Ever feel that unnerving vibration creeping through the floorboards of your Polaris General on a hard acceleration? Or maybe you’re hearing a clunking or grinding noise from underneath that just doesn’t sound right. If you’re nodding along, you’ve come to the right place. That driveline shudder is more than just an annoyance; it’s your UTV’s way of telling you something is wrong.
Here at FatBoysOffroad, we know that a healthy driveline is the backbone of any good trail ride. A failing drive shaft can sideline you in the middle of nowhere, turning a great day into a long walk back. We promise this guide will give you the confidence and know-how to tackle this job yourself.
This comprehensive polaris general drive shaft replacement guide will walk you through everything from diagnosing the problem and gathering the right tools to the step-by-step process of swapping out the old parts for new. Let’s get your machine running smoothly and reliably again.
Why a Healthy Drive Shaft is Non-Negotiable for Your General
Think of the drive shaft as the critical link that transfers power from your transmission to your differentials. Without it, you’re not going anywhere. But its job is more complex than just spinning; it has to handle immense torque, constant changes in angle, and the harsh environment of off-roading.
Understanding the benefits of a polaris general drive shaft replacement is key. A new, well-balanced shaft eliminates those destructive vibrations that can wear out other components like transmission seals and differential bearings. It restores that smooth, direct power delivery you need for climbing hills and powering through mud.
What is a Drive Shaft and Why Does it Fail?
Your Polaris General has a multi-piece driveshaft system, typically consisting of a front shaft, a rear shaft, and a carrier bearing in the middle that supports the assembly. The ends of the shafts have U-joints (universal joints) or CV joints that allow them to flex as the suspension moves.
Failures usually happen at the weakest points:
- U-Joints: Lack of grease, contamination from water and dirt, or simple wear and tear can cause the needle bearings inside to fail, leading to play and vibration.
- Carrier Bearing: The rubber support on the factory carrier bearing is a notorious weak spot. It can tear or degrade, allowing the shaft to flop around, causing catastrophic vibration.
- Shaft Balance: A bent shaft from hitting a rock or a thrown balancing weight will cause a speed-dependent vibration that you can’t ignore.
Spotting the Signs: Is It Time for a Polaris General Drive Shaft Replacement?
Before you start turning wrenches, you need to be sure the drive shaft is the culprit. A proper diagnosis saves you time and money. These are the most common problems with a Polaris General drive shaft that you should be looking for.
Telltale Symptoms of a Failing Drive Shaft
Keep an eye (and an ear) out for these classic signs of driveline trouble. They often start small and get progressively worse.
- Vibrations: This is the number one symptom. You’ll feel a vibration under acceleration that gets worse as you go faster. It might feel like it’s coming from the center console or your feet.
- Unusual Noises: Listen for clunking when you shift from forward to reverse, a squeaking sound at low speeds (dry U-joints), or a rhythmic grinding or rattling noise that changes with your speed.
- Visible Play: Safely get under your machine (use jack stands!) and try to move the drive shafts by hand. There should be almost no up-and-down or side-to-side play. If you can wiggle it, especially near the U-joints or carrier bearing, you’ve found a problem.
A quick pro tip: If the vibration is worst at a specific speed, it’s almost certainly a balance or alignment issue with a rotating part like the drive shaft. This is one of the most useful polaris general drive shaft replacement tips for diagnosis.
Gearing Up: Tools and Parts You’ll Need for the Job
Having everything ready before you start makes the job go ten times smoother. Nothing’s worse than having your rig in pieces only to realize you’re missing a specific socket. Here’s your shopping and tool-gathering list.
Essential Tools
- Safety First: Jack, heavy-duty jack stands, safety glasses, and mechanic’s gloves.
- Socket Set: A good metric socket set with extensions and a ratchet. You’ll likely need 13mm, 15mm, and 18mm sockets.
- Wrenches: A set of metric combination wrenches.
- Torque Wrench: Absolutely crucial for correctly tightening bolts on reassembly.
- Dead Blow Hammer or Mallet: For persuading stuck parts to come loose.
- Pry Bar: Useful for carefully separating components.
- Grease Gun: For greasing the new U-joints before and after installation.
- Paint Marker or White-Out: For marking the orientation of the shafts. This is a critical step!
Choosing Your Replacement Parts
You have two main options: OEM (Original Equipment Manufacturer) or aftermarket. OEM will be a direct replacement but may have the same weaknesses as your original parts (like that carrier bearing).
High-quality aftermarket brands like SuperATV, RCV Performance, or Demon Powersports often offer significant upgrades. Look for shafts with stronger U-joints, improved carrier bearings (like a “pillow block” style), and better overall construction. This is an excellent opportunity to build more durability into your machine.
The Complete Polaris General Drive Shaft Replacement Guide: A Step-by-Step Walkthrough
Alright, let’s get to the main event. This is how to polaris general drive shaft replacement is done. We’ll break it down into removing the old shafts and installing the new ones. Remember to work on a level surface and ensure the vehicle is stable on jack stands before you get under it.
