Polaris Sportsman 700 Efi 2005 Service Manual page 190

FINAL DRIVE
FRONT DRIVE SHAFT CV
JOINT BOOT REPLACEMENT
1. Remove wheel, brake caliper and wheel hub.
Refer to Front Drive Axle Removal Page 7.2 for
procedure.
2. Remove cotter pin and castle nut from A-arm ball
joint.
3. Disconnect A-arm from ball joint using a tie rod
fork.
4. Slide strut off end of drive shaft and tie it up out of
the way of the shaft.
5. Remove clamps from rubber boot using the
proper boot clamp pliers.
6. Remove the large end of the boot from the CV
joint, slide the boot back and separate the wheel
spindle and CV joint assembly from the axle shaft
by pulling the shaft sharply outward, away from
the CV joint. It may be necessary to tap the CV
joint assembly outward with a soft faced hammer.
7.4
Pull shaft to remove from
CV joint
7. Remove small clamp and boot from driveshaft.
NOTE: If the ATV has been operated with a damaged
boot, the CV joint grease may be contaminated.
Inspect the grease carefully for contamination, and
clean the joint thoroughly if necessary. Front drive
axle CV boot replacement requires 3.5 oz. of grease.
8. Before installing the new boot, remove all grease
from the boot area and shaft.
NOTE: It is very important to use the correct type and
quantity of grease. Use only the grease contained in
the boot kit. DO NOT use a substitute grease and DO
NOT overfill or underfill the CV joint.
CV Joint Grease -3.5 oz. (Refer to
parts manual for boot kit)
CV Boot Clamp Pliers:
Earless Type
Boot replacement with complete CV
joint cleaning requires the entire 3.5 oz.
of grease.
9. Slide the new clamp and boot (small end first)
over the splined shaft, then slide (tap) the CV joint
into the splines of the axle.
10. Add grease through large end of boot.
11. Install a new boot onto the axle shaft and fill the
CV joint and boot with the correct type and
amount of grease.
12. While pulling out on the CV shaft, fully extend the
CV joint and slide a straight O-ring pick or a small
slotted screw driver between the small end of the
boot and the shaft. This will allow the air pressure
to equalize in the CV boot in the position that the
joint will spend most of its life. Before you remove
your instrument, be sure the small end of the boot
is in its correct location on the axle. CARE MUST
Retaining ring
(PN 8700226)