front drive shaft prob...

[luckycharms]

On a ride and some deep ruts and water My machine was pulling every now and then to the left with a clunk and then it would release. I pulled both hubs and drained the front gear case and added all ne fluids and a good cleaning. i decided to start the bike up on the lift and and check the 4x4 . The handle bar pulling to the lft. and rgt. was still there. I would rev it up at low low throttle and the handle bars would pull to the left and actually lock up. a slight pull to the straight position and it would click. I noticed the the right boot was ripped and the hard click noise was in fact coming from the right side in the boot. I pulled the hub back off and all looks good iam thinking that the problem is in the boot. I put a strap around the strut and cranked it up to close the shock . How do I get the axel out to take that boot off and inspect. I took the top tie rod off and the nut on the bottom of the strut. I need more info if theres a trick or a easier way. Any info would be great......Thanks Mark Its a 2003 400 sportsman

[Rubberdown]

pull the tire, the hub, the breaks, the outer tie robs, and the ball joinbt bolt, once the ball joint bolt is off, pop the a-arm from the ball joint stem. Then you should be able to undo the 2 bolts on the strut cartridge and slide it off the shock while pulling the outer end of the axle (CV joint) through the hole in the strut cartridge. Then you can inspect the CV joint by removing the boot, but if the boots ripped, and its clicking like that and pulling hard to the side, your joint is in peices. If the boot is actually ripped, unclamp the bands with a pair of needle nose pliers and remove the boot, just slide it up the shaft towards the center of the machine. You will know if the CV if fubared because it will likely have balls dropping out of it and peices of the cage.

If this is your problem, get ahold of CD from this site and he can sell you a CV joint for much MUCH less than your polaris dealer.

let me know how it turns out eh Mark, and welcome to my forum, I'm glad to see you posting, we gotta get out for a ride again soon buddy, its been too long, a couple years at least now.

Paul.

[luckycharms]

Hey Paul Thanks for the info. I will give it a go some time today. One question should I release the strap around the srtut compressing the shock. A ride sounds good soon. As soon as I can let go of my BOW and stop waking up so early and sitting in the woods all day....
Thanks

[luckycharms]

Yah paul the boot was tor good and probaly for some time. The Cv joint was almost completly rusted together. i believe that was the problem. The balls and joint intself looks good after many degreasing and gear oil soak jobs. Before I left for work it was moving very freely and looked alot better. My question now is How do I get a new boot on? The shaft is still on machine. Do I need to take the end of the shaft off and how do you remove the circlip in the Cv area. From my view this looks like the only way to get the boot on. Thanks for the help.

[OnlyPolaris]

just slid the boot on the shaft then put the joint back on and then put the boot into position and put the clamps on.

[Rubberdown]

Do what popo500efi said, but first you have to remove that circlip as you mentioned, then the joint should slide off.

Are you going to use this joint still or are you replacing it? If it was rusted that bad, chances are it will not last too long but you could give it a shot anyways if you dont want to buy a new joint right now. If you do replace it, be sure and check out that guy I mentions, his handle here is CD.

[cd]

and so we meet up on both forums on the same problem, if that joint is actually rusted then throw it away and get with me, i'll get you a new one. BTW 89.95 until wednesday, then back to 99.95 for the joint until I get in a promo kick again.


Went and looked you have a 2003 SP400 and I have one here.

[luckycharms]

How do I get the circlip off there seems to be no way to get at it?

[cd]

theres not really, but if you can get something in their to pry the ends apart like 2 screwdrivers and have someone pull on it at the same time that works.

[luckycharms]

Some times looks can be decieving when it comes to repairs. Iam all set putting everything back together and let me say thanks to all the polaris boyz......