Hi All,

New member to ATV Connection from Ottawa Canada, nick name Magic Man, got that handle from one of my hunting buddies girl friend,,, won't say how...

I have been reading a few of the threads on front axle replacements for the polaris sportsman 500, and I'm not sure if I need to tap out the roll pin above the U joint, or to give the big tug and pull the axle out of the diff.

My 2000 Sportsman 500 has a CV outer on the axle and a U joint on the inner end of the axle neer the diff. There is definately a roll pin through the splined shaft that comes out of the diff.

Dealer told me to pull the axle out of the diff then knock out the roll pin and replace the axle. Only problem is that the axle doesn't want to come out of the diff and there is litle if any room to knock out the roll pin.

Any of you guys/gals have any suggestions???

Don't want to bring it too the dealer, already got me for over $400 bucks for the axle.

Any help would be apprecited.

Magic Man

 

Welcome

 

Very little room to get the roll pin out,but you need a fairly long punch you can grind down to the roll pin size,jack the atv up and turn the drive shaft to where roll pin slightly faces toward the front where there is a small cutout in the frame. Then you can drive it out. Polaris had a roll pin remover I ordered which was a joke: A 2' 1/2" diameter bar stock with it milled down to roll pin size about 3 inches from the end. Didn't last a month. OR what I found was the best was to use an air chisel with a long bit you can modify.Zips em out in a hurry. OPT

 

Thanks buddy,

I found a small hole in the front end that was just big enough four a 1/4 inch rod, about 8 inches away from the roll pin.
A 12 inch Snap-On phillips screw driver with 4 inches from the tip bent to a 10 to 15 degree angle, and a few well placed hits on the screw diver handle with a standard hamer and the pin came out. It was a little stuburn at first, but once it started to move a little, it came out easily.
Forgot to mention that a sprayed it well the night before with WD-40 (penatrating oil)

Thanks again,

Magic Man

 

I forgot to mention that I have replaced the roll pin with a 5/16 by 2" stainless steel bolt with a nylon/stainless lock nut.