Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 179 / 289

FRONT SHAFT
Joint Capacity
30 Grams
Boot Capacity
30 Grams
Front outboard joint capacity: 30g if boot
is replaced only. Another 30g (60g total) if
joint is cleaned.
GENERAL INFORMATION
7.11
5. Remove clamps from rubber boot using the
proper boot clamp pliers.
Retaining ring
Pull shaft to remove from
CV joint
6. Remove the large end of the boot from the CV
joint, slide the boot back and separate the wheel
spindle and CV joint assembly from the axle shaft
by pulling the shaft sharply outward, away from
the CV joint. It may be necessary to tap the CV
joint assembly outward with a soft faced hammer.
7. Remove small clamp and boot from driveshaft.
If the ATV has been operated with a damaged boot,
the CV joint grease may be contaminated. Inspect the
grease carefully for contamination, and clean the joint
thoroughly if necessary. Front drive axle CV boot
replacement requires 30g of grease. If CV joint is
cleaned, an additional 30g of grease is required.
Refer to information below.
8. Before installing the new boot, remove all grease
from the boot area and shaft.
NOTE: It is very important to use the correct type and
quantity of grease by using the grease contained in
the boot kit. DO NOT use a substitute grease and DO
NOT overfill or underfill the CV joint.
9. Slide the new clamp and boot (small end first)
over the splined shaft, then slide (tap) the CV joint
into the splines of the axle. Install small boot
clamp.
10. Add grease through large end of boot.
11. Position large end of boot on CV joint, purge
excess air by partially compressing axle into CV
bell, lift one edge of boot to let out excess air
Secure with
clamp.
CV Joint Grease - 30g PN 1350046
CV Boot Clamp Pliers:
Earless Type 8700226
Boot Replacement requires 30g
Boot replacement with complete CV
joint cleaning requires an additional
30g. (Total 60g)
CV Joint Grease - 30g (PN 1350046)
CV Boot Clamp Pliers:
Earless Type (PN 8700226)