Polaris 2007 Sportsman 450 EFI, Service Manual

Page: 265 / 406

7.37
FINAL DRIVE
7
5. Refit CV joint on interconnecting shaft by tapping with a
plastic hammer on the joint housing. Take care not to
damage threads on the outboard CV joint. The joint is fully
assembled when the snap ring is located in the groove on
the interconnecting shaft.
6. Install and tighten large boot clamp with boot clamp pliers.
7. Remove excess grease from the CV joint's external surfaces
and position joint boot over housing, making sure boot is
seated in groove. Position clamp over boot end and make
sure clamp tabs are located in slots.
NOTE : Before
tightening boot clamp on inboard joint, make sure any air
pressure which may have built up in joint boot has been
released. The air should be released after the plunging joint
has been centered properly. Tighten boot clamp using boot
clamp pliers.
CV Boot Replacement
1. Remove CV joint from end of shaft.
2. Remove boot from shaft.
NOTE: When replacing a damaged boot, check the
grease for contamination by rubbing it between two
fingers. A gritty feeling indicates contamination. If
the grease is not contaminated, the boot can be
replaced without cleaning the CV joint. Use the
recommended amount of grease for boot
replacement only (see below). Proceed to Boot
Installation.
3. Thoroughly clean and dry the CV joint and inspect ball
tracks and cages for wear, cracks or other damage.
NOTE: Shiny areas in ball tracks and on the cage
spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.
4. Add the recommended amount of grease for CV joint
cleaning to the joint as shown below. Be sure grease
penetrates all parts of the joint.
5. Refit CV joint on interconnecting shaft by tapping with a
plastic hammer on the joint housing. Take care not to
damage threads on the outboard CV joint. The joint is fully
assembled when the snap ring is located in the groove on
the interconnecting shaft.
6. Add grease through large end of boot.
7. Install a new boot onto the axle shaft and fill the CV joint
and boot with the correct type and amount of grease.
Tap joint onto shaft
Open snap ring and pull CV
joint away
from shaft