Does anyone know how to remove and install a new upper CV Boot on a 2003 Polaris Sportsman 700? Or could someone possibly point me in the right direction to begin? Thanks

 

Well if you have the axle off then remove the boot down in the joint there is a c-clip you will have to keep it open then slide the joint off the shaft and do it in reverse to put it back together. I can replace the rear now from jacking up the quad and then lowering it in less then 3 hours I through one obout every 300 miles on the rear front no problem sofar have 2k on my older machine.1. Remove clamps from rubber boot(s) using the
proper boot clamp pliers.
CV Boot Clamp Pliers:
Earless Type (PN 8700226)
2. NOTE: Photo at right is shown without shaft for
clarity. Wipe grease away from recess in CV joint
inner hub to locate snap ring.
Snap ring located in
recessed area
Snap ring
3. Open the snap ring using a snap ring pliers or
small needle nose pliers. Tap CV housing off
shaft with a soft faced hammer while holding snap
ring open.
Tap CV Housing
Off Shaft
Spread ends of snap ring
to remove joint from shaft
4. Place a new snap ring in the groove of the CVjoint
inner hub, with tabs facing the shaft as shown.
Tabs face shaft
FINAL DRIVE
7.23
5. Refit CV joint on interconnecting shaft by tapping
with a plastic hammer on the joint housing. Take
care not to damage threads on the outboard CV
joint. The joint is fully assembled when the snap
ring is located in the groove on the
interconnecting shaft.
Tap joint onto shaft
6. Install and tighten large boot clamp with boot
clamp pliers.
7. Remove any excess grease from the CV joint
external surfaces and position joint boot over
housing, making sure boot is seated in groove.
Position clamp over boot end and make sure
clamp tabs are located in slots. NOTE: Before
tightening boot clamp on inboard joint, make sure
any air pressure which may have built up in joint
boot has been released. The air should be
released after the plunging joint has been
centered properly. Tighten boot clamp using boot
clamp pliers.
Open snap ring and pull
CV joint away from shaft
Boot Replacement
1. Remove CV joint from end of shaft. (See Page
7.20)
2. Remove boot from shaft.
NOTE: When replacing a damaged boot, check the
grease for contamination by rubbing it between two
fingers. A gritty feeling indicates contamination. If
the grease is not contaminated, the boot can be
replaced without cleaning the CV joint. Use the
recommended amount of grease for boot
replacement only (see below). Proceed to Boot
Installation.
CV Joint Cleaning / 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.
3. Thoroughly clean and dry the CVjoint and inspect
ball tracks and cages for wear, cracks or other
damage.
4. Add the recommended amount of grease forCV
joint cleaning to the joint as shown below. Be
sure grease penetrates all parts of the joint.
Boot Installation
5. Fit joint boot and clamps on interconnecting shaft.
Make sure small end of boot is fully seated in
groove.
6. Position small clamp over small end of boot. Be
sure it is seated all the way around in the clamp
recess on the boot.
7. Tighten small boot clamp using boot clamp pliers.
8. Fill boot with grease supplied fromboot service kit
and spread evenly inside CV joint. Be sure to use
only the Constant Velocity Joint grease supplied
with boot service kit. NOTE: IF CV JOINT WAS
CLEANED, add the recommended amount of
grease to the joint in addition to the grease pack
supplied with boot kit.
FINAL DRIVE
7.24
Joint Capacity
50 Grams
Boot Capacity
30 Grams
Joint Capacity
50 Grams
Boot Capacity
50 Grams
INBOARD
100g Total
OUTBOARD
80g Total
NOTE: CV Joint Grease Capacity:
CV Joint Grease - 30g (PN 1350046)
50g (PN 1350047)
Outboard joint - 30g if boot is replaced only. Another
50g (80 total) if joint is cleaned.
Inboard joint - 50g if boot is replaced only. Another

 

If you need any help checkout my instructions on line at www.thecvman.com. Just click on "tech tips" and go to cv boot replacement. Call if you need any pointers.
Dan thecvman