I'm exhausted from banging a punch so much that I distorted the tip & maybe the roll pin
which is 1/3 out on front inboard axle yoke 03 sp500.
It's been soaked for a couple of days with penetrating oil & also applied some heat to it but not too long cuz I am afraid it will heat up the output shaft & melt the seal.
Anybody have any ideas?

 

did you try the other direction? my 00 sportsman wasent that hard. is yours that rusty? take a drill and drill it out.

 

Thanks for responding chuck_raduenz.
I just got it out. Had to remove the radiator to get to get a full swing.
Yea it was really rusty and had fallin apart. Not to mention that the punch I had been using
I'd banged the tip to were it had widened (is that a word?) and it was hanging up at the output shaft edge not being able to push it thru.
Glad I move the radiator out the way cuz it gave me a chance to inspect the backside
where it is obstructed by the fan & housing, and found it incased with mud.
should run cooler after I clean it...and the work keeps on piling.And I have yet to take it for a real ride. Hope it doesn't dissappoint when I finally do.

 

the punch was flared, mushroomed? dont feel so bad. my new wheeler seems to be a lemon for electronics. first the battery froze in jan and the solinoid whent out, and now the gas gauge level sensor in the tank always reads full, when it seems the tank is half full. id rather fix something made of metal then of something electonic. trade ya???

 

Yes mushroomed is a great description. The previous owner said it needed some work
but he suuure down played it.lol Trade? Sure anytime, I've practically have the mechanics down, why not add electronics...and before you know it I'd be answering questions here.
and I've only riden this wheeler appx. 2 miles total.

 

you answer the mechanics questions. i can answer electronic questions. and together we can fix a whole wheeler. lol..... if i have one more issue i might go with honda.

 

I got so sick of those stupid pins. Had a couple work their way out on the rear shaft of my 02 700 when I had it and one on my 05 800 that trashed the tranny housing. Luckily my dealer replaced the tranny(they somehow got it covered by Popo because it wasn't under warranty anymore). After that I gave up on the roll pins and the dealer had some shear bolts from an Ariens(I think) snowblower that were just long enough and the perfect diameter to fit with a nylock nut. Never had an issue after that.

 

hey switzomatic I had the same problem with my roll pin on the rear shaft. Mine ate a hole in the case also but we were in the mountains of colorado when it happened. I just cleaned it up real good with brake clean and some sand paper,then filled the hole with jb weld and it has held up without leaking. I put another roll pin in but might go with the shear bolt like you got.

 

IM starting to agree with chuck on the honda thing . My 05 500 had the timing chain sprocket blow apart with only 130 hr on it. trail riding not hammering on it

 

I don't know chuck , I'll probably have everything that can wear replaced on this wheeler & not have too many issues after I iron all the kinks out.....I know,I know I'm being optimistic.lol
I'll probably have some electronic questions for you after I tackle everything I'm working on now. 1 thing I'll have to address for sure is the speedo not working.

Thanks for the idea switzomatic.
Gonna go and grab a couple of grade 8 bolts to do just that.