Can any one tell me how to remove the circlip in the front CV joint. I want to install a new boot and I need to remove the Cv joint first. I have the boot off. I just cant seem to find a way to remove the clip? Thanks Mark

 

Its a 2003 400 sportsman

 

I've managed to tear two rear boots in the last two weeks on my '07 500. I understand your frustration.

I'm not positive that the '03 400 is exactly the same, but with mine the breakthough came when I pulled on the axle while someone else turned the opposite wheel. The "knuckle" pulls out and the bearings fall out. Then you've got the axle off the wheeler and can work with it.

After it is cleaned up so you can see it, spread the clip with a screw driver and hit the end of the axle with a hammer (I bought a clip spreader for $18 that is easier, but a flat screw driver works). One of my axles popped right out and one I had to use a punch to drive it the whole way out.

This is the way to get to wheel side and inner boots.

Good luck - it'll be easy once you've done it once.

 

i not sure if its the same clip as the one im showing in my pics. (under the camera) but take a look as its very hard to see until you clean the grease off. i used 2 screwdrivers to take it out i think. its pic no. 12. cant remeber but i think it was the rear one.

 

On my 03 Polaris Sportsman 500, the circlip is left alone. You can pull out the axle in front by just having the strut & spring lower itself down after you disconnect it from the frame. The axle will practically fall out from the cv joint. I took off the old cv boot and installed a new cv boot. Then disconnected the A-arm from the frame so that I could line up the axle spline back inside the cv joint. The circlip will contract to fit back inside again without any tool. Hope this helps out.

 

luckycharms5 i bought the pliers that come in a plastic case at sears for $14.99 and they had all the different tip's to remove and install the c and e surclip's , and they are Craftsman Brand with the liftime replacement Guarrantee ; i have used screw drivers and needle nose pliers but the right tool makes the job go easier ! Of course i have been in the small engine service and repair industry for over 20 yrs. so i needed them for more than 1 job ! .....

 

<div class="FTQUOTE"><begin quote>Originally posted by: Williebee

luckycharms5 i bought the pliers that come in a plastic case at sears for $14.99 and they had all the different tip's to remove and install the c and e surclip's , and they are Craftsman Brand with the liftime replacement Guarrantee ; i have used screw drivers and needle nose pliers but the right tool makes the job go easier ! Of course i have been in the small engine service and repair industry for over 20 yrs. so i needed them for more than 1 job ! .....</end quote></div>

i agree 100 % on the right tool for the right job, but for this clip there isnt any holes for the tool to go into. it takes a special tool to use on this one i beleave. but i think his is differnt anyways from the one i showed in the pic.

 

hey Guys thatnks for the info. At first iwas like weary on removing it till I seen its the only way to install a boot. I just smacked it with a rubber hammer not hard at all and the thing just popped off. I was like what the hell all this worry and it just popped off now how about getting it on. It just popped on. I cleaned the cv joint up real good greased and now I just need to put the boot on. Everybody Thanks for the help Mark

 

FYI on the Polaris rear inner cv joint. Models after 2003 are staked in (they punch the end of the ball tracks with a chisel. On the earlier models (up to 2003) have a large clip that goes around the inside of the joint to keep the ball, cage, & race from pulling out. On these vehicles you'll want to get behind the clip with a small flat head screw driver or utility knife. Once the clip is removed the shaft and the internal parts will pull out with ease. To remove the inner race (the star looking piece that is attached to the shaft). You'll want to spread the clip ends open (located in the half moon cut out of the race) and tap lightly on the race and it will slide off. One key point to putting it all back is that you must assemble them in this order: boot, cage (the part with the 6 windows that the ***** set into), and the attach the race. This way your sure to have the narrow opening of the cage facing out toward the wheel. If you put the race on first and then put the cage over top it you'll end up with the ***** riding in the wrong position on the race and they will over ride the tracks. This can cause click or could even crack the cage. I have all those parts available so don't worry if you have a need for anything replaced.
Dan "thecvman" on Ebay

 

so what about my 1988 TB I tore a boot this weekend, and its all apart but I ran out of brake clean. I was trying to clean it so I could find the clip but I don't think its got one but I haven't smacked it with a hammer yet.