Polaris Ranger 500 2x4 2007 Service Manual page 214

6. Remove the large end of the boot from the CV joint, slide
the boot back and separate the wheel spindle and CV joint
assembly from the axle shaft by pulling the shaft sharply
outward, away from the CV joint. It may be necessary to
tap the CV joint assembly outward with a soft faced
hammer.
Retaining Ring
Pull shaft to remove
7. Remove small clamp and boot from driveshaft.
If the unit has been operated with a damaged boot, the CV
joint grease may be contaminated. Inspect the grease
carefully for contamination, and clean the joint thoroughly
if necessary. Front drive axle outer boot replacement
requires 30g of grease. Inner boot replacement requires 20g
of grease. If either of the joints are cleaned, double the
amount of grease is required. Refer to information below
and illustration to the right.
Boot Replacement Grease Requirement:
Outer
CV Joint Grease - 30g PN 1350046
Inner
Plunging Joint Grease - 20g PN 1350059
8. Before installing the new boot, remove all grease from the
boot area and shaft.
NOTE: It is very important to use the correct type
and quantity of grease by using the grease
contained in the boot kit. DO NOT use a substitute
grease and DO NOT overfill or underfill the CV joint.
9. 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. Install small boot clamp.
10. Add grease through large end of boot.
11. Position large end of boot on CV joint, purge excess air by
partially compressing axle into CV bell, lift one edge of
boot to let out excess air Secure the CV boot with clamp.
from CV joint
FRONT SHAFT (4X4)
Joint Capacity*
30 Grams
Joint Capacity**
20 Grams
*CV joint capacity: 30g if boot is replaced only.
Another 30g (60g total) if joint is cleaned.
**Plunging joint capacity: 20g if boot is replaced
only. Another 20g (40g total) if joint is cleaned.
FINAL DRIVE
Boot Capacity
30 Grams
Boot Capacity
20 Grams
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