Polaris RZR 800 2013, Manual

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9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
6. Remove the upper ball joint pinch bolt.
7. Using a soft faced hammer, lightly tap on the bearing
carrier while removing the upper ball joint end.
8. Remove the drive shaft from the front bearing carrier.
9. With a short, sharp jerk, remove drive shaft from the
front gearcase.
Drive Shaft / CV Joint Handling Tips
Care should be exercised during drive shaft removal or
when servicing CV joints. Drive shaft components are
precision parts.
Cleanliness and following these instructions is very
important to ensure proper shaft function and a normal
service life.
• The complete drive shaft and joint should be
handled by getting hold of the interconnecting
shaft to avoid disassembly or potential damage to
the drive shaft 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 drive shaft is not to 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.
Outer CV Joint / Boot Replacement
NOTE: Refer the “Electronic Parts Catalog” for the
required parts to service the drive shaft. Some drive
shafts have “Boot Replacement Kits” that include a
new boot, clamps, and the required amount of
grease.
1. Remove clamps from rubber boot using the proper
boot clamp pliers.
CV Boot Clamp Pliers:
Earless Type - 8700226
2. Remove the large end of the boot from the CV joint
and slide the boot back.
3. Use a soft-faced hammer or brass drift to separate
the outer CV joint from the drive shaft.
NOTE: If using a brass drift, be sure to tap on
the inner race of the joint only.
FINAL DRIVE