Taking a CV apart, the inboard end. |
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SteveA
Bolt Sorter Joined: Sep/01/2010 Status: Offline Points: 7 |
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Posted: May/12/2011 at 11:20am |
We need to make new shafts for our CV shafts which are Polaris sportsman 300 shafts. I have managed to take the outboard end off that does not plunge, a few good hits and the came right off. The problem is the inboard side, the side that plunges. I am unable to get these off, I have looked all over the place and the only thing I can find is ones where you have to remove a clip around the housing because the plunge happens on the housing, but on the sportsman 300 the plunge happens on the shaft. Anyone know how to get that end off?
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dillon_b12
Baja Godfather Joined: Nov/15/2008 Status: Offline Points: 781 |
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Got any pictures of it?
Bikebandit.com shows internal clips on both ends of that axle, provided I'm looking at the right thing. I'd start by sliding the boots back and cleaning the crap out of everything with acetone. Get the grease out and everything cleaned up and you might be able to see how to get it apart. What year are you using?
Edited by dillon_b12 - May/12/2011 at 11:35am |
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ErikHardy
Baja Godfather Joined: Apr/12/2010 Location: Hood, Flint, MI Status: Offline Points: 939 |
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BFH You have to break the clips and they come apart, just replace with new ones and all is good
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dillon_b12
Baja Godfather Joined: Nov/15/2008 Status: Offline Points: 781 |
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Sounds about right, Erik. The Hondas we've used take a BF slide hammer to get apart.
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tp
Welding Master Joined: Mar/31/2009 Location: Corvallis, OR Status: Offline Points: 348 |
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BFH. Here's some videos:
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-Tom
Oregon State BajaSAE Team Captain |
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SteveA
Bolt Sorter Joined: Sep/01/2010 Status: Offline Points: 7 |
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Ok, I have hit it pretty hard but basically I just need to hit it harder. I have cleaned them out fairly well and there is absolutely no way to see down inside of it to take a clip off so that would seem right. I'm not sure they are off of, I was not the one that got them, just the person who got tasked with taking them apart.
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dillon_b12
Baja Godfather Joined: Nov/15/2008 Status: Offline Points: 781 |
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One of guys (bibrow on here) made a behemoth custom slide hammer to do ours. It struggled sometimes, but eventually got the job done.
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Rob71zilla
Welding Master Joined: Feb/09/2009 Location: Utica, NY Status: Offline Points: 324 |
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I took ours to a supplier one year because I got sick of trying. I assume a dealership should be able to do it pretty quick too, and maybe even for free.
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Robbie
Former Team Captain SUNY Institute of Technology Current Engineer for Remington Arms A Redline a day keeps the carbon away. |
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SteveA
Bolt Sorter Joined: Sep/01/2010 Status: Offline Points: 7 |
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Thats doubtful, our dealer in town is the cheapest place on the face of the earth. They are terrible. By cheapest I mean that they wont do anything for free or even be willing to help, I will probably have to pay them just to ask a question.
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collinskl1
Baja Godfather Joined: Jan/21/2009 Location: Saginaw, MI Status: Offline Points: 1056 |
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I'm by no means an ATV expert, but I'm not so sure those pieces are supposed to be servicable... meaning they'd be considered a normal wear item that is assembled in a factory and never expected to be taken apart, so when/if you need a new one, you would get a new one.
Regardless, I'd just be careful about brinelling the balls into the tulip/race/whatever you call the cup thingy.
Out of curiosity, why are you disassembling them?
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Kyle Collins
Lipscomb University Alumni 2x Project Manager Nexteer Automotive Product Engineer, Electronic Power Steering ... and the 8th simple machine: a bigger hammer. |
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ErikHardy
Baja Godfather Joined: Apr/12/2010 Location: Hood, Flint, MI Status: Offline Points: 939 |
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Usually the balls slip into the tulip with no problem Its normally the retaining clip on the splines that is the problem. We took ours apart so we could lengthen them. |
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SteveA
Bolt Sorter Joined: Sep/01/2010 Status: Offline Points: 7 |
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we are taking ours apart to lengthen them also. If possible we are going get new ones machined, if we can get our sponsor to do the splines for us. If not we will have to cut them on a bias and splice in a piece and weld it.
