7.35
FINAL DRIVE
7
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
6. Remove the CV boot from the shaft.
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.
NOTE: Shiny areas in ball tracks and on the cage
spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.
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 it’s groove
machined in the shaft.
11. Install a new circlip on the end of the shaft.
12. 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.
NOTE: The amount of grease provided in the boot
kit is pre-measured. Use entire contents of package.
13. Slide the joint onto the drive shaft splines and align the
circlip with the lead-in chamfer on the inner race of the
joint.
14. Use a soft-faced hammer to tap the joint onto the drive
shaft until it locks into place.
15. Pull on the joint to make sure it is securely locked in
place.
16. Remove excess grease from the CV joint's external
surfaces and place the excess grease in the boot.
17. 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.
Complete disassembly of the CV 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.
The grease provided in the replacement kit is
specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.
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