Polaris RZR XP Service Manual page 297

5. Pull the shaft / joint straight out from the housing.
CAUTION
Do NOT strike the joint with a hammer.
6. Using a brass or steel hammer, strike the backside of
the cage assembly to separate it from the shaft.
7. The plunging joint is fitted with a circlip at the end of
the shaft inside the housing. The shaft is likely to be
damaged from striking the cage / race to separate the
joint from the shaft. It is recommended to replace the
entire half shaft assembly if there is damage to the
inner joint.
8. Remove the boot from the shaft.
CAUTION
Complete disassembly of the plunging 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.
IMPORTANT
If the grease in the joint is obviously contaminated with
water and/or dirt, the joint should be replaced.
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
© Copyright Polaris Industries Inc.
9. 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.
10. Visually inspect the joint for damage. Replace if
needed.
11. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
12. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in its groove
machined in the shaft.
13. Install the cage / ball assembly on the shaft. Listen for
an audible "click" indicating the internal circlip has
fully engaged with the cage assembly.
14. 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.
NOTICE
The amount of grease provided in the boot kit is pre-
measured. Use entire contents of package.
FINAL DRIVE
7
7.19