How to replace inner CV Boot-IRS

sleddog · 01-20-2009, 04:59 PM

1. With ATV on ground loosen lug nuts, Remove Spindal cotter key, and loosen spindal nut.(rear)

2. Raise machine and remove rear wheels

3. Remove spindal nut, washer, and spindal hub.

sleddog · 01-20-2009, 05:03 PM

4. Loosen the chain. You must loosen the upper and lower carrier bolts, and then back off the adjuster.

5. Now remove you chain sprocket if your working on the left side. You will have to bend the locking tabs flat, and remove the four bolts.

sleddog · 01-20-2009, 05:06 PM

6. Next remove the upper carrier bolt. You can actually tilt the carrier out of the way when removing the shaft, but I removed all the suspension parts, as this was a great time to lube the pivot points.

sleddog · 01-20-2009, 05:11 PM

7. Now it is time to remove the boot clamps and slide the boot back.

sleddog · 01-20-2009, 05:13 PM

8. The inner ring should pop out with a screwdriver.

sleddog · 01-20-2009, 05:15 PM

9. Once both clamps are off, just slide the boot out of the way, or even roll it inside out.

sleddog · 01-20-2009, 05:19 PM

10. Now you can get to the joint. There is a small snap ring in a groove in front of the joint. Using an o-ring pick, pry it out of the groove.(It may be hard to see with all of the grease, but it is there)

sleddog · 01-20-2009, 05:23 PM

11. Once you get the ring out, you can pull the whole shaft out. Now clean up the housing and joint.

sleddog · 01-20-2009, 05:24 PM

Another view

sleddog · 01-20-2009, 05:25 PM

12. To replace the boot, you are going to have to press the joint off.

***he said I could add this so.....I just put the shaft in a vice and use a brass drift or equivalent and hit the CV joint right by the shaft and it pops right off. Be careful as the bearings can and will pop out if it hits the floor like one of mine did. SSJEFF***

01-20-2009, 04:59 PM	#1 (permalink)
sleddog Senior Member Join Date: May 2007 Location: dekalb Posts: 544	How to replace inner CV Boot-IRS 1. With ATV on ground loosen lug nuts, Remove Spindal cotter key, and loosen spindal nut.(rear) 2. Raise machine and remove rear wheels 3. Remove spindal nut, washer, and spindal hub. __________________ 2007 525--JD jet kit+Titanium screw,PP Nerfs(Pro Armor)+Heel pocket(REM), EHS lid,UNI Filter, BRAP Bolts,Vapor computer,PP Hand Guards,GPS Tab,12 volt accessory outlet, rear fender braces,PP Frt.+ Rear grab bar, 15 tooth sprocket,(updated rear suspension),I-razr's on 10" Douglas, KTM slave/case saver, Case vent (Thumper Racing), Muzzy full S.S. system

01-20-2009, 05:03 PM	#2 (permalink)
sleddog Senior Member Join Date: May 2007 Location: dekalb Posts: 544	4. Loosen the chain. You must loosen the upper and lower carrier bolts, and then back off the adjuster. 5. Now remove you chain sprocket if your working on the left side. You will have to bend the locking tabs flat, and remove the four bolts. __________________ 2007 525--JD jet kit+Titanium screw,PP Nerfs(Pro Armor)+Heel pocket(REM), EHS lid,UNI Filter, BRAP Bolts,Vapor computer,PP Hand Guards,GPS Tab,12 volt accessory outlet, rear fender braces,PP Frt.+ Rear grab bar, 15 tooth sprocket,(updated rear suspension),I-razr's on 10" Douglas, KTM slave/case saver, Case vent (Thumper Racing), Muzzy full S.S. system

01-20-2009, 05:06 PM	#3 (permalink)
sleddog Senior Member Join Date: May 2007 Location: dekalb Posts: 544	6. Next remove the upper carrier bolt. You can actually tilt the carrier out of the way when removing the shaft, but I removed all the suspension parts, as this was a great time to lube the pivot points. __________________ 2007 525--JD jet kit+Titanium screw,PP Nerfs(Pro Armor)+Heel pocket(REM), EHS lid,UNI Filter, BRAP Bolts,Vapor computer,PP Hand Guards,GPS Tab,12 volt accessory outlet, rear fender braces,PP Frt.+ Rear grab bar, 15 tooth sprocket,(updated rear suspension),I-razr's on 10" Douglas, KTM slave/case saver, Case vent (Thumper Racing), Muzzy full S.S. system

01-20-2009, 05:11 PM	#4 (permalink)
sleddog Senior Member Join Date: May 2007 Location: dekalb Posts: 544	7. Now it is time to remove the boot clamps and slide the boot back. __________________ 2007 525--JD jet kit+Titanium screw,PP Nerfs(Pro Armor)+Heel pocket(REM), EHS lid,UNI Filter, BRAP Bolts,Vapor computer,PP Hand Guards,GPS Tab,12 volt accessory outlet, rear fender braces,PP Frt.+ Rear grab bar, 15 tooth sprocket,(updated rear suspension),I-razr's on 10" Douglas, KTM slave/case saver, Case vent (Thumper Racing), Muzzy full S.S. system

