Rear Drive Shaft Disassembly; Rear Drive Shaft Assembly - Polaris Magnum 2x4 Service Manual

Rear Drive Shaft Disassembly
FINAL DRIVE
Rear Drive Shaft
NOTE:
Drive shaft must be aligned properly to avoid vibration. Before disassembling driveshaft, be sure to mark
the shaft and all U-joints, taking note of the position of grease fittings to ease assembly.
1 . Remove shaft boot clamp.
2. Separate drive shaft halves.
3. Inspect the inner and outer splines.
4. Refer to page 7.18 for axle cardan U-Joint
disassembly procedure. When disassembling
U-Joint, the yoke bore alignment must be
inspected. Refer to page 7.19 for procedure.
Assembly
NOTE:
When assembling U-Joints, be sure to position
grease fittings correctly.
1 . Assemble axle cardan U-Joints as described on
page 7.19. Be sure to inspect yoke bore alignment
on all yokes. If a yoke is twisted, warped, or
misaligned, it
must
be replaced or pre-mature joint
failure will result.
2. Install drive shaft boot on one of the drive shaft
halves.
3. Grease splines of shaft with Polaris Premium
U-Joint Lubricant.
NOTE:The
only recommended lubricant for the U-joints is
Polaris Premium U-Joint Lubricant. Do not use inferior lu-
bricants in U-Joints or pre-mature failure may result.
4. In order to prevent driveline vibration, the inner and
outer yokes must be aligned properly (refer to
illustration on page 8.42). Assemble rear drive
shaft, aligning inner and outer yokes and grease
fittings.
5. Install boot clamps using boot clamp pliers.
6. Collapse driveshaft assembly and grease until
grease starts to run out of hole on end of shaft.
Polaris Industries Inc. 7.28m
10/96