prop shaft removal - Polaris ATV Forum
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post #1 of 43 (permalink) Old 11-08-2010, 09:51 AM Thread Starter
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prop shaft removal

I have an 04 700 sportsman, can the front prop shaft be removed without removing the u joints. I replaced the ones in the front drive shafts, what a pain. I can get the whole shaft w/ u joints for $25 more than just 2 u joints.
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post #2 of 43 (permalink) Old 11-08-2010, 06:32 PM
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You can buy the u-joints much cheaper at an NAPA or an ag equip dealer. I bought mine at the local New Holland tractor dealer (part number 139842) and it's greasable. They were $17 and change as opposed to $40+ at Polaris. I checked on Babbit's parts and the 04 700 uses the same u-joint as my 05 400. If you haven't lubed it much, the slip yoke is probably worn too...in that case, the shaft from the dealer might be the cheap way to go. I saw a post where someone listed a PN for the joint NAPA at a few bucks cheaper (search propellor shaft).
Removal of the shaft isn't that bad. After removal of appropriate plastic, drive the drift pin out of the front yoke, lube the input shaft and rear/slip yoke so it will slide back easily. Pry the yoke off the front diff until it's free move the front of the prop shaft to a point where you can slide/pry it forward, off the output shaft...VOILA! Back on in reverse order. It might be a good idea to soak the drift pin and yokes in WD40 the night before. Holy $h!t, I think it took me longer to type this post than to remove the shaft. Jim
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post #3 of 43 (permalink) Old 11-09-2010, 04:40 AM
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Thumbs up prop shaft

Quote:
Originally Posted by rifleman24 View Post
I have an 04 700 sportsman, can the front prop shaft be removed without removing the u joints. I replaced the ones in the front drive shafts, what a pain. I can get the whole shaft w/ u joints for $25 more than just 2 u joints.
Yes it can. Look at the yoke at the front diff, you'll see a pin that goes thru the yoke, simply drive the pin out with the proper punch then slide the shaft back until it comes off the diff input shaft. After which, you can remove the shaft from the tranny output shaft by sliding the prop shaft forward. That's it. Oh, by the way, the napa joint number 338. Just make sure you install the grease fitting facing the shaft and not the yoke.

Con

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Last edited by racer37l; 11-09-2010 at 04:42 AM.
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post #4 of 43 (permalink) Old 11-11-2010, 01:49 AM
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here's a little trick to make it much easier

Raise up the front end of your quad so you can get under it with enough room to swing a hammer. There's a hole in the front center of the skid plate directly under the yoke where it connects to the front diff. Rotate the shaft till you can see the end of the roll pin and use your punch through that hole. It's a lot easier than trying to punch it out under the fender, or removing a wheel to have enough room to use your hammer. Once the pin is out, the shaft will slide backwards(further up the output shaft on the tranny) until the front yoke comes off the diff. Probably have to use your hammer to knock it backwards. Also, soak both the front and rear yokes with parts blaster, wd40, etc to make it slide off easier.

The bonus to the napa joints is that they are greasable, and the popo ones aren't. Oh, and they're a LOT cheaper.
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post #5 of 43 (permalink) Old 11-13-2010, 12:18 PM
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Anyone know if the greasable NAPA u joints listed for the 04 700 are the same as the ones on an 08 500?

04 Sportsman 700 efi black and silver, Big Gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Black Rock wheels,Polaris(warn) winch and plow, 2 inch receiver, Filtermag.
08 Sportsman 500 efi Browning camo, Big gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Polaris(warn) winch, Cycle Country plow, 2 inch receiver, Black rock wheels,Filtermag
00 Magnum 325 not very HO green, rolled, wrecked and rebuilt,heated grips and thumb warmer, Filtermag.
88 Yamaha Warrior 350 my first
88 Honda Foreman 350 takes care of the yard work
91 Suzuki DR 350 solves the urge to ride wheelies and catch big air
05 Kawasaki KLR 650 scratches the paved road itch
92&93 Indy 500 EFI SKSs takes care of the need to get away from home in the winter
04 Yerf Dog spiderbox buggy was supposed to be for the kids but I find I cant quit tinkering with it
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post #6 of 43 (permalink) Old 11-13-2010, 10:10 PM
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Not sure. Go to babbitts online and look up the oem part numbers for both models and see if they are the same.
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post #7 of 43 (permalink) Old 11-14-2010, 08:41 AM
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Cross referenced the U joint numbers for my 04 700 and my 08 500 and it looks like all the U joints for both the front and rear prop shafts on the 700 and the front prop shaft on the 500 are all the same. Looks like I'm off to NAPA to get some greaseable joints.
Thanks

04 Sportsman 700 efi black and silver, Big Gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Black Rock wheels,Polaris(warn) winch and plow, 2 inch receiver, Filtermag.
08 Sportsman 500 efi Browning camo, Big gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Polaris(warn) winch, Cycle Country plow, 2 inch receiver, Black rock wheels,Filtermag
00 Magnum 325 not very HO green, rolled, wrecked and rebuilt,heated grips and thumb warmer, Filtermag.
88 Yamaha Warrior 350 my first
88 Honda Foreman 350 takes care of the yard work
91 Suzuki DR 350 solves the urge to ride wheelies and catch big air
05 Kawasaki KLR 650 scratches the paved road itch
92&93 Indy 500 EFI SKSs takes care of the need to get away from home in the winter
04 Yerf Dog spiderbox buggy was supposed to be for the kids but I find I cant quit tinkering with it
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post #8 of 43 (permalink) Old 03-05-2011, 09:05 AM
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Help with REAR prop shaft

Any help about hot to install the rear prop shaft?

Sportsman 800 EFI

Do I have to release the rear gearcase?
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post #9 of 43 (permalink) Old 03-06-2011, 12:17 PM
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the rear is a pain in the butt on 05+. You will have to unbolt the rear diff. If memory serves me right, it was 9 or 10 bolts. I ended up removing the front bolt of the rear a-arms and the bottom shock bolts for access as well. Just finished a few hours ago. Took about 2 hours to do it.
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post #10 of 43 (permalink) Old 09-16-2011, 07:18 PM
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I have an 07 Polaris 800 EFI, the u-joints in the rear are bad. Upon looking at it, I think I can remove the front u-joint (at the transmission) from the prop shaft. I then would have enough room to remove the prop shaft without removing the rear differential. If the caps pound out fairly easily, does anyone see a problem with it?
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