01-20-2009, 05:13 PM	#5 (permalink)
sleddog Senior Member Join Date: May 2007 Location: dekalb Posts: 544	8. The inner ring should pop out with a screwdriver. __________________ 2007 525--JD jet kit+Titanium screw,PP Nerfs(Pro Armor)+Heel pocket(REM), EHS lid,UNI Filter, BRAP Bolts,Vapor computer,PP Hand Guards,GPS Tab,12 volt accessory outlet, rear fender braces,PP Frt.+ Rear grab bar, 15 tooth sprocket,(updated rear suspension),I-razr's on 10" Douglas, KTM slave/case saver, Case vent (Thumper Racing), Muzzy full S.S. system

01-20-2009, 05:15 PM	#6 (permalink)
sleddog Senior Member Join Date: May 2007 Location: dekalb Posts: 544	9. Once both clamps are off, just slide the boot out of the way, or even roll it inside out. __________________ 2007 525--JD jet kit+Titanium screw,PP Nerfs(Pro Armor)+Heel pocket(REM), EHS lid,UNI Filter, BRAP Bolts,Vapor computer,PP Hand Guards,GPS Tab,12 volt accessory outlet, rear fender braces,PP Frt.+ Rear grab bar, 15 tooth sprocket,(updated rear suspension),I-razr's on 10" Douglas, KTM slave/case saver, Case vent (Thumper Racing), Muzzy full S.S. system

01-20-2009, 05:19 PM	#7 (permalink)
sleddog Senior Member Join Date: May 2007 Location: dekalb Posts: 544	10. Now you can get to the joint. There is a small snap ring in a groove in front of the joint. Using an o-ring pick, pry it out of the groove.(It may be hard to see with all of the grease, but it is there) __________________ 2007 525--JD jet kit+Titanium screw,PP Nerfs(Pro Armor)+Heel pocket(REM), EHS lid,UNI Filter, BRAP Bolts,Vapor computer,PP Hand Guards,GPS Tab,12 volt accessory outlet, rear fender braces,PP Frt.+ Rear grab bar, 15 tooth sprocket,(updated rear suspension),I-razr's on 10" Douglas, KTM slave/case saver, Case vent (Thumper Racing), Muzzy full S.S. system

01-20-2009, 05:23 PM	#8 (permalink)
sleddog Senior Member Join Date: May 2007 Location: dekalb Posts: 544	11. Once you get the ring out, you can pull the whole shaft out. Now clean up the housing and joint. __________________ 2007 525--JD jet kit+Titanium screw,PP Nerfs(Pro Armor)+Heel pocket(REM), EHS lid,UNI Filter, BRAP Bolts,Vapor computer,PP Hand Guards,GPS Tab,12 volt accessory outlet, rear fender braces,PP Frt.+ Rear grab bar, 15 tooth sprocket,(updated rear suspension),I-razr's on 10" Douglas, KTM slave/case saver, Case vent (Thumper Racing), Muzzy full S.S. system

01-20-2009, 05:24 PM	#9 (permalink)
sleddog Senior Member Join Date: May 2007 Location: dekalb Posts: 544	Another view __________________ 2007 525--JD jet kit+Titanium screw,PP Nerfs(Pro Armor)+Heel pocket(REM), EHS lid,UNI Filter, BRAP Bolts,Vapor computer,PP Hand Guards,GPS Tab,12 volt accessory outlet, rear fender braces,PP Frt.+ Rear grab bar, 15 tooth sprocket,(updated rear suspension),I-razr's on 10" Douglas, KTM slave/case saver, Case vent (Thumper Racing), Muzzy full S.S. system

01-20-2009, 05:25 PM	#10 (permalink)
sleddog Senior Member Join Date: May 2007 Location: dekalb Posts: 544	12. To replace the boot, you are going to have to press the joint off. *he said I could add this so.....I just put the shaft in a vice and use a brass drift or equivalent and hit the CV joint right by the shaft and it pops right off. Be careful as the bearings can and will pop out if it hits the floor like one of mine did. SSJEFF* __________________ 2007 525--JD jet kit+Titanium screw,PP Nerfs(Pro Armor)+Heel pocket(REM), EHS lid,UNI Filter, BRAP Bolts,Vapor computer,PP Hand Guards,GPS Tab,12 volt accessory outlet, rear fender braces,PP Frt.+ Rear grab bar, 15 tooth sprocket,(updated rear suspension),I-razr's on 10" Douglas, KTM slave/case saver, Case vent (Thumper Racing), Muzzy full S.S. system