01 sportsman front outer cv joint removal from axle - Polaris ATV Forum
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post #1 of 13 (permalink) Old 05-29-2012, 08:01 PM Thread Starter
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01 sportsman front outer cv joint removal from axle

OK,
found this site and hope its going to be as informative as other I have found for sleds/boats etc... anyway,, here goes.

I have a 2001 sportsman 500 and need to replace the front/outer cv boot. I have pretty much everything done up to the point of getting the cv joint off the axle to get the new boot on. And here is my problem,[I] I can't find the SNAP RING to expand to get the joint to slide off the splines[/I]. I cleaned alot of the grease out and can't find a recessed spot in the cv joint that the snap ring would fit in? Do I need to remove any balls and ball holders/cage or whatever?? Do all polaris have snap rings, or do I tap it off the axle..

Thats it guys/gals save the day for me,,,
as I am running out of bud lights... lol.
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post #2 of 13 (permalink) Old 05-29-2012, 08:58 PM
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Welcome to the board!
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post #3 of 13 (permalink) Old 05-29-2012, 09:34 PM
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Just give it a good jerk it will come off replace boot the tricky part is getting it lined back up with all the grease in there pop it in and bolt it back up helps too if you take the tie rod off

02 500 sportsman x
warn 2500 front-back winch
2 inch lift
heated grips
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post #4 of 13 (permalink) Old 05-30-2012, 07:57 AM
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Here is my tip: When in doubt, check the exploded parts diagram on any parts website. I go to cheapcycleparts.com. Here is the link for what you are looking for:
CV JOINT - BTB - A01CH50AA Polaris SPORTSMAN 500 HO (A01CH50AA) 2001 OEM Parts - Cheap Cycle Parts

It shows a circlip, which isn't an eared snapring. It is instead a compression spring that keeps a little tension on and can be overcome with a few stiff whacks from a hammer of some sort.
Happy wrenching (and whacking)(the cv joint tha is)

MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)
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post #5 of 13 (permalink) Old 05-30-2012, 09:08 AM
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Im having the same problem today! Whacking and whacking and it doesnt budge. Tough little retaining spring. Must try a bigger hammer, the 5# dead blow isnt working very well.

  • 08 500 EFI
  • LandR rear box
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post #6 of 13 (permalink) Old 05-30-2012, 10:19 AM
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I think you can just jerk n it will come off

I changed one a while back and took a little muscle the hardest part for me was getting the splines lined up and popping it back in but was not too hard just be sure you have it lined up good when putting axle into CV hope this helps

02 500 sportsman x
warn 2500 front-back winch
2 inch lift
heated grips
customized muffler
heat wrap pipe
2 halogen beams
tamarack passenger pegs
HERS
99 350 Big Bear
14" SS wheels
ITP baja cross 26" tires
Kolpin fr.-Back bags
thumb throttle extender
custom exhaust
3" additional lights on front
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post #7 of 13 (permalink) Old 05-31-2012, 04:44 AM
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CAREFULLY READ THE POSTS - some of you are talking about different ends of the axles. The inner joint has the ring to retain it in the differential - the outer end just slides on and off as jmowery stated, his is the same as mine and it will just slide on and off.

Fred
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post #8 of 13 (permalink) Old 05-31-2012, 05:40 AM
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Actually on an '01 the front inner joint is a u-joint. Not a cv joint. So he can only be talking about removing the outer cv joint. Not sure what year they changed that but my '04 has front inner u-joints and my '07 has front inner cv-joints.

MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)
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post #9 of 13 (permalink) Old 05-31-2012, 05:58 PM Thread Starter
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update

All right, thanks for the advice.

For the most part the information given was correct. Two quick pops with a soft mallet and it popped right off.

also the 01' does have a U-joint style inner joint. Now how do I pop it back on... same process just in reverse???

thanks again guys,,, I'll spend much more time on here..
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post #10 of 13 (permalink) Old 05-31-2012, 06:26 PM
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Happy to help Eye-Guy. I have been helped innumerable times by the forum hive-mind. It has saved me tons of money and because of the friendly folks here, neither of my machines has ever been "in the shop." So I try to help others when it is something I have some knowledge about.

MINE:2015 Sportsman SP 800 Sunset Red
completely stock FOR NOW

HERS:2007 Sportsman 700 EFI Black Metallic
Tamarack Cargo Seat, Fender Guards with footpegs from Thor, UNI air filter, Symtec heated grips
Warn 2500 with synthetic rope, ThermoTec exhaust wrap, Reverse Override, 3 Headlight Mod
26" Maxxis Bighorn 2.0



RIP Sarge (2004 Sportsman 700 EFI killed on trail 32, Rock House, Hatfield-McCoy)
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