Polaris Sportsman 400 Service Manual page 246

FINAL DRIVE
FRONT DRIVE SHAFT CV JOINT BOOT REPLACEMENT, CONT.
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.
7. Remove small clamp and boot from driveshaft.
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 below.
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 by using the grease contained in the
boot kit. DO NOT use a substitute grease and DO NOT
overfill or underfill the CV joint.
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 bell, lift one
edge of boot to let out excess air Secure with
clamp.
Joint Capacity
30 Grams
Front outboard joint capacity: 30g if boot is replaced only.
7.14
- projex@inbox.lv -
FRONT SHAFT
Boot Capacity
30 Grams
Another 30g (60g total) if joint is cleaned.
Retaining ring
Pull shaft to remove from
CV joint
CV Joint Grease - 30g PN 1350046
CV Boot Clamp Pliers:
Earless Type 8700226
Boot Replacement requires 30g
Boot replacement with complete CV
joint cleaning requires an additional
30g. (Total 60g)