'01 Sportsman rear axle removal - Polaris ATV Forum
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post #1 of 30 (permalink) Old 06-04-2017, 09:12 AM Thread Starter
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'01 Sportsman rear axle removal

Hey all, I've been searching on here and you tube and can't find any help on this. I'm trying to replace my left rear axle on my 500HO but it won't come out.
My Clymer's manual and all the on-line advice says "hold the axle straight out and give it a good hard pull" but this be-ach just won't give. Tried spraying WD-40 into the joint and letting it soak for a few days, but no joy. I'm trying to use a screwdriver as a wedge but not getting anywhere here either - kinda worried about cracking the tranny case.
Anyone overcome this problem or have some experienced suggestions?

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My other ride is a 2-stroke sport quad.

Last edited by Muggzy; 06-04-2017 at 09:16 AM.
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post #2 of 30 (permalink) Old 06-04-2017, 06:51 PM
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hi, try soaking spring clip with BP BLASTER penetrating oil, it works much better than wd40 in my opinion/ experience.
another thing could be its got 1998-99 500 parts, those years had a small bolt holding axle in place, bolt would be right where your screwdriver is placed in that small gap.


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post #3 of 30 (permalink) Old 06-05-2017, 03:55 AM
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Quote:
Originally Posted by Muggzy View Post
Hey all, I've been searching on here and you tube and can't find any help on this. I'm trying to replace my left rear axle on my 500HO but it won't come out.
My Clymer's manual and all the on-line advice says "hold the axle straight out and give it a good hard pull" but this be-ach just won't give. Tried spraying WD-40 into the joint and letting it soak for a few days, but no joy. I'm trying to use a screwdriver as a wedge but not getting anywhere here either - kinda worried about cracking the tranny case.
Anyone overcome this problem or have some experienced suggestions?

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do you still have the problem??? If so remove the other axle once its removed use a solid bar like a rebar and with a sledge hammer pound on the problem axle from the other side and it will come out....once you install new axles or reinstall old ones always remember to apply anti-seize on axle threads don't be shy with it..I had the same problem with my 03 sportsman 600
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post #4 of 30 (permalink) Old 06-05-2017, 01:12 PM Thread Starter
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Sportsman Dan, Thanks. I'll try PB Blaster, I actually used Liquid Wrench repeatedly over the course of a few days with no luck. And thanks for the suggestion re the year of the parts but they're def orig. '01

Carch4, also thank you for the suggestion. As a last resort, I may try the other side and pound it through as per your suggestion but I'm really reluctant to, 'cause what if that side is just as bad? Then I've ripped into both sides and got nowhere. Like I said, I'll keep that for the last resort.

I was hoping that someone who does this for a living may have a trick or two up their sleeve, but I appreciate all ideas at this point. Thanks In advance!

'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; 06-05-2017 at 02:58 PM.
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post #5 of 30 (permalink) Old 06-05-2017, 05:51 PM
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Take the boot off the inner joint, remove everything from the cup so all that is left is the cup, vise grips on one side & that screwdriver on the opposite side, pry & pull till it pops.
That's how I was able to get mine out, it's a b***h, but it can be done. I'll second the use of anti-seize, I lathered the ends with it.

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post #6 of 30 (permalink) Old 06-06-2017, 08:58 AM
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"...apply anti-seize on axle threads..." You mean splines, right? I haven't messed with axles yet, but didn't think there were any threads involved?
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post #7 of 30 (permalink) Old 06-06-2017, 09:29 AM
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"...apply anti-seize on axle threads..." You mean splines, right? I haven't messed with axles yet, but didn't think there were any threads involved?
Yes, splines
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post #8 of 30 (permalink) Old 06-11-2017, 03:46 AM Thread Starter
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Sooo I tried pounding 2 screwdrivers in as "wedges" against the transmission case and still getting no where. I haven't tried using an air impact hammer with a chisel but I'm not sure what else to do. Really worried about cracking the tranny case though. Anyone ever tried to do it this way successfully?

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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 #9 of 30 (permalink) Old 06-11-2017, 07:00 AM
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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.
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post #10 of 30 (permalink) Old 06-11-2017, 07:12 AM
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'01 Sportsman rear axle removal

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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Last edited by carch4; 06-11-2017 at 07:14 AM.
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