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Old 05-08-2011, 11:01 AM
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Front drive shaft removal

I can't figure out what I'm doing. I have 2 Polaris quads. a 330 Magnum and a 55 ATP. Both are 2004. Both have bad cv joints and need to be replaced. The 500 is destroyed and needs the whole shaft replaced so I bought 2 whole shafts. I can not get them out of the front differentials to save my butt!
There is a circlip on the end of the shafts that keeps them in the differential. How on earth do you get them out? I've searched youtube and can only find people taking apart other quads, not Polaris. Those just seem to pop right out by hand. Mine will not! I've tried prying them out, yanking them out and all kinds of mess. My neighbor is a big guy and he can't get them out. HELP ME PLEASE, SOMEONE!!!!!
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Old 05-08-2011, 12:17 PM
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Get 2 pry bars or screwdrivers, and put them on the opposite side of each other and pry at the same time. It should pop right out, that's how I did it,
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Old 05-08-2011, 02:39 PM
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Old 05-08-2011, 06:20 PM
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Quote:
Originally Posted by jleo1 View Post
I can't figure out what I'm doing. I have 2 Polaris quads. a 330 Magnum and a 55 ATP. Both are 2004. Both have bad cv joints and need to be replaced. The 500 is destroyed and needs the whole shaft replaced so I bought 2 whole shafts. I can not get them out of the front differentials to save my butt!
There is a circlip on the end of the shafts that keeps them in the differential. How on earth do you get them out? I've searched youtube and can only find people taking apart other quads, not Polaris. Those just seem to pop right out by hand. Mine will not! I've tried prying them out, yanking them out and all kinds of mess. My neighbor is a big guy and he can't get them out. HELP ME PLEASE, SOMEONE!!!!!
Most of the time you have to soak them with penetrating oil for a while, then try the pry bars. Sometimes they can be stubborn!!
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2007 Sportsman 800 efi , L&R tall windshield, Viper Max 4000 lb. winch with 3/16" Amsteel rope by Atv Winch Rope, 25' Amsteel tow rope by Atv Winch Rope, RDC fairlead, RDC deluxe gas cap, RDC shifter, RDC overflow bottle cap, RDC 2" lift , 27" Maxxis bighorns s/w on Vision Outback 12" wheels, Uni air filter, Dalton o/bl primary clutch spring, front and rear brushguard, front and rear rack extensions, and a SanAngelo backrest
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Old 05-09-2011, 06:57 AM
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Thumbs up Thanks

Thanks guys,

My son and I got them all out. While waiting for a reply we went out and took the whole front differential out with both shafts still in place. We then disassembled the whole thing to see how it was built.

We found that the shaft never actually enters the differential so I sprayed WD-40 all down around the shaft at the differential (basically filled the hole up) and let it sit awhile.

In the meantime I ran to my brother's and borrowed his ball joint fork. It barely fit but it was good enough. Tryed it on the one without WD-40 and it didn't want to budge. Tryed the one with WD-40 and pop... right out it came! Sprayed the other one and waited a couple seconds and it came right out too.

Until I learned, by taking it apart, that I would only be prying against the cup which held the shaft I was afraid of tearing something up by hitting it to hard. The WD-40 is what made it all happen though.

Thanks for the info everyone! I appreciate it. Now we both know how they are built too and I especially like the part that my 15 YR old son is learning something besides Xbox and texting and just tearing up the quads and cycles and then leaving them for me to fix! And he seems interested. Thanks again, Jeff
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Old 05-09-2011, 06:36 PM
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Way to go!

Glad to see you're making the repair a family project!!

It's always good to see things like this from two perspectives!

Good luck!!
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