Step 1: Preparation and Safety
First, park your General on a flat, level surface. Chock the wheels that will remain on the ground. Use a floor jack to lift the machine and securely place it on four jack stands. You want enough room to comfortably work underneath.
Remove any skid plates that are blocking access to the drive shafts. This is usually a handful of bolts and is a straightforward process.
Step 2: Marking and Removing the Rear Drive Shaft
Before you unbolt anything, take your paint marker and make alignment marks. Mark the rear drive shaft’s relationship to the transmission yoke and the rear differential yoke. This ensures you can reinstall it in the same orientation, which is vital for balance.
Using your socket or wrench (typically 15mm), remove the four bolts connecting the rear drive shaft to the rear differential yoke. You may need to put the machine in neutral to rotate the shaft for access to all the bolts.
Next, remove the two bolts holding the carrier bearing to the frame. Once these are out, the entire rear shaft and carrier bearing assembly should be free. You can now slide the shaft off the splined output of the transmission and remove it from the vehicle.
Step 3: Removing the Front Drive Shaft
Just like the rear, start by marking the front drive shaft’s orientation relative to the transmission yoke and the front differential yoke. Do not skip this step.
At the front differential, you’ll find a roll pin or a pinch bolt holding the shaft to the yoke. Use a punch and hammer to drive the roll pin out. A little penetrating oil can help here.
With the front disconnected, you can slide the shaft rearward and off the splined output of the transmission. The front shaft is now free to be removed.
Step 4: Installing the New Drive Shafts
Installation is essentially the reverse of removal, but with a few key points to follow for one of the most important polaris general drive shaft replacement best practices.
- Grease Everything: Before installing, use your grease gun to pump fresh grease into all the zerk fittings on your new U-joints until you see it just start to seep from the seals.
- Install the Front Shaft: Slide the splined end of the new front shaft onto the transmission output. Then, align the front of the shaft with the front differential yoke, making sure your paint marks line up. Reinstall the roll pin or pinch bolt.
- Install the Rear Shaft & Carrier Bearing: Slide the new rear shaft onto its transmission spline. Loosely bolt the new carrier bearing to the frame—just a few threads to hold it in place.
- Connect to Rear Differential: Align your paint marks at the rear differential and install the four bolts. Use a drop of blue Loctite on the threads. Torque these bolts to the factory specification found in your service manual (typically around 40 ft-lbs, but always verify).
- Final Carrier Bearing Alignment: With both ends of the rear shaft connected, you can now fully tighten the carrier bearing bolts. This ensures it’s not in a bind.
Common Problems and Best Practices During Installation
Even a straightforward job can have its hitches. Here are some pro tips to avoid common pitfalls.
One of the most frequent common problems with polaris general drive shaft replacement is improper phasing. If you fail to align your marks, the U-joints will work against each other, causing a nasty vibration. Always double-check your marks before tightening anything.
If a shaft is difficult to remove from a yoke, don’t just wail on it with a steel hammer. Use a dead blow hammer and some penetrating oil. A little patience goes a long way and prevents damage to expensive differentials or transmissions.
When it comes to a sustainable polaris general drive shaft replacement, consider investing in a high-quality, rebuildable aftermarket shaft. A cheaper shaft might fail sooner, creating more waste. A premium shaft can be serviced with new U-joints for years, making it a more eco-friendly choice in the long run. Dispose of your old metal parts at a local scrap metal recycler.
Post-Replacement Care: Your Drive Shaft Care Guide
Your new drive shaft isn’t a “fit and forget” part. A little bit of maintenance will ensure it lasts for thousands of miles. This is your essential polaris general drive shaft replacement care guide.
After your first ride (about 20-30 miles), get back under the machine and re-check the torque on all the bolts you touched. It’s common for things to settle slightly.
Regularly grease your U-joints. A good rule of thumb is to hit them with a pump or two of quality marine-grade grease every oil change or after any particularly wet or muddy ride. This pushes out contaminants and keeps everything moving smoothly.
Frequently Asked Questions About Polaris General Drive Shaft Replacement
Can I replace just the U-joints or carrier bearing?
Yes, you can. If the shaft tube itself isn’t bent or damaged, you can press out old U-joints and press in new ones. The carrier bearing is also replaceable on its own. However, if you have high miles or the original carrier bearing failed, replacing the whole assembly with an upgraded unit is often a more reliable and time-effective repair.
How long does a Polaris General drive shaft replacement take?
For a DIY mechanic with the right tools, plan on about 2-4 hours. If you’re dealing with rusty bolts or a stubborn roll pin, it might take a bit longer. Take your time, and prioritize doing it right over doing it fast.
What does “phasing” a drive shaft mean?
Phasing refers to the rotational alignment of the U-joints at each end of the shaft. For them to cancel out vibrations correctly, the yokes need to be aligned with each other. This is why marking the shafts before removal is so critically important for a smooth result.
Tackling a polaris general drive shaft replacement is a totally achievable weekend project that will make a massive difference in how your machine rides. You’ll save a bundle on labor costs and gain the satisfaction of knowing the job was done right. Take it one step at a time, double-check your torque specs, and get ready to enjoy a smoother, quieter, and more reliable ride on the trails.
Now get out there and ride safe!
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