set up the same. Will that bolt come all the way off? May be what is holding things up. Might need a little heat persuasion.

 

I do not think heat is a good idea, there are seals behind the yoke- heat may damage them. The bolt will come out- when the yoke slides off- thats the way it looks in the manual.
Any ideas- anyone- on how to remove the yoke? I am open to all suggestions.
Thanks
rust

 

Use a slide hammer , it will come out.I rig a small piece of chain around the shaft by the inner joint, hook it to my slide hammer and give it a few whacks, some are stubborn but they come off.

 

thanks Kirbbirds, but I was able to change the inner universal without removing the yoke. I had to remove a lot of parts around the area- so I had room to use a press type universal joint removal tool.
I changed two u joints- inner on the right side and outer on the left side, the other two were OK.
Glad that is over with, but it gave me a chance to inspect all the suspension parts- all OK !
If I ever have to remove the yokes- I will use your idea.
Thanks
rust