Polaris Sportsman 800 EFI 4x4 2012 Service Manual page 333

7. Remove the CV boot from the shaft.
CAUTION
Complete disassembly of the CV 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.
NOTE: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint
should be replaced.
8. 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.
9. 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.
10. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
11. 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.
12. Install a NEW circlip on the end of the shaft.
13. Grease the joint with the special CV joint grease
The grease provided in the replacement kit is specially
DO NOT use substitutes or mix with other lubricants.
PN 1350059 - 20g / PN 1350046 - 30g / PN 1350047 -
14. Slide the joint onto the drive shaft splines and align
15. Use a soft-faced hammer to tap the joint onto the
16. Pull on the joint to make sure it is securely locked in
17. Remove excess grease from the CV joint's external
18. Pull the boot over the joint and position the boot lips
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
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
formulated for wear resistance and durability.
IMPORTANT: The amount of grease that's
provided is pre-measured, so use all the grease.
Boot Replacement Grease Requirements:
Grease Only Service Kits
50g
Outer CV Joint Capacity:
Front - 42.5g / Rear - 85g
the circlip with the lead-in chamfer on the inner race
of the joint.
drive shaft until it locks into place.
place.
surfaces and place the excess grease in the boot.
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
FINAL DRIVE
7
7.67