Polaris RZR 800 2013 Manual page 350

FINAL DRIVE
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.
NOTE: Shiny areas in ball tracks and on the
cage spheres are normal. Do not replace CV
joints because parts have polished surfaces.
Replace CV joint only if components are cracked,
broken, worn or otherwise unserviceable.
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 the
groove machined in the shaft.
11. Install a NEW circlip on the end of the shaft.
12. 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.
The grease provided in the replacement kit is specially
formulated for wear resistance and durability. DO NOT
use substitutes or mix with other lubricants.
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:
RZR - 80g
RZR S / RZR 4 - 90g
Grease Only Service Kit: PN 1350047 (50g)
7.38
CAUTION
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
13. Slide the joint onto the drive shaft splines and align
the circlip with the lead-in chamfer on the inner race
of the joint.
14. Use a soft-faced hammer to tap the joint onto the
drive shaft until it locks into place.
15. Pull on the joint to make sure it is securely locked in
place.
16. Remove excess grease from the CV joint's external
surfaces and place the excess grease in the boot.
17. 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.
18. Install and tighten the large clamp using the
appropriate clamp tool.
Axle Boot Clamp Tool: PU-48951
CV Boot Clamp Pliers: 8700226
or