Rear Axle removal

[aflumb]

So for the last week and a half i have been in the process of replacing all the bushing on the rear suspension on my 2002 Sportsman 500. well i also needed to replace the left (sitting on atv) rear inner boot. its been ripped for a while but not much riding. now to the fustrating part. i have been trying for 2+ days to get the axle out of the trans. im really hoping one of you guys can give me another idea to get it out. i am a mechanic and know how to get these type of axle out. it just seems to be locked in there. i have tried prying with 2 pry bars, lubing it, and snatching the h3ll out of it. im just not getting any where. i would really be thankful for any other ideas.

[robkelley13]

I just replaced mine and I ended up having to put it completely up on jack stands, have a friend put it in low gear and keep lightly bump the throttle to move the axel, while I was using a flat prior bar and a hammer tapping it in and trying to hold it wedged in between the rear end and the joint housing. Eventually it loosened up and poped right off.

[pjmartin]

If it's like my 2001 500HO there's a circular groove near the inboard end of the splines. There's a locking ring which sits in the groove and there's a gap in the spring locking ring so that it can compress. My manual says the following; "Pull sharply outward to remove shaft from transmission. Install a new lock ring upon assembly." The ring is on the right of the parts diagram.
Drive Shaft.jpg

[polman500]

I haven't tried it but there's a guy with a youtube video on the net entitled something like "Redneck axle removal" that looks like it'd work. He laid the machine up on it's side and removed the outer part of the axle. He then wrapped a chain around the short shaft into the differential and hoisted the bike a couple inches off the garage floor with a ratchet tie down to the rafters. He then whacked on the shaft after having soaked it with PB Blaster. It popped right out. It's a little extreme but would work for axles that have rusted in place.
Good Luck!

[aflumb]

thanks for the info everyone. so after soaking it all night and the next day. i got home yesterday after 3 good pulls it was out. and the problem was rust. i dont think this axle has ever been out.

so i got everything apart, and replaced. now it seems it doest want to go back in. but ill get it soon. still got to wait on the rest of my bushings for the other side any way!!

[polman500]

Way to go aflumb...I recently picked up an 02 that had bad boots and rather than go through all that hassle I just took the axles apart leaving the short shaft in the differential and rebuilt them on the bike. I soaked them good and will deal with complete removal if/when it becomes necessary. Had'em done and back on wheels in about 2 hours.
I was always told there's more than one way to skin a cat!

[robkelley13]

If I remember right put the gap on the snap ring up, which will allow it to stay in place better and it should slide right in. If that doesn't work put the gap of the ring down. Can't remeber which way it was but I do remember if it was on the side it wouldn't go in at all.

[aflumb]

Originally Posted by robkelley13

If I remember right put the gap on the snap ring up, which will allow it to stay in place better and it should slide right in. If that doesn't work put the gap of the ring down. Can't remeber which way it was but I do remember if it was on the side it wouldn't go in at all.

cool thanks for the tip. that was my probem. that and i dont want to pull the new boot loose. ill give it a try tonight. then ill let you guys know what happend.

[aflumb]

update:


so i got the jeft side all done and back together . no im just waiting on a couple more bushings and ill be ready to finish the right side. tom. im going to order a new starter and bendix seeing as mine has decided to quit on me. oh well.

[aflumb]

so after a week of waiting on parts, i finally got my quad back together. rode it around the sub divesion. cant wait to go back to NC to ride for real!