I have a 2002 polaris sportsman 500 HO. The front outer cv boot is ripped and i am trying to replace it. Does anyone know of where I can find directions on how to replace the boot. Or can someone help me out by offering instructions. I have the boot and now its just trying to figure out how to put it on. But i need the old one off first.

 

If your machine is anything like my buddies, you're going to have a hell of a time trying to replace it on your own. He has an 07 sportsman 500. his rear outer boot is ripped and after about 2 hrs of trying to get the old one off, we gave up. seems like you have to take the whole rod assembley off. it's almost like they disigned it that way so you have to bring it back to the dealer to have it done. duck tape works well for the time being.

 

I wouldnt go the duct tape route unless your out in the middle of nowhere and I would avoid all mud water etc. You do have to take the axle out to replace. keep checking in a lot of guys on here change their own and they will help you out!!

 

Well I guess I will tell you how. First take off the wheel. Remove the carter pin and remove the axle nut. Take out the bolt holding the tie rod on. Remove the carter pin and castle nut off the bottom of the A arm. To drop the A arm off the strut you must use a hammer. Don't hit the ball joint! All you have to do is push down on the A arm and bang the side of it to vibrate it off. Once the A arm is off all you have to do is pull back and the axle and the strut. It may take a little work and some wiggle but it will come out. Now take off the old boot and ****** the cv off the axle. Clean all the grease out of the cv joint useing gas or brake clean. Take the cv grease and back the cv up realy good. Slip the boot on the axle and then put the cv back on. Now reattach the boot. (helps to have the earless boot pliers that you can rent from autozone for about $10.00 or you can purchase them for the same price.) Burp the boot. Reinstall everything like it was. I don't know all of the torgue put you can do a search and find them. I will tell you that the washers on the axle nut are beveled out and need to be put on beveled out. Sounds like alot but I can now do it in about 15 to 30 minutes.(not counting cleaning out the grease from old cv.)

 

I really appreciate the info on cv boot re-instal for the sportsman 500 I am pritty handy with tools and repairing motors.The info you gave was spot on.I got everything done in 1 hour right up to the last step it took me longer to wash my hands lol .I am wondering the upper rear cv joint does not want to come free from the rear end and I am going to buy some of those earless boot pliers.Could you tell me if I am missing something.There is movement in and out but it does not want to come free,from what I thought it should just slide out.If you could offer up some info on what I might be doing wrong.

 

Should I cut the cv joint off you said ''Now take off the old boot and ****** the cv off the axle'' does this mean if I cut the clip of it should slide out???