U-Joint Disassembly; U--Joint Assembly - Polaris SPORTSMAN 600 2003 Service Manual

Roll Pin Remover Tool (PN 2872608)
NOTE: If removing front housing, use roll pin removal
tool to remove the pins from both front drive axles.

U-JOINT DISASSEMBLY

CAUTION: Wear eye protection at all times.
1. Remove internal or external snap ring from all
bearing caps.
NOTE: If yoke or bearing is removed, cross bearing
must be replaced. Note orientation of grease fitting
and mark inner and outer yoke for correct
re-positioning during installation.
2. Support inner yoke as shown and drive outer yoke
down (bearing cap out) with a soft face hammer.
3. Support U-joint in vise as shown and drive inner
yoke down to remove remaining bearing caps.
4. Force U-joint cross to one side and lift out of inner
yoke.
U-JOINT REASSEMBLY
1. Install new bearing caps in yoke by hand.
Carefully install U-joint cross with grease fitting
properly positioned inward toward center of shaft.
Take care not to dislodge needle bearings upon
installation of cross joint. Tighten vise to force
bearing caps inward.
FINAL DRIVE FINAL DRIVE
7.7