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ATV-1048
3. Apply 80 grams (2/3 of contents) of grease from the
pack into the bearing housing.
NOTE: Steps 1-3 can be used to replace the out-
board boot.
NOTE: In the outboard boot, use the final 40 grams (1/3 of
contents) of grease from the pack in the bearing housing.
INSTALLING REAR DRIVE AXLE
1. Push the axle shaft into the CV cup to release the
detent balls; then while holding the axle firmly in,
push the CV splined end into the gear case.
CF633A
NOTE: To assure proper seating of the axle, give it a
light pull; the axle should remain “clipped” in place.
2. Swing the knuckle up and onto the drive axle; then
place the knuckle into place in the upper A-arm.
Secure the knuckle to the A-arm with a cap screw
and a new lock nut. Tighten to 35 ft-lb.
3. Place the hub into position on the axle followed by a hex
nut. Tighten the hex nut only until snug at this time.
4. If the brake calipers were removed, position them on
the knuckle and secure with new “patch-lock” cap
screws. Tighten to 20 ft-lb.
5. Pump up the hand brake lever; then engage the brake
lever lock.
6. Using an appropriate spanner wrench, tighten the
hub nut (from step 3) to 200 ft-lb; then install and
spread a new cotter pin making sure each side of the
pin is flush to the hex nut.
NOTE: If the cotter pin does not line up, always
tighten to the next alignment.
CD027
7. Install the wheel. Tighten to 40 ft-lb (steel wheels) or
80 ft-lb (aluminum wheels).
8. Remove the ATV from the support stand and release
the brake lever lock.
INSTALLING FRONT DRIVE AXLE
1. Position the drive axle in the gear case and steering
knuckle; then insert the upper A-arm ball joint into
the steering knuckle. Secure with a cap screw tight-
ened to 50 ft-lb.
2. Place the brake hose into position on the upper A-arm;
then secure the lower shock eyelet to the A-arm with a
cap screw and a new lock nut. Tighten to 50 ft-lb.
3. Secure the tie rod to the steering knuckle with a new
lock nut. Tighten securely; then install and spread a
new cotter pin.
4. Slide the hub w/brake disc into position in the steer-
ing knuckle followed by a washer and hex nut.
Tighten finger-tight at this time.
5. Install the brake caliper on the steering knuckle using
new “patch-lock” cap screws. Tighten to 20 ft-lb;
then pump up the hand brake lever and engage the
brake lever lock.
6. Using an appropriate spanner wrench, tighten the
hub nut (from step 4) to 200 ft-lb; then install and
spread a new cotter pin making sure each side of the
pin is flush to the hex nut.
NOTE: If the cotter pin does not line up, always
tighten to the next alignment.
CD027
7. Install the wheel and tighten to 40 ft-lb (steel wheels)
or 80 ft-lb (aluminum wheels).
