Kinda new to this forum, lots of good info in here!
I only have 40 miles on my '08 Sportsman 500. Unfortunately I also have 1 small stick in the left front CV boot. Those guards are pretty much worthless! There's a big gap between the hub and guard! Anyways, I'm pretty good w/ a wrench, so is this something I can tackle without a manual?

 

Probably, but why would you want to do it without a manual? A shop manual is less than $40... a drop in the bucket compared to what you paid for your machine and what you would pay to take it to the shop, and if you do any riding at all, you WILL need to do some work on it from time to time.

Anyway, sorry I don't have advice about your specific problem, but I highly recommend investing in a shop manual if you plan on doing any kind of mechanical or electrical work on your machine yourself.

 

i bet someone can post the site where you can get a pdf manual for that bike on here for you for free. its not too bad of a job changing the boot as long as you can get the cv clamps off and on.

 

It would definately make it easier if you had a manual but if you are good with a wrench it can be done if you take your time and don't rush it. I have changed both the front and rear on my 700 without a manual. If you search you will find a lot of post about changing cv boots.

Good Luck
Wheels47

 

Just google cv boot replacement and you will get all kinds of help. I have an '03 600 and have replaced both front and back a number of times. The front can be done without removing the axle from the front pumpkin. I order my boots from mfgsupply.com. They will send the boot, the new band and a banding tool, with instructions cheaper then anywhere else. Good Luck!!

 

Thanks to all for the advice and info! I will likely get a manual to add to my already huge collection of manuals for things I no longer own and tackle the job myself. It would be sweet if I could find the PDF version! I have done CV joints and struts on my car so I'm thinking it'll be similar to that. Thanks again!

Edit: Big600twin, you say you've replaced your boots a number of times. What's damaging them or do they just wear out that often?

 

Just some helpful tips I learned while doing the front outer cv boot replacement on my '08 Sp. 500 H.O. efi.

1) Invest in the service manual! Saves lots of headaches.
2) Disconnect the lower A-arm from the frame to remove axle, Much easier!
3) Don't mess with the inner joint in attempt to install the new boot from that end, which was recommended in many of the on-line how to's I found! You can end up damaging the inboard clamps which aren't sold seperately for these machines anymore, and you have to buy the whole inboard kit to get new ones.
4) According to a tech at my dealer, the outer CV joint comes apart with just the right hammering and prying, but doesn't come off the shaft in one piece. That is the recommended way of changing the outer boot. Again, service manual would have helped alot here!
5) The clamps and boots for the inner and outer joints are just slightly, slightly different. No matter how much they look the same, they are different.
6) A side cutter or channel lock pliers works pretty good for re-installing the clamps, but alot of squeezing force is needed.

Cheers

 

if you do some lookin on this forum there is a link to an 08 500 manual in pdf form.

 

Piece of cake..once you do one they are easy.............However, I also recommend the shop manual.. I found a CD for mine on E-bay for ten bucks. And it was a Polaris manual to boot!!!!!!!!!!!!!! Best money you could possibily spend for your quad......