Polaris Ranger 500 2x4 2007, Service Manual

Page: 233 / 345

7.30
FINAL DRIVE
8. Refit CV joint on the 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 shaft.
NOTE: It is very important to use the correct type
and quantity of grease by using the grease
contained in the boot kit. DO NOT use a substitute
grease and DO NOT overfill or underfill the CV joint.
9. Fill the CV joint and/or boot with the recommended type
and amount of grease. Rear drive shaft inner or outer boot
replacement requires 50g of grease if the CV joints were not
disassembled.
NOTE: If the joints were disassembled and cleaned,
refer to the call-out below or
Figure 7-31 for the
correct amount of grease required.
10. Remove excess grease from the CV joint's external surfaces
and position the boot over the housing, making sure the
boot is seated in the groove. Position clamp over the large
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.
11. 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.
12. Install the small clamp on the boot.
Boot Replacement Grease Requirement:
Inner Plunging Joint Grease - PN 1350047
Only boot replacement - 50g
Boot replacement w/joint cleaning - 100g
Outer CV Joint Grease - PN 1350047
Only boot replacement - 50g
Boot replacement w/joint cleaning - 75g
Tap joint onto shaft
REAR SHAFT
Joint Capacity*
25 Grams
Boot Capacity
50 Grams
Boot Capacity
50 Grams
Joint Capacity*
50 Grams
CV Joint
Figure 7-31
Retaining
Ring
Large Clamp
Grease
PN 1350047
Boot
Small Clamp
Boot
Grease
PN 1350047
Large Clamp
Retaining
Ring
Plunging Joint
Spring Ring