Polaris SPORTSMAN 600 Service Manual page 177

FRONT DRIVE SHAFT CV
JOINT BOOT REPLACEMENT
1. Remove wheel, brake caliper and wheel hub.
Refer to Front Drive Axle Removal Page 7.3 for
procedure.
2. Remove cotter pin and castle nut from A-arm ball
joint.
3. Disconnect A-arm from ball joint using a tie rod
fork.
4. Slide strut off end of drive shaft and tie it up out of
the way of the shaft.
5. Remove clamps from rubber boot using the
proper boot clamp pliers.
6. Remove the large end of the boot from the CV
joint, slide the boot back and separate the wheel
spindle and CV joint assembly from the axle shaft
by pulling the shaft sharply outward, away from
the CV joint. It may be necessary to tap the CV
joint assembly outward with a soft faced hammer.
Pull shaft to remove from
CV joint
7. Remove small clamp and boot from driveshaft.
NOTE:If the ATV has been operated with a damaged
boot, the CV joint grease may be contaminated.
Inspect the grease carefully for contamination, and
clean the joint thoroughly if necessary. Front drive
axle CV boot replacement requires 30g of grease. If
CV joint is cleaned, an additional 30g of grease is
required. Refer to information following.
8. Before installing the new boot, remove all grease
from the boot area and shaft.
NOTE: It is very important to use the correct type and
quantity of grease. Use only the grease contained in
the boot kit. DO NOT use a substitute grease and DO
NOT overfill or underfill the CV joint.
CV Joint Grease -30g (PN 1350046)
CV Boot Clamp Pliers:
Earless Type
Boot Replacement requires 30g
Boot replacement with complete CV
joint cleaning requires an additional
30g. (Total 60g)
9. Slide the new clamp and boot (small end first)
over the splined shaft, then slide (tap) the CV joint
into the splines of the axle. Install small boot
clamp.
10. Add grease through large end of boot.
11. Position large end of boot on CV joint, purge
excess air by partially compressing axle into CV
FINAL DRIVE
Retaining ring
(PN 8700226)
7.5