While replacing front springs on my 2002 SP 500HO the right front axle pulled out of the hub. How do I get it back in? Is it a splined or keyed shaft? Do I have to dismantle the entire hub to make sure nothing is out of place or will the shaft go back in if I fight with it for another hour or two? Advice appreciated.

 

Take it apart and check everything out.
do the other too.
Splined shaft !

 

It is a splined shaft, held into the CV joint with a spring-loaded clip. Chances are the CV joint twisted under the boot without you realizing it, and is no longer in line with the axle. You will have to loosen the CV boot clamps, and slide the boot up the axle a little, so you can see how the hub in the CV joint is oriented. Get it in line with a screwdriver shank or something similar, and put it back together. You can get room to work either by unbolting the top of the strut, or by popping apart the ball joint at the bottom of the strut from the A-arm.

Farmr