Need help in good old germany. I bought a 97 Sportsmann 500. The pre owner never used a grease gun on the drive lines. Now I need to change the the jonits on the rear gear box. I loosen the two bolts which holt the forks to the gearbox. Than I tried to take the drive shafts off. I only took a light force by a hammer, but the forks are dam tight on the gearbox. I be afraid to by using my big hammer to break somesing on my ATV. Can somebody give me a good advice to solve this problem ?
Thx in advance

Reinhold

 

'96 - '98 SP500's were a challenge on the rear drive shafts if you don't know the trick. There is a 9/16" bolt head behind the U joint closest to the gearbox, on both shafts. You will have to use an open end wrench to loosen this bolt. The threaded spacer (ties both shafts together in the gearbox) will stay with one of the shafts (in other words you only need to loosen one side to get both shafts out). When you lose your working space (bolt head backs against U joint), pull out on the axle some to give you more room. The axle is splined into the gearbox, and once the bolt is completely unthreaded, will just slide out - marking the shaft's left or right will help assembly be much easier. Also make sure the threaded spacer is tight to whichever axle it came out with prior to putting it back together.

Here is a diagram to give you a better idea: '97 SP Rear Axle

 

The splines may be rusted/seized, try some penetrating oil in the spline area and let it set a few hours. Keep soaking them so it helps disolve the rust. Screw the bolt back in most of the way then install a spacer between the bolthead and the u-joint, now as you loosen the bolt it will act like a press to separate the splines. Good luck!!!!

 

Hi Quadwrench and powerslider

Thx for yor hints.

I have used today my big hammer , penetrating oil und gas burner to heat the U-forks up. Bud they don´t move a little bit. I´m lttle bit frustrated today :-((
How the polaris fitters get them off? Have they a special puller ?

Reinhold

 

Did you remove the clips ("C" shaped clip) from the inside end of the U joint caps?? there are 4 for each U joint - one on each cap - this is what keeps the U joint in place (not a compression fit). Take a screw driver and catch one end with it and smack it with a hammer - they ususally just fly off. I've never had one that I could not come out - a few stubborn ones that with a little heat would press out ( I use a hydrolic press for U joints - takes some of the chance of bending the yokes out of the picture).