Polaris 2009 Sportsman XP 850 Service Manual page 235

7. Remove the CV boot from the shaft.
CAUTION
Complete disassembly of the CV 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.
8. 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.
9. 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.
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.
10. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
11. 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.
12. Install a NEW circlip on the end of the shaft.
Do not replace CV joints
13. 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.
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.
NOTE: The amount of grease that's provided is pre-
measured, so use all the grease.
Boot Replacement Grease Requirements:
Grease Only Service Kits
PN 1350059 - 20g / PN 1350046 - 30g / PN 1350047 - 50g
Outer CV Joint Capacity:
Front - 80g / Rear - 90g
14. Slide the joint onto the drive shaft splines and align the
circlip with the lead-in chamfer on the inner race of the
joint.
15. Use a soft-faced hammer to tap the joint onto the drive shaft
until it locks into place.
16. Pull on the joint to make sure it is securely locked in place.
17. Remove excess grease from the CV joint's external surfaces
and place the excess grease in the boot.
18. 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.
FINAL DRIVE
Place any
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