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dillon_b12
Baja Godfather Joined: Nov/15/2008 Status: Offline Points: 781 |
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This is completely off-topic, but you need to find a new dealership to work with. Ours is EXTREMELY helpful and knowledgeable. Furthermore, I wouldn't support a dealership like that by buying parts from them. If you can get stuff cheaper elsewhere, do it. Here's some reading for you when you're ready to lengthen them yourselves. |
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collinskl1
Baja Godfather Joined: Jan/21/2009 Location: Saginaw, MI Status: Offline Points: 1056 |
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So why take them apart to lengthen them? The link Dillon supplied references a method of lengthening that to me doesn't require the removal of the CV... Is it to reduce the risk of heat damage?
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Kyle Collins
Lipscomb University Alumni 2x Project Manager Nexteer Automotive Product Engineer, Electronic Power Steering ... and the 8th simple machine: a bigger hammer. |
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dillon_b12
Baja Godfather Joined: Nov/15/2008 Status: Offline Points: 781 |
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Yep. The method we use is way easier if you're working with a bare axle shaft. Plus, I throw some serious heat in that mofo during welding.
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collinskl1
Baja Godfather Joined: Jan/21/2009 Location: Saginaw, MI Status: Offline Points: 1056 |
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Oh I remember how many water bottles you used cooling them down in the Auburn paddock the night before endurance
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Kyle Collins
Lipscomb University Alumni 2x Project Manager Nexteer Automotive Product Engineer, Electronic Power Steering ... and the 8th simple machine: a bigger hammer. |
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dillon_b12
Baja Godfather Joined: Nov/15/2008 Status: Offline Points: 781 |
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MTomasko2011
Milling Master Joined: Apr/24/2009 Location: Ohio Northern Status: Offline Points: 50 |
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We had this same problem with these same axles. A BFH did not work, and our local Polaris dealer couldnt even get them apart. Your application is likely different than ours, but since we were cutting off the splined stub anyways, we cut and faced the joint with the shaft still in. We then used the lathe to drill a hole in the center of the housing coaxial with the shaft. Using a small piece of steel as a spacer and a 20 ton press, the shaft popped right out!
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Ohio Northern University
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SteveA
Bolt Sorter Joined: Sep/01/2010 Status: Offline Points: 7 |
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We try to avoid it as much as possible, we dont order anything from them at all unless we absolutely have to. The problem is that the next nearest Polaris dealership is over an hour from here.
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ErikHardy
Baja Godfather Joined: Apr/12/2010 Location: Hood, Flint, MI Status: Offline Points: 939 |
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I think you need a bigger hammer. Remember BFH not just FH, BFH. Part 6 is a retaining clip that has to be broken in order to get them out. Those clips expand after you slide the cv in all the way.
This picture came from www.cheapcycleparts.com We don't order anything through a dealer and all our oem parts come from that site, they have part diagrams for most oem's.
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SteveA
Bolt Sorter Joined: Sep/01/2010 Status: Offline Points: 7 |
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Part 6? we are trying to get part 1 out of part 4.
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blue2kss
Welding Master Joined: Dec/23/2008 Location: USF Status: Offline Points: 169 |
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When I lengthend our Hawkeye 300 shafts I couldn't get the joint off either and welded it assembled. Worked just fine. Just welded hot and fast in the lathe to keep everything straight. We also covered the boot in a cold wet cloth and I am sure that helped. Edited by blue2kss - May/13/2011 at 6:25pm |
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Dustin Bride
University of South Florida SAE Alumni/Consultant Mechanical Engineer - Naval Surface Warfare Center, Marine Corps. Counter IED Development |
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Bettner12
Welding Master Joined: Jan/24/2011 Location: Hanover, Pa Status: Offline Points: 239 |
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looks like part # 5 is the retaining clip
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ErikHardy
Baja Godfather Joined: Apr/12/2010 Location: Hood, Flint, MI Status: Offline Points: 939 |
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My Mistake bettner is on it. |
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SteveA
Bolt Sorter Joined: Sep/01/2010 Status: Offline Points: 7 |
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Well, finally got the shafts out, just like you all said it just takes a BFH. Now that we got them apart we can make our own shafts instead of having to weld them. :)
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dillon_b12
Baja Godfather Joined: Nov/15/2008 Status: Offline Points: 781 |
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Anybody ever used one of these?
After a recent battle with a particularly stubborn set of axles, we're considering making one of these setups.
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Bettner12
Welding Master Joined: Jan/24/2011 Location: Hanover, Pa Status: Offline Points: 239 |
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I like it
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Greenreed1936
Bolt Sorter Joined: Aug/31/2009 Location: Rapid City Status: Offline Points: 24 |
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We have a piece of 1.25 pipe that we use as a big slide hammer for removing the axles. Just slip your axle into it and hammer both pieces down on a piece of wood to get the axle to break the retaining clip.
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