Polaris Sportsman 800 EFI 4x4 2012 Service Manual page 331

13. 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
boot.
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.
IMPORTANT: The amount of grease that's
provided is pre-measured, so use all the grease.
Boot Replacement Grease Requirements:
Grease Only Service Kits
PN 1350059 - 20g / PN 1350046 - 30g / PN 1350047 -
50g
Outer CV Joint Capacity:
Front - 42.5g / Rear - 85g
14. Slide the joint onto the drive shaft splines and align
the circlip with the lead-in chamfer on the inner race
of the joint.
15. Use a soft-faced hammer to tap the joint onto the
drive shaft until it locks into place.
16. Pull on the joint to make sure it is securely locked in
place.
17. Remove excess grease from the CV 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.
19. Install and tighten the large clamp using the Axle
20. While pulling out on the CV shaft, fully extend the CV
21. Install and tighten the small clamp on the boot using
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
Boot Clamp Tool (8700226 or PU-48951).
Axle Boot Clamp Tool
8700226 or PU-48951
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 shaft.
the Axle Boot Clamp Tool (8700226 or PU-48951).
Axle Boot Clamp Tool
8700226 or PU-48951
FINAL DRIVE
7
7.65