Polaris Outlaw 500, Service Manual

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5.24
BODY / STEERING / SUSPENSION
5. Pack the housing assembly and inner boots with a total of
8.75 oz. of Hi-Temperature CV joint grease. Distribute
grease evenly.
6. Install the inner CV ball cage and retaining rings.
7. Ensure the retaining ring is seated properly in the rear
housing groove.
8. Clean and apply a thin coat of sealant to both the boot and
sealing surface before installing inner boots. Install
retaining rings.
9. Install boot clamps.
NOTE: Before tightening boot clamp on inboard
joints, make sure any air pressure which may have
built up in joint boot has been released using the
boot ‘burping’ process. The air should be released
after the plunging joint has been centered properly.
Tighten boot clamps using boot clamp pliers.
Installation
1. Reverse the steps described in the Removal/ Disassembly
procedure.
2. Attach the rear housing mounting bolts, chain adjustment
components and brackets. Torque brackets to
17 ft.lbs. (23
Nm). Do not tighten chain adjustment or housing bolts
until chain adjustment has been completed.
3. Attach the brake disc and drive sprocket to rear housing.
4. Install and torque the brake disc bolts to 18 ft.lbs. (25 Nm) .
5. Install and torque the drive sprocket bolts to 26 ft.lbs. (35
Nm) .
6. Install each rear CV shaft end into hub carrier from and
attach the upper a-arm to the hub carrier.
Rear Housing Hi-Temp CV Grease
Capacity: 8.75 oz. (248.05 grams)
8.75 oz. (248.05 grams)
NOTE: Use Special Hi-Temp CV Grease
CV GREASE
Apply sealant before assembly
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