Inner Plunging Joint / Boot Replacement - Polaris 2012 RANGER RZR 570 INTL Service Manual

Inner Plunging Joint / Boot Replacement

1. Remove th e fr ont dr ive 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 u sing a bras s dr ift, be sur e to ta p on t he
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.
CAUTION
Complete disassembly of the plunging joint is
NOT recommended. The internal components
are a 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 cag e, 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.
12. Grease the joint with the special joint grease provided
NOTE: The amount of grease that's provided is pre-
measured, so use all the grease.
13. Fully compress the joint and push the d rive shaft firmly
14. Align the circlip with the lead-in chamfer.
15. Use a soft-faced hammer to tap the joint onto the drive
16. Pull on the joint to make sure it is securely locked into
17. Remove excess grease from the plun ging joint's
18. Pull the boot over the joint and position the boot lips
19. Install and secure the small clamp on the boot using
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
in the boot replacement kit. Fill the cavity behind the
balls and the s plined hole in the joint's inner race.
Pack the ball tracks and outer face flush with grease.
Place any remaining grease into the boot.
CAUTION
The grease provided in the replacement kit is
specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.
Boot Replacement Grease Requirement:
Grease Service Kit
1350047 (50g)
Inner Plunging Joint Capacity: 80g
into the inner race.
shaft until it locks into place.
place.
external surfaces and place the excess grease in the
boot.
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
the "earless" clamp pliers.
CV Boot Clamp Pliers
Earless Type: 8700226
FINAL DRIVE
7
7.9