U-Joint Inspection; U-Joint Assembly (Typical) - Polaris Magnum 2x4 Service Manual

U ... Joint Inspection
FINAL DRIVE
U ... Joint Service
NOTE: When rebuilding Type IV shaft drive rear U-Joints it is necessary to inspect the yoke cap bores for align-
ment or warpage. If a yoke cap bore is warped or twisted, the yoke must be replaced.
1. Make sure yoke bores are free of nicks or burrs from
disassembly.
2. Slide the appropriate tool through both bores as
shown. Hold the tool so the flat portion is in line with
the yoke centerline. If yoke tool does not slide freely
in both bores, replace yoke.
3. Pull tool out and turn 90°. Slide tool through both
bores. Tool must slide freely into both bores.
U-Joint Assembly (Typical)
1. Install new bearing caps in yoke by hand. Carefully
install U-joint cross with grease fitting properly
positioned. Take care not to dislodge needle
bearings upon installation of cross joint. Tighten vise
to force bearing caps in.
2. Using a suitable arbor, fully seat bearing cap in one
side. Continually check for free movement of
bearing cross as bearing caps are assembled.
3. Install snap ring to contain bearing cap just installed.
Repeat procedure for other side.
4. Install outer yoke, aligning marks made before
disassembly.
Polaris Industries Inc. 7.19
5/98