Inner Plunging Joint / Boot Replacement - Polaris 2013 RANGER RZR S Service Manual

FINAL DRIVE
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 its 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
7.8
9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2012 Polaris Sales Inc.

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
3. Remove the large end of the boot from the plunging
joint and slide the boot back.
4. Use a soft-faced hammer or brass drift to separate the
plunging joint from the drive shaft.
NOTE: If using a brass drift, be sure to tap on the
inner race of the joint only.
5. Make sure the circlip remains on the shaft and not left
in the joint. Discard the circlip.
6. Remove the boot from the drive shaft.
Complete disassembly of the plunging joint is
NOT recommended. The internal components
are precision fit and develop their own
characteristic wear patterns. Intermixing the
internal components could result in looseness,
binding, and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should
be replaced.
7. 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.
8. 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.
9. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in it's groove
machined in the shaft.
11. Install a NEW circlip on the end of the shaft.
CAUTION