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9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
3. Remove the large end of the boot from the plunging
joint and slide the boot back.
4. Use a soft-faced hammer or brass drift to separate
the plunging joint from the drive shaft.
NOTE: If using a brass drift, be sure to tap on
the inner race of the joint only.
5. Make sure the circlip remains on the shaft and not
left in the joint. Discard the circlip.
6. Remove the boot from the drive 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.
7. 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.
8. Visually inspect the joint by tilting the inner race to
one side to expose each ball. Severe pitting, galling,
play between the ball and its cage window, any
cracking or damage to the cage, pitting or galling or
chips in raceways call for joint replacement.
9. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in the
groove machined in the shaft.
11. Install a NEW circlip on the end of the shaft.
12. Grease the joint with the special 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.
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 Requirement:
Inner Plunging Joint Capacity: 80g
Grease Service Kit: PN 1350047 (50g)
13. Fully compress the joint and push the drive shaft
firmly into the inner race.
14. Align the circlip with the lead-in chamfer.
15. Use a soft-faced hammer to tap the joint onto the
drive shaft until it locks into place.
16. Pull on the joint to make sure it is securely locked
into place.
17. Remove excess grease from plunging joint’s external
surfaces and place the excess grease in the boot.
18. Pull the boot over the joint and position the boot lips
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
19. Install and secure the small clamp on the boot using
the “earless” clamp pliers.
CV Boot Clamp Pliers
Earless Type: 8700226
20. Pull out on drive shaft to center the joint in the
housing. Slide a straight O-ring pick or a small
slotted screw driver between the large end of the
boot and joint housing and lift up to equalize air
pressure in the boot.
FINAL DRIVE
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