Polaris Ranger RZR SW, Service Manual, Page: 223 / 346

7.7
FINAL DRIVE
7
4. Make sure the circlip remains on the shaft and not left in
the joint. Discard the circlip as it will be replaced.
5. Remove the small clamp and 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.
6. 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.
7. 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.
8. Apply a light coat of grease to the end of the drive shaft and
slide the new clamp and boot (small end first) over the shaft
and position the boot in its groove machined in the shaft.
9. Install a NEW circlip on the end of the shaft.
10. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
and the splined hole in the joint’s inner race. Pack the ball
tracks and outer face flush with grease. Place any remaining
grease into the boot. Install small boot clamp.
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 under fill the CV joint.
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.
Boot Replacement Grease Requirement:
Grease Service Kits
PN 1350059 (20g) / PN 1350046 (30g) / PN 1350047 (50g)
Outer CV Joint Capacity: 80g
Circlip
Pull shaft to remove
from CV joint
CV Boot Clamp Pliers
Earless Type: 8700226
CV Boot Clamp Pliers
Earless Type: 8700226