Polaris RZR XP 1000 Service Manual page 330

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6. Remove the CV boot from the shaft.
Complete disassembly of the CV joint is NOT
recommended. The internal components are 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.
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 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. 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.
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
© Copyright 2014 Polaris Industries Inc.
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
inner race. Pack the ball tracks and outer face flush
with grease. Place any remaining grease into the
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 provided in the
boot kit is pre-measured. Use entire contents of
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
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.


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