Polaris 1999 Sportsman 400 Service Manual page 305

FRONT DRIVE SYSTEM
299
®
®
drive unit,
I f
necessary,
remove
the
drive axle and
perform
the pro cedur e
at a workbench.
NO TE
If
()1l~V
replacing the rubber boous),
proceed
10
Step / 3.
12. To remove the dri ve axle, remo ve Ihe roll
pin (Fig ur e 35 ). S lide the drive ax le and inner
universal joint off the spline
all
the front drive
ecc entric shaft.
13. To remove the CV joi nt boot, perform tho
fol lowing:
a. Remo ve the largo c lamp (A , Fig ure
36 )
se-
curing the rubb er boo t to the front spind le
portion of the CV jo int. Slide the boo t off
the CV joint.
b. Withdraw the front spind le port ion (8,
Figure
36)
of the CV j o int from the fronl
drive ax le . Ifn ec essary, usc a plastic malle t
and tap on the inner surface of the front
sp ind le to se parate it fro m the circl ip o n the
end of the dr ive axle.
e. Remove the small clamp (C, Figure 36) sc- _ ,
curing the rubber boot to the drive axle and
~
s lide the rubber boot off the driv e axle.
Inspecti on/Lu b r tcatl on
I . Chec k the driv e axle for da mage (Figure 37 ).
2. Inspect the fro nt spind le splines (A , Fig ure
38) for wea r or dama ge. Mino r damage can be
cle aned up with a fine-cut file, but ifd amage is
severe, repla ce the damaged parts.
3. ln spect the spindle nut thread s (8 , Figure 38)
fo r da mag e.
4. Inspect th e universa l j oin t (Figure 39 ) for
wear or damage.
5. Check the rubber boo ! (Figure 40) for hard-
ness, tears or damage. Rep lace
if necessary.
6. If the rubbe r boot was removed, per form the
foll owing:
a. Inspect the splines on both the front spin-
dl e and front ax le for wea r or damage. Mi-
nor damaged can be cleaned up wi th
a
fi ne -cu t file. but
if damag
e is se ve re, re -
plac e the damag ed parts .
b. Make sure the circlip is secured
onto
the
drive axle . If loo se, ins tall a new ci rclip