Inner Plunging Joint / Boot Replacement - Polaris 2009 RANGER 700 Service Manual

FINAL DRIVE

Inner Plunging Joint / Boot Replacement

1. Using a side cutters, cut away and discard the boot clamps.
2. Remove the large end of the boot from the plunging joint
and slide the boot down the shaft.
3. Clean the grease from the face of the joint.
4. Place the drive shaft in a soft-jawed vise.
5. Using a soft-faced hammer, or brass drift, strike the inner
race of the joint to drive the joint off the drive shaft. Be
sure to tap evenly around the joint to avoid binding.
IMPORTANT: Tap on inner race only!
7.44
Brass Drift Shown
6. Make sure the circlip is still on the shaft and not left in the
joint.
7. Remove the boot from the shaft.
Complete disassembly of the plunging joint is
NOT recommended. The internal components
are a precision fit and develop their own
characteristic wear patterns. Intermixing the
internal components could result in looseness,
binding, and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should
be replaced.
8. Thoroughly clean the joint with an appropriate solvent and
dry the joint to prevent any residual solvent from being left
in the joint upon reassembly.
9. Visually inspect the joint for damage. Replace if needed.
10. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first) onto
the drive shaft and position the boot in its groove machined
in the shaft.
Circlip
CAUTION