Polaris Ranger RZR XP 900 2011 Service Manual page 278

FINAL DRIVE
6. Remove the CV boot from the shaft.
A
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.
7. 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.
8. Visually inspectthe joint by tilting the innerrace 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 it's groove machined
in the shaft.
11. Install a new circlip on the end of the shaft.
7.30
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 innerrace. Pack the ball
tracks and outer face flush with grease. Place any remaining
grease into the boot.
A
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.
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.
9923144 - 2011 RANGER RZR XP 900 Service Manual
© Copyright 2011 Polaris Sales Inc.