I love my 2000, Magnum 500 but there is a bit of play in the drive shaft coupling at the rear differential coupling. The splines on the pinion shaft and the coupling has started to show signs of wear. I have always kept all drive joints well greased and this is the only wear I have found in the rear drive train. I only have 1400 miles on this quad. Eventually I may require a new pinion shaft and coupling.

All parts info I have found shows a roll pin at the Differential end connecting the Diff shaft to the coupling. On my quad there isn't a hole in the pinion shaft or coupling for a roll pin to be installed.

My dealer was not too quick to offer of any solutions, nor did they confirm that there should be a pin installed at the diff. end.

Any suggestions to help me prolong the life of this connection. Drilling a hole in the shaft is not an option, as they are hardened steel. Has anyone else had a similiar problem or dealings with Polaris

Thanks

 

There is only one pin at the trans end. they do get loose from wear, as they are softer than the shafts. better to wear the yoke than shaft. there really isn't anything other than to replace the yokes or coupler to fix this properly.
also, look up the part diagram in ronnie's part fiche at the top of the post page. it shows the rear shaft that is your set up. its under suspension - rear swingarm and axle

 

Thanks for the info, but on the parts diagram from Polaris "for the rear swing arm w/ axle " it does show a pin at the rear differental. A closer look at the diagrams also indicates that there is a hole in the pinion shaft at the diff end. There is also a pin at the transmission end (this one I do have on my atv). I am not too troubled about replacing the coupling, but if I have to replace the pinion shaft (which is starting to show wear on the splines) it is a bit more expensive. Has anybody ever tried using a locking compound on this coupling (on the diff shaft end only) ??

Here in Manitoba the coupling costs $70.00 and the pinion shaft is around #260.00.

 

flanders, i rechecked and i see what you mean about the pin being shown. its just at the wrong end of the diagram. none of the mags ive worked on have a pin at the diff.
i think i would just replace the coupler for now, if it were mine. you'll still get a good bit of life out of the shaft before needing another coupler. also, make sure to grease the coupler, there is a fitting on it unless it got knocked out.
as for a locking compound, the coupler is made to move with the travel of the suspension. probably wouldn't do much, maybe give you a problem.