This is likely going to sound a bit stupid, but how is the inner axle CV joint "supposed" to be pulled out of the differential on a `91 King Quad? I was told that it just pulls out, maybe requiring a bearing splitter/slide hammer, but I want to be sure before I put too much pressure on it in case there is an inner clip, or something inside the differential that I could damage. The book I have from Suzuki tells me how to separate the inner CV joint, done that a few times to replace boots no problem. The book says, in the "Front Differential Removal" section, chapter 12, that chapter 11 describes how to remove the axle, but all it says is how to separate the inner CV joint from what I can see. The reason I am doing this is that I just pulled the plow off the king and was checking it over to find that a new boot I installed in the fall had lost it's outside clamp, fairly recently I would say. There isn't a bunch of grease all over the place and most of it seems to be still inside the boot. The replacement boot from Suzuki seemed to be shorter than the original and I told the dealer. He claimed that all the new boots seem to be shorter because they are new! Anyone else notice that? Anyway I needed a clamp, so I called the dealer this afternoon, who let me speak to a mechanic. The mechanic says the boot should not seem shorter and to bring the axle over to him to check it out. He said clamp a set of vice grips on the center of the axle, hold the axle out straight and whack the vice grips a few times to remove the complete axle. I tried that and it didn't budge, so before putting more pressure to it I wanted to ask what the proper way to do it is.

 

Wileys; just take a long rod & slip it through the frame to sort of come at the housing from behind & give it a couple stout wacks with a hammer it'll come right off. If the clamp is just missing & the grease is clean enough why not just put a hose clamp on it?

 

Thanks sxr6. The grease is clean and I have some x-tra to put in it. It doesn’t seem like there is enough space between the upper ball-joint and the boot to fit a hose clamp on it. When the axle rotates I think the screw part will hit the bottom of the ball-joint. I think the boot is too short myself ... I think the dealer sold me the wrong boot last fall when I replaced it. It is only 31/8" long and the old one is over 4". The parts guy still says it is the proper one, even though their own mechanic says it isn't!

 

Sx ir rite about the bar, i just removed a cv out of my 95 by doin the very same way. I used a large pry bar cause the slight hook on the end helps to get arount the diff a little easyer. Also I wouldnt buy the whole story bout the boot being shorter since its new, cause the boot will shink the older it gets not longer. Rob

 

You can also use boots from a auto & save big $$, I replaced mine with a $9.95 boot & fits better.

 

Which auto?

 

Yea which auto? Here in Canada I paid almost $40 + the nice 15% tax for each boot kit! They tell me you can't buy the clamps separate either, which seems silly. I am about to spend a bunch more on it, so if anyone knows a place I can get good parts reasonable I need front shocks, a muffler and wouldn't mind new plastic, but that definately isn't important.

Thanks for the info guys.

 

I don't know if the `95 is different robh, but on the few I have worked on, `93 and older, the axle don't have to come out of the housing to change the inner cv joint, just separate the axle at the joint and replace the cv joint on the spline. I wanted to get the whole axle out of the front-end housing and I think that is what you are saying you did to change the cv joint.? The outter joint is not replaceable ... requires a whole new axle so they tell me. I would think that would come all together with the inner piece and all, so you would have to pull the axle out when replacing the whole axle. On mine I give it a few good snaps with a long pry bar and no way it wanted to come out, so I just measured around the boot, 8 3/4" and got a clamp to fit it ... the only thing free I ever got from a dealer!

 

CANADA EH; I use Empi brand boots part #86-1188-D at about $9.00 cdn. Other brand boots use Outside boot for 85-91 Chev Sprint. This is for front of 300 Cat or 300 Suz, should also fit 500 Cat's & Suz's.

 

[img]i/expressions/face-icon-small-smile.gif[/img]Hey Sxr6: Do you think that these parts will fit a 2001 kingquad as well?
I'm tring to make a parts log for my new ride just in case I need parts!
Thanks for this info! (This is the best place to gain info.)-other than going thru the experences yourself,that is... thanks again.Jb

My first Suzuki Converted from YAHAMA-
<u>Old rides included: '89 350 Big Bear 2x4 </u>Stollen
'85 Yahama 225 MOTO 4 (still going)
Present Ride:
2001-KingQuad
2000 Warn winch
Cooling fan-(ordered)
Front storage boxw/windsheld attached-(not installed to bike yet)

You know it Would be nice if someone would start a thread on just the modifing of the KingQuad with the how2's and costs/benifits ect.
Anyway thanks for this info....James