8.12
9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual
© Copyright Polaris Industries Inc.
CV JOINT / BOOT REPLACEMENT
NOTICE
Outer CV Joint replacement is not recommended. If the
outer joint is damaged, a new half shaft assembly
should be installed.
NOTICE
This procedure applies to inner and outer boot
replacement for the rear drive axles.
1. Use a side cutters to cut and discard the boot clamps
q
.
2. Remove the large end of the boot from the CV joint
and slide the boot down the shaft.
3. Clean the grease from the face of the joint.
CAUTION
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.
IMPORTANT
If the grease in the joint is contaminated with water and/
or dirt, the joint should be replaced.
4. The CV joint is fitted with a circlip at the end of the
shaft inside the housing. The shaft is likely to be
damaged from striking the cage / race to separate the
CV joint from the shaft. It is recommended to replace
the entire half shaft assembly if there is damage to
the outer joint.
5. Remove the inner joint from the shaft to remove the
CV boot.
6. Slide the boot clamp and boot (large end first) onto
the plunging joint end of the drive shaft and position
the boot in it’s groove machined in the shaft.
7. 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.
NOTICE
The amount of grease provided in the boot kit is pre-
measured. Use entire contents of package.
8. Remove excess grease from the CV joint's external
surfaces and place the excess grease in the boot.
9. 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.
FINAL DRIVE
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