Polaris 2008 RZR Service Manual page 220

FINAL DRIVE
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.
recommended amount
replacement only.
4. Remove boot from the shaft.
5. 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.
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.
6. Place a new snap ring in the groove of the CV joint inner
hub with tabs facing the shaft as shown.
7. Before you assemble the CV joint, slide the new boot (small
end first) and clamp over the splined shaft.
7.26
Use the
of grease for
Do not replace CV joints
Tabs face the shaft
8. Refit CV joint on the 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 the groove on the shaft.
boot
NOTE: It is very important to use the correct type
and quantity of grease by using the grease
contained in the boot kit. DO NOT use a substitute
grease and DO NOT overfill or under fill the CV joint.
9. Refer to information below or Figure 7-28 for grease
capacity requirements.
Boot Replacement Grease Requirement:
Grease Service Kits
Inner Plunging Joint:
Boot replacement only - 40g
Boot replacement w/joint cleaning - 80g
Outer CV Joint:
Boot replacement only - 30g
Boot replacement w/joint cleaning - 60g
10. Remove excess grease from the CV joint's external surfaces
and position the boot over the housing, making sure the
boot is seated in the groove. Position clamp over the large
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. The air
should be released after the plunging joint has been
centered properly. Tighten boot clamp using boot
clamp pliers.
Tap joint onto shaft
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g