I'm trying to help out a friend who has a 01 Sportsman 500 and needs the frt u-joint replaced the one nearest to the front differential.First I soaked everything with penetrating oil, then I knocked out the roll pin that goes through the pinion shaft & yoke, Ive tried sliding the shaft forwards, backwards and even removed the 4 bolts that hold the front differential in place so I could hopefully slid the yoke off the pinion shaft by sliding the diff. forwards all with no success. Is there a trick to it or am I missing something here? Any help or suggestions guys will be greatly appreciated---Thanks MW

 

is it just rust holding it on? did it move at all when the roll pin was removed? i would use heat , but you would have to be real careful not to get it too hot or damage would may hapen to diff. seals.

 

Man O' man I drenched it with liquid wrench, used a wooden dowel rod and 3lb beater, plus like I said above I even took out the bolt holding the front diff. and tried to slide it ahead to get it off & nada, I was just wondering if I was missing a step or procedure that wasn't obvious, I'm kind of stumped over it and I don't want to have my riding Bud bring it to the shop for such a supposed easy repair-lol- Please guys, any suggestions will be appreciated.

 

Sometimes have to use liquid wrench,HEAT,HEAT,HEAT, and I sometimes have to use a blunt tip on my air chisel to FINALLY get them off! Pain in the butt I know!! KEEP trying will come off. Good luck

 

Thanks OPT, I told my Bud to keep spraying it with the liquid wrench a couple of times a day over the weekend and I also left the roll pin out and suggested that he ride it around the dooryard after spraying in hopes that it would make the liquid wrench penetrate better. Then come Monday afternoon we'll tackle it and if necessary use a map gas bottle.

 

Wow all the ones ive ever seen the yoke was way loose.

 

Yep thats how mine is, the darn thing rattles when low on grease-lol-my friend was spazing over this-all worried he is going to have to buy more parts. I'll let you all know how I make out when i finish it Monday afternoon.