Hello, John Talley here with partzilla.com. Today we're going to be working with our 2011
Polaris Sportsman 850. In particular, we're going to be looking at the half-shaft on this
particular unit. If you're driving along and you hear something
clicking in the front end, more than likely you have a damaged half-shaft.
These things should be fairly flexible and real smooth. If you're driving along and you're
hearing "click, click, click," it means you're going to have to replace this.
Alright, to do that we need to pull our hub assembly apart and then get the half-shaft
actually pulled out of the front differential. It's a little bit of work, but I'll show you
how to get it done. So let's get started. To take it apart, pull off our center cap.
We've got a cotter pin we've got to get out of the way.
Now we want to go ahead and break our axle loose. We want it to just slide back a tick.
There she goes. We've got two of what they call cone washers
in here. They are directional. Next, we just need to get the caliper out
of the way, it's just two 15mm bolts: one at the top and one at the bottom. We're taking
them straight out of the carrier and lifting the whole thing off as an assembly.
Next, go ahead and move that shock mount just so we have more room to work.
Then we want to remove our upper ball joint just where we can get the knuckle to come
down and then drive that axle out of there. Alright, now we'll take a center punch and
start knocking her back. Alright guys, at that point according to Polaris
at that point you just start pulling on this and this snap ring right there would have
let it come out. That didn't happen. Not even close.
What I had to do was go to the machine shop and get a bolt, just a regular steel bolt,
that matched up with my puller and then welded on to the outside of this half-shaft, screwed
in there. And as you can tell it took a lot of effort to bring it out.
The reason being: this was just completely rusted on all those splines and up inside
the housing. So that was a very aggressive way to get something out of there. I didn't
see an alternative to it because we pried on it and pulled and it was just not going
to release, not without something really substantial. And that's how far we had to go to get it
off of there. Alright, so assembly is just the reverse of
what we just did-- minus the bolt. Alright guys, we've got our shiny new pre-assembled
half-shaft. All we need to do is get some grease on the end of these splines and up
in that housing and get it put back together. Same thing for the splines out here.
Alright, with our A-arm reattached, go ahead and get our upper knuckle in there. Remember
to line it up on that edge to where the bolt can go through.
Right there. Just a 13mm.
Next, let's get our hub back on, the cone washers, and that 27mm bolt.
Alright, next let's go ahead and get our caliper back on, two 15mm.
Alright, this outer bolt needs to be set to 80 ft-lbs. I'm going to have my assistant
go on the other side of the machine and hold the brakes.
And there it is. If you're not sure how to route your brake
line, you can check out our brake disc video that shows how to do that.
Alright, next we just need to get our cotter pin back in.
Then our outer cap. Alright guys, well that pretty much finishes
it up. All that's left now is to put the tire on and take it out for a spin.
Listen, if there's something you couldn't see that I was doing or you have a question
or a comment, just leave them in the comments section below and I'll do my best to answer
them. If you need any of the parts I used here, come see us at partzilla.com and until
next time we just want to say thanks for watching.