'01 Sportsman rear axle removal - Page 2 - Polaris ATV Forum
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post #11 of 30 (permalink) Old 06-11-2017, 07:45 AM
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Chances are he can't get either side out so repeatedly saying this isn't helping at all!
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post #12 of 30 (permalink) Old 06-11-2017, 07:46 AM
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Chances are he can't get either side out so repeatedly saying this isn't helping at all!
my bad good point
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post #13 of 30 (permalink) Old 06-11-2017, 10:43 AM
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Get a pry bar in the inside u joint and find something to pry it against or hold the other end of the bar and smack it with a hammer as close as you can to the axle. The screw driver won't get much leverage there and like what was said above could get seals. Possibly break part of the housing.


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post #14 of 30 (permalink) Old 06-11-2017, 11:11 AM
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Wrap one end of an old strap around the center section of the axle and tie a loop into the other end. Put a sledge hammer through the loop and give it a good swing outwards. Kinda acts like a slide hammer. It's always worked for me.


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post #15 of 30 (permalink) Old 06-11-2017, 05:33 PM Thread Starter
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Originally Posted by carch4 View Post
Did you remove the other side by now? Or still messing around problem side of axle? Pound out thru other side. wow this is a week old brother


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Like I said, that is a last resort. I don't believe the other side will come off any easier. Yeah, it's been getting soaked most every day for more than a week now.

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'01 Polaris Sportsman 500 HO project (needs a 'lil TLC. OK, OK, a LOT of TLC)
My first 4WD ATV!

1" wheel spacers, 25" STI Black Diamond Tires, Front and rear storage with seat.

My other ride is a 2-stroke sport quad.
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post #16 of 30 (permalink) Old 06-11-2017, 05:39 PM Thread Starter
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Driving those screwdrivers in that way will probably cause the seal to start leaking and may in fact damage/crack the housing. It also cocks the cup and ring to one side binding it and making it even harder to get out.
Keep soaking with PB and go all around the cv cup with a 3 lbs. hammer jarring it. Then repeat. Then yank on it some. Then repeat. The splines and/or spring ring are rusted together because they haven't been removed for 17 years. The trick is to break them free with vibration. Keep at it and it will eventually come loose. It also helps to have an assistant keep outward pressure on it while you pry and jar.
You can remove the axle shaft from the cup and tack weld a short piece of chain to attache a slide hammer if you are impatient. But that's pretty extreme. I've always been able to get them to come with persistence.
Thanks polman. I'll keep at it as you described.

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'01 Polaris Sportsman 500 HO project (needs a 'lil TLC. OK, OK, a LOT of TLC)
My first 4WD ATV!

1" wheel spacers, 25" STI Black Diamond Tires, Front and rear storage with seat.

My other ride is a 2-stroke sport quad.
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post #17 of 30 (permalink) Old 06-12-2017, 11:06 AM Thread Starter
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Originally Posted by Tmtbob View Post
Get a pry bar in the inside u joint and find something to pry it against or hold the other end of the bar and smack it with a hammer as close as you can to the axle. The screw driver won't get much leverage there and like what was said above could get seals. Possibly break part of the housing.


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Wasn't using the screw drivers to pry. Was using the blades as a wedge. Gonna keep putting pb blaster on it til the weekend. Should have a new air hammer by then too. I'll see if I can drive it out by putting the air hammer against the inside of the outer u-joint and pushing away from the machine with it.

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'01 Polaris Sportsman 500 HO project (needs a 'lil TLC. OK, OK, a LOT of TLC)
My first 4WD ATV!

1" wheel spacers, 25" STI Black Diamond Tires, Front and rear storage with seat.

My other ride is a 2-stroke sport quad.

Last edited by Muggzy; 06-12-2017 at 06:16 PM.
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post #18 of 30 (permalink) Old 06-12-2017, 12:29 PM
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There is a seal behind the inner axle cup so be careful you could damage it with the screw drivers. Use something to pry out on the axle and hit that inner cup with a hammer, work your way around the axle, just apply the pressure toward the axle. I used a long 90 degree needle nose pliers to pry with, it put pressure on two sides of the axle at the same time. And yes like previously stated coat the splines with anti-seize....See the link below, these are exactly what i used along with 2lb hammer.

https://www.harborfreight.com/11-inc...ers-39539.html



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post #19 of 30 (permalink) Old 06-14-2017, 03:32 PM
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Quote:
Originally Posted by Bshuk57 View Post
Wrap one end of an old strap around the center section of the axle and tie a loop into the other end. Put a sledge hammer through the loop and give it a good swing outwards. Kinda acts like a slide hammer. It's always worked for me.


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This technique will work too Mugzy ^^^I forgot about the ole sledge hammer trick.
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post #20 of 30 (permalink) Old 06-15-2017, 09:24 AM Thread Starter
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Quote:
Originally Posted by Bshuk57 View Post
Wrap one end of an old strap around the center section of the axle and tie a loop into the other end. Put a sledge hammer through the loop and give it a good swing outwards. Kinda acts like a slide hammer. It's always worked for me.


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This technique will work too Mugzy ^^^I forgot about the ole sledge hammer trick.
Thanks again Polman, I'm gong to focus on this repair on Saturday. On way or another, that damn thing is coming off.

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'01 Polaris Sportsman 500 HO project (needs a 'lil TLC. OK, OK, a LOT of TLC)
My first 4WD ATV!

1" wheel spacers, 25" STI Black Diamond Tires, Front and rear storage with seat.

My other ride is a 2-stroke sport quad.
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