The Polaris Sportsman is one of the best-selling all-terrain vehicles on the world. Because owners typically use the Sportsman as a recreational vehicle in off-road environments, these vehicles often need maintenance. Damage to the axle is typical with rough usage, and replacement is often necessary. Before installing a new axle, the old one must be removed.
Park the Sportsman on a flat surface.
Wedge the wheel chocks behind the rear wheels. This is important for safety reasons so that the Sportsman does not move backwards.
Jack the front of the vehicle up.
Unbolt the lug nuts from one of the front wheels (whichever one you prefer) and remove the wheel.
Unbolt the stick stopper from the A-arm and remove it.
Remove the bolts from the tie rod end with a wrench and remove it from the strut.
Unscrew the two mounting bolts from the brake caliper and slide the brake caliper off the brake disc.
Remove the retaining nut from the axle and slide the hub out.
Loosen (but do not remove) the nut holding the lower ball joint in place.
Tap the lower A-arm lightly so it disengages from the lower ball joint.
Remove the but holding the lower ball joint in place and disengage the lower-A arm from the strut.
Swing the strut slowly in an outward direction in order to move it out of the way of the axle shaft.
Slide out the axle shaft from the strut.
Remove the clamps from the inner CV boot.
Slide the inner CV boot down the axle shaft until the inner CV joint becomes accessible.
Remove the snap ring from the CV joint housing.
Detach the axle shaft assembly, including the axle.
