Final Drive

FINAL DRIVE

19. Install and tighten the large clamp using the appropriate clamp tool.

Inner Plunging Joint / Boot Replacement

1.

Use a side cutters to cut and discard the boot clamps.

Axle Boot Clamp Tool: PU-48951 or

CV Boot Clamp Pliers: 8700226

20. 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 shaft.

21. Install and tighten the small clamp on the boot using the appropriate clamp tool.

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 inner race of the joint to drive the joint off the drive shaft. Be sure to tap evenly around the joint to avoid binding.

Brass Drift Shown

Axle Boot Clamp Tool: PU-48951 or

CV Boot Clamp Pliers: 8700226

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9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

FINAL DRIVE

IMPORTANT: Tap on inner race only!

6.

Make sure circlip is on the shaft and not left in the joint.

Circlip

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.

12. Install a NEW circlip on the end of the shaft.

13. Grease the joint with the special CV joint grease provided in the boot replacement kit. Fill the cavity behind the balls and the splined hole in the joint’s inner race. Pack the ball tracks and outer face flush with grease. Place any remaining grease into the boot.

CAUTION

The grease provided in the replacement kit is specially formulated for wear resistance and durability. DO NOT use substitutes or mix with other lubricants.

7.

Remove the boot from the shaft.

CAUTION

Complete disassembly of the plunging joint is

NOT recommended. The internal components are 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.

NOTE: It is very important to use the correct type and quantity of grease by using all the grease included with the boot kit. DO NOT use a substitute grease and DO NOT overfill or under fill the CV joint.

Boot Replacement Grease Requirements:

Inner Plunging Joint Capacity:

Front - 60g / Rear - 100g

Grease Only Service Kit: PN 1350047 (50g)

14. Fully compress the joint and push the drive shaft firmly into the inner race.

15. Align the circlip with the lead-in chamfer.

7

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 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.

16. Use a soft-faced hammer to tap the joint onto the drive shaft until you reach the end of the splines and the joint locks in place.

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9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.