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Offline bezerk1

800EX CV Joint Boot Replacement
« on: January 22, 2016, 11:55:02 am »
I recently replaced a the boot on the front right outboard CV joint of my friends 800EX.  Here are some pictures I took to document to project.  The first picture show what the joint looked like after I cut the boot off. After a few light taps with a hammer I could not get the outer axle shaft off the axle bar.  Instead of getting a bigger hammer I decided to rig up my slide hammer to pull the axle out.  After two light taps the joint came loose.  It took longer to assemble the puller.  The third picture show the CV joint with the axle removed.
« Last Edit: January 22, 2016, 12:00:40 pm by bezerk1 »

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Offline bezerk1

Re: 800EX CV Joint Boot Replacement
« Reply #1 on: January 22, 2016, 12:06:45 pm »
The first picture here shows the outer axle cup cleaned up.  It took quite a bit of work to get the bearings, inner hub, and race out of the outer axle cup.  The machine this joint came out of only has about 50 miles on it.  The joint was very tight and not broken in yet.  The second picture shows the inner hub and race.  It is important to note the axle shaft fits into the beveled splines.  This is the side that faces inboard.  The third picture is of the back of the assembly.  This piece goes into the cup first and faces outboard.  There is a small retainer ring the holds the axle bar into the inner hub.  Also note that the thinner side of the bearing race faces inboard.
« Last Edit: January 22, 2016, 12:28:22 pm by bezerk1 »

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Offline bezerk1

Re: 800EX CV Joint Boot Replacement
« Reply #2 on: January 22, 2016, 12:14:20 pm »
The parts of the CV joint are laid out here in the first picture.  As you can see it is very simple and, almost exactly like a Polaris CV joint.  Picture two shows the cleaned an re assembled joint.  I gave everything a good spray of brake cleaner after it was assembled.  Cleanliness is very important in a CV joint.  The last picture show the part number of the replacement boot I ordered.  I would not use this boot kit again if possible.  I feel like the boot is too short to fit properly.  The cup and axle shaft dimensions were on after trimming but, the boot is just too short.  Time will tell on how well the kit works.  I have rebuilt at least 10 Polaris joint with this brand, and I've never had a problem or failure.
« Last Edit: January 22, 2016, 12:54:14 pm by bezerk1 »

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Offline bezerk1

Re: 800EX CV Joint Boot Replacement
« Reply #3 on: January 22, 2016, 12:20:24 pm »
Below are the items included in the kit, boot, grease, instructions, band tool, and 2 clamps.  I filled the cup with as much grease as possible through the splines in the center.  The rest I spread around the top.  As you can see in the third picture, the boot is too large for the cup.  Banding it like this would lead to disaster.  The instructions tell you to trim the outer ring off.  So I did.  The inner ring has a nice tight seal around the cup.  This is the same procedure for a Polaris CV Joint.

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Offline bezerk1

Re: 800EX CV Joint Boot Replacement
« Reply #4 on: January 22, 2016, 12:26:52 pm »
Picture one shows the boot and clamp in place after trimming.  Picture 2 shows what the clamp looks like after being bent over with the tool.  The tool makes it easy the put a lot of tension on the band.  The last picture show the completed band.  I like to flatten the band where it is folded over with a few light taps from a ball and peen hammer.  Then I bend the two tabs over the band to lock it in place and tap them again with said hammer.  I used my cutoff wheel to trim the excess band.  Be careful not to cut into the new boot.