Polaris 2012 Sportsman Forest 500 International, Service Manual

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7.40
FINAL DRIVE
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Drive Shaft and CV Joint Handling Tips
Care should be exercised during driveshaft removal or
when servicing CV joints. Driveshaft components are
precision parts.
Cleanliness and following these instructions is very
important to ensure proper shaft function and a normal
service life.
• The complete driveshaft and joint should be
handled by holding only the interconnecting shaft
to avoid disassembly or potential damage to the
driveshaft joints.
• Over-angling of joints beyond their capacity could
result in boot or joint damage.
• Make sure surface-ground areas and splines of
shaft are protected during handling to avoid
damage.
• Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components.
• The CV interconnecting shaft should never be
used as a lever arm to position other suspension
components.
• Never use a hammer or sharp tools to remove or
to install boot clamps.
• Be sure joints are thoroughly clean and that the
proper amount and type of grease is used to refill
when joint boots are replaced and when joints are
cleaned. Refer to text for grease capacity of CV
joints and CV joint boots.
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 illustration).
NOTE: Use only the Constant Velocity Joint grease
supplied with boot service kit. IF CV JOINT WAS
CLEANED, add the recommended amount of grease
to the joint in addition to the grease pack supplied
with boot kit.
Outer CV Joint / Boot Replacement
1. Using a side cutters, cut away and discard the boot
clamps.
2. Remove the large end of the boot from the CV joint
and slide the boot down the shaft.
3. Clean the grease from the face of the joint.
4. Place the drive shaft in a soft-jawed vise.