Guys, I finally got my front end together on my 500 sportsman HO. I installed EPI springs and had to pull the entire front end apart due to the fact that the axles came out! Oh well live and learn. I was able to put on new CV boots but after running the machine I have just a slight bit of grease coming out of the large end of the boot. I don't have any idea how I could have gotten the clamp any tighter, I even used a clamp tool! Is a slight bit of grease to be expected? If not I will have to take it to the dealer for his expertise.

Thanks for your replies..

 

is the clamp actually tight? did you pack it right full of grease too, maybe the extra is pushing its way out

 

Yes the clamp is tight or as tight as I thought I could possibly get it. I am thinking that the little bit coming out is from maybe just too much being in the boot. Thanks for your reply.

Superintendent

 

Is this aftermarket boots you are using? I tried to use some aftermarket boots and was having the same problem you are describing. I couldn't keep the large end of the boot tight on the cv. The little end worked find. The large end would alway leak grease or even come off. So I went back to using factory boots.

 

You are absolutely right they are aftermarket boots and they are definately thicker than the stock boots. I still have the stock boots and they are in good shape perhaps I will just reinstall them. What the heck now I am an expert at tearing down this front end. It may be alot of work but I just don't want to be out on a ride and have the large end of the boot fall off! It is simply not worth the couple of hours it will take to replace with new ones!

Thanks for your reply I have found this forum to be very useful. Hey another question, I just replaced my battery and only at idle with the lights on the little battery light on the spedo flashes. Once I raise the RPMs or turn off the lights it stops. ANY SUGGESTIONS?

Thanks again. Superintendent

 

i dont really know but id geuss weak battery, low idle, or maybe its nothing at all. could also be the cold, batteries dont like the cold much

 

If your idle is to low it will do that. Whats your rpms at idle?

 

Sportsman, I will check the idle speed tomorrow and post what I found out. Thanks again for your time. I will also be changing my front CV boots back to the stock ones to avoid any problems.

Later, Superintendent