Polaris 2005 SPORTSMAN 500 Servise Manual page 214

FINAL DRIVE
(BOOT INSTALLATION)
5. 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.
6. Add grease through large end of boot.
7. Install a new boot onto the axle shaft and fill the
CV joint and boot with the correct type and
amount of grease.
8. While pulling out on the CV shaft, fully extend the
CV joint and slide a straight O-ring pick or a small
slotted screw driver between the small end of the
boot and the shaft. This will allow the air pressure
to equalize in the CV boot in the position that the
joint will spend most of its life. Before you remove
your instrument, be sure the small end of the boot
is in its correct location on the axle. CARE MUST
BE TAKEN TO AVOID DAMAGE TO THE
NEWLY INSTALLED BOOT.
9. Install the small clamp on the boot.
10. Be sure to use only the Constant Velocity Joint
grease supplied with boot service kit. IF CV
JOINT WAS CLEANED, add the recommended
amount of grease to the joint in addition to the
grease pack supplied with boot kit.
NOTE: CV Joint Grease Capacity:
7.26
Joint Capacity
50 Grams
OUTBOARD
80g Total
Boot Capacity
Boot Capacity
30 Grams 50 Grams
CV Joint Grease - 30g PN 1350046
50g PN 1350047
Outboard joint - 30g if boot is replaced only. Another
50g (80 total) if joint is cleaned.
Inboard joint - 50g if boot is replaced only. Another
50g (100 total) if joint is cleaned.
Joint Capacity
50 Grams
INBOARD
100g Total