I have 26" 589 tires on my 700. A couple of weeks ago I went into a mud hole and my front wheels got cocked hard to the right. I put it in low and 4wd and exploded my front left u-joint. I have to replace my front cv shaft (axel) because it spread my yoke. My question is do I have to crack open the front diff to get the old yoke out(the one that comes out of the diff)? ....and also that yoke that comes out of diff has alot of play going back into diff, is that normal? Thanks...............David

 

this doesnt have a cv joint on each end? you said it's an 04'. looking at the parts break down, it doesn't show universals? but if it did i would guess yes you would have to to tear apart the fornt housing to fix it. just my guess w/out looking.

 

Axle just pulls out of diff, I use a slide hammer on some cause they can be tough, usuallly a good sharp yank will get them out.

 

I would of thought the plastic roller cage would give way well before a yoke would bend. The cage is the weakest link in the front drive line.

 

i actually did the same thing as mentioned above to my 800 w/ out breaking the cage thankfully lol.

 

I've been in that situation before where the wheels are fully cocked one direction and I've been afraid of stressing the joints. I usually back up a lite to help the angle then try her in forward again.
Wouldn't it be great if all quad manufacturers came out of the box with gorrilla axles. If the quantity went up that much the price would have to come down and then most quads would be bullet proof.

 

Thanks guys....been super busy and now just got back to reply. I bought a service manual(what a life saver) and just yanked the yoked shaft out of the front gear case. With all of this happening, I noticed I need ball joints in a bad way. I removed the screws and plate but dont have the polaris "tool" they tell ya to use to get the ball joint out....any help? Thanks, David

 

Do you mean u- joint ?

Here is a good link to get parts for your ATV at a auto parts store at much cheaper prices.

Make a list of common numbers we need

 

Ball joints.....I got one out with a home made puller...guess i will "beat" new one in with hammer and wood or piece of brass. Any suggestions?

 

I had to replace one on a '04 400 that was sheared off in a collision with a tree. There was nothing to attach a puller to so I just heated the strut with a small torch and is puller right out. I used a hammer with a large socket to re install new one. I have not had any problems with the strut nor the ball joint so I guess it was a success. Good luck, but its really pretty simple this way.