Polaris 2011 RANGER RZR, Service Manual

Page: 261 / 418

7.8
FINAL DRIVE
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.
11. Slide the joint onto the drive shaft splines and align the
circlip with the lead-in chamfer on the inner race.
12. Use a soft-faced hammer to tap the CV joint into the splines
of the axle. Pull on the joint to ensure it’s securely installed.
13. Add the remaining grease through large end of boot.
14. Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
boot is not dimpled or collapsed.
15. Install and secure the CV boot with the large clamp using
the “earless” clamp pliers.
16. While pulling out on the CV shaft, 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 shaft.
17. Install and secure the small clamp on the boot using the
“earless” clamp pliers.
Inner Plunging Joint / Boot Replacement
1. Remove the front drive shaft from the vehicle (see
“FRONT DRIVE SHAFT - Removal”).
2. Remove and discard the boot clamps.
3. Remove the large end of the boot from the plunging joint
and slide the boot back.
4. Use a soft-faced hammer or brass drift to separate the
plunging joint from the drive shaft.
NOTE: If using a brass drift, be sure to tap on the
inner race of the joint only.
5. Make sure the circlip remains on the shaft and not left in
the joint. Discard the circlip.
6. Remove the boot from the drive shaft.
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should
be replaced.
7. Thoroughly clean the joint with an appropriate solvent and
dry the joint to prevent any residual solvent from being left
in the joint upon reassembly.
8. Visually inspect the joint by tilting the inner race to one side
to expose each ball. Severe pitting, galling, play between
the ball and its cage window, any cracking or damage to the
cage, pitting or galling or chips in raceways call for joint
replacement.
9. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first) onto
the drive shaft and position the boot in it’s groove machined
in the shaft.
11. Install a NEW circlip on the end of the shaft.
CV Boot Clamp Pliers
Earless Type: 8700226
CV Boot Clamp Pliers
Earless Type: 8700226
CV Boot Clamp Pliers
Earless Type: 8700226
CAUTION
Complete disassembly of the plunging joint is
NOT recommended. The internal components
are a precision fit and develop their own
characteristic wear patterns. Intermixing the
internal components could result in looseness,
binding, and/or premature failure of the joint.