Polaris SPORTSMAN 400 2003 Service Manual page 191

FINAL DRIVE
5. Refit CV joint on interconnecting shaft by tapping
with a plastic hammer on the joint housing. Take
care not to damage threads on the outboard CV
joint. The joint is fully assembled when the snap
ring is located in
interconnecting shaft.
Tap joint onto shaft
6. Install and tighten large boot clamp with boot
clamp pliers.
7. Remove excess grease from the CV joint's
external surfaces and position joint boot over
1. Remove CV joint from end of shaft. (See Page 7.25)
2. Remove boot from shaft.
NOTE: When replacing a damaged boot, check the
grease for contamination by rubbing it between two
fingers. A gritty feeling indicates contamination. If
the grease is not contaminated, the boot can be
replaced without cleaning the CV joint. Use the
recommended amount
replacement only (see below).
Installation.
(CV JOINT CLEANING / REPLACEMENT)
3. Thoroughly clean and dry the CV joint and inspect
ball tracks and cages for wear, cracks or other
damage.
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.
7.26
the groove on the
of grease for boot
Proceed to Boot
housing, making sure boot is seated in groove.
Position clamp over boot end and make sure
clamp tabs are located in slots. Note: Before
tightening boot clamp on inboard joint, make sure
any air pressure which may have built up in joint
boot has been released.
released after the plunging joint has been
centered properly. Tighten boot clamp using boot
clamp pliers.
Open snap ring and pull
CV joint away from shaft
(Boot Replacement)
4. Add the recommended amount of grease for CV
joint cleaning to the joint as shown below. Be
sure grease penetrates all parts of the joint.
(BOOT INSTALLATION)
5. Fit joint boot and clamps on interconnecting shaft.
Make sure small end of boot is fully seated in
groove.
6. Position small clamp over small end of boot. Be
sure it is seated all the way around in the clamp
recess on the boot.
The air should be