Polaris SPORTSMAN 400 2003 Service Manual page 175

FINAL DRIVE
3. Install drive shaft in strut.
4. Install lower ball joint, torque nut to 25 ft. lbs. (34.5
Nm) and install new cotter pin.
5. Follow procedure to install hilliard clutch
components and hub as outlined on Page 7.9.
6. Tighten hub nut following procedure on Page 7.5.
DRIVESHAFT AND CV JOINT
HANDLING TIPS
Care should be exercised during driveshaft removal or
when servicing CV joints. Driveshaft components are
precision parts.
Cleanliness and following these instructions is very
important to ensure proper shaft function and a normal
service life.
S The complete driveshaft and joint should
be handled by getting hold of the
interconnecting shaft
disassembly or potential damage to the
driveshaft joints.
S Over-angling of joints beyond their
capacity could result in boot or joint
damage.
S Make sure surface-ground areas and
splines of shaft are protected during
handling to avoid damage.
S Do not allow boots to come into contact
with sharp edges or hot engine and
exhaust components.
S The driveshaft is not to be used as a lever
arm to position
components.
S Never use a hammer or sharp tools to
remove or to install boot clamps.
S Be sure joints are thoroughly clean and
that the proper amount and type of
grease is used to refill when joint boots
are replaced and when joints are
7.10
to avoid
other suspension
cleaned. Refer to text for grease
capacity of CV joints and CV joint boots.
FRONT DRIVE SHAFT CV
JOINT BOOT REPLACEMENT
1. Remove wheel, brake caliper and wheel hub.
Refer to front hub disassembly Page 7.3 for
procedure.
2. Remove cotter pin and castle nut from A-arm ball
joint.
3. Disconnect A-arm from ball joint using a tie rod
fork.
4. Slide strut off end of drive shaft and tie it up out of
the way of the shaft.
NOTE: Be careful not to damage the wheel coil wires
when positioning the strut. Front Drive Shaft CV Joint
Boot Replacement Cont.