How to replace the outer CV joint or boot on an ATV
1. Jack the vehicle off the ground and secure it from rolling.
2. Remove the wheel.
3. Remove the axle nut (large nut on the outside of the hub)
4. Remove the lower control arm bolt from the ball joint and hub assembly. Then remove the bolt from the shock and upper control arm
5. The hub will be able to swing out away allowing the outer CV joint to be slipped out through the back. This may require a tap on the threaded end of the outer CV joint. Put the axle nut back on half way so that you can tap on it without damaging the threads.
6. The inner CV joint will be the only thing holding it axle in place. The inner CV joint is held in by a ?c? clip, just pry it away from the differential and it will pop out, you may need to tap it from behind. Now you should be able to pull it out of the differential.
7. If you are only replacing the boot you?ll want to do that from the inner CV joint end of the shaft, refer to inner CV joint instructions). However, if you are removing the outer CV joint you?ll want to put the CV axle in a vise by the shaft close to the inner CV or u-joint. Cut the boots clamps and make sure that your CV joint is not held on by a clip that you can see on the shaft under the boot (this is only on a few later models). If there is no clip you?ll want to tap lightly on the outer CV joint and then give it a few good hits to knock it off of the shaft (I use a 5 lb sledge. (wear glasses, grease may fly!) It usually comes off with one or two good blows with the hammer. However, If it doesn't come off put the axle in a vise and try again. If it still doesn't come off use your hammer to break the cage and remove the ball bearings. This will expose the race. You'll need to press the race off of the shaft. You can use a punch and hammer to punch the shaft back through the race. Other wise you'll need to use a press. Or cut it off with a cutoff saw. Cut the race in the direction of the splines on the shaft. That way it won't affect your new joint going onto the splines.
8. Now that the joint is removed cut away the old boot and clamps and clean the shaft with parts cleaner or Brake clean.
9. Put on the new boot and slide it toward the inner out of the way.
10. Cut the corner of the grease packet to make it like a baker?s bag. This will allow you to squirt the grease into the hole were the shaft will go. Fill the outer CV joint until the grease comes up around the ***** and set the rest aside for later in this procedure.
11. Now put a little grease on the "c" clip on the shaft to help hold it centered
12. Take the outer CV joint and line up with the splines of the shaft and make sure that your clip is not sticking out to one side or the other.
13. Now place the axle nut onto the threads half way to avoid damaging the threads and tap the joint back onto the shaft. If it doesn't go fairly easily then back off and use a screw driver the press the clip in while putting pressure until it is no longer exposed then the joint will tap on with ease.
14. Now squirt the remaining grease around the top of the joint (it may not require all of the grease packet just use about a 1" bead all the way around) were the shaft meets the joint and slide your boot down and clamp the large clamp first.
15. Now use a screwdriver to go in between the small end of the boot and shaft to release any trapped air or suction that may be deforming the boot. Then install the small clamp.
16. Now ready to install the axle. Just use your removal procedure in reverse.
If you have any questions or concerns please email me at theCVman@comcast.net
or call 1-800-338-2326 M-Sat. 8-6 e.s.t. Thank you, Danny Walburn CV Restoration