Polaris RZR 800 2013, Manual

Page: 322 / 500

7.10
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
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 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 the
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 all the
grease included with the boot kit. DO NOT use a
substitute grease and DO NOT overfill or under
fill the CV joint.
Boot Replacement Grease Requirement:
Outer CV Joint Capacity: 80g
Grease Service Kit: PN 1350047 (50g)
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.
CV Boot Clamp Pliers
Earless Type: 8700226
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 the correct location on the
shaft.
17. Install and secure the small clamp on the boot using
the “earless” clamp pliers.
CV Boot Clamp Pliers
Earless Type: 8700226
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.
CV Boot Clamp Pliers
Earless Type: 8700226
FINAL DRIVE