Polaris Ranger RZR XP 900 2011 Service Manual page 280

FINAL DRIVE
5. Make sure the circlip is on the shaft and not left in thejoint.
6. Remove the boot from the shaft.
A
CAUTION
Complete disassembly of the plunging 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 inspect the joint for damage. Replace if needed.
9. Clean the splines on the end ofthe shaft and apply a light
coat of grease prior to reassembly.
7.32
10. Slide the small boot clamp and boot (small end fIrst) onto
the drive shaft and position the boot in its groove machined
in the shaft.
11. Install a new circlip on the end of the shaft.
12. Grease the joint with the special 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.
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. Fully compress the joint and push the drive shaft fIrmly into
the inner race.
14. Align the circlip with the lead-in chamfer.
15. Use a soft-faced hammer to tap the joint onto the drive shaft
until you reach the end ofthe splines and the joint locks in
place.
16. Pull on the joint to test that the circlip is seated and that the
joint is securely fastened to the shaft.
17. Remove excess grease from the plunging 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.
9923144 - 2011 RANGER RZR XP 900 Service Manual
© Copyright 2011 Polaris Sales Inc.