Polaris 2007 Sportsman 450 EFI, Service Manual

Page: 233 / 406

7.5
FINAL DRIVE
7
3. Disconnect A-arm from ball joint using a tie rod fork.
4. Slide strut off end of drive shaft and tie it up out of the way
of the shaft.
5. Remove clamps from rubber boot using the proper boot
clamp pliers.
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.
NOTE: 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 3.5 oz. of grease.
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. Use only the grease
contained in the boot kit. DO NOT use a substitute
grease and DO NOT overfill or under fill 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.
10. Add grease through large end of boot.
11. Install a new boot onto the axle shaft and fill the CV joint
and boot with the correct type and amount of grease.
12. While pulling out on the CV shaft, fully extend the CV joint
and slide a straight O-ring pick or a small slotted screw
driver between the small end of the boot and the shaft. This
will allow the air pressure to equalize in the CV boot in the
position that the joint will spend most of its life. Before you
remove your instrument, be sure the small end of the boot
is in its correct location on the axle. CARE MUST BE
TAKEN TO AVOID DAMAGE TO THE NEWLY
INSTALLED BOOT.
Retaining Ring
Pull Shaft to Remove from
CV Joint
CV Joint Grease -3.5 oz.
(Refer to parts manual for boot kit)
CV Boot Clamp Pliers:
Earless Type: (PN 8700226)
Boot replacement with complete CV joint
cleaning requires the entire 3.5 oz. of grease.