Here's a general guide to help you replace a CV joint on an ATV:
Tools Needed:
- CV boot tools
- Socket wrench set
- Screwdriver
- Pliers
- Grease
Step 1: Preparation:
- Safety: Ensure the ATV is properly secured, preferably on a lift.
- ATV Cooling: Allow the ATV's engine to cool down.
Step 2: Remove CV Joint Boot:
- Grease Cleanup: Remove any excess grease around the CV boot using a rag or degreaser.
- CV Joint Boot Removal: Follow your specific ATV's maintenance manual for instructions on how to remove the outer CV joint boot.
Step 3: Pry Out the CV Joint:
- Joint Removal: Use pry bars or a CV joint puller to pry out the CV joint from the differential. Depending on the ATV model, you may need to remove other components to access the CV joint.
- Note the Joint's Position: Carefully note how the CV joint is oriented when removing it. This will be important for reinstalling it correctly.
Step 4: Remove the Old Joint:
- Ball Cage Removal: Remove the circlip or retaining ring that holds the ball cage in place.
- Ball Cage and Joint Separation: Tap on the ball cage to separate it from the joint.
- CV Joint Disassembly: Separate the CV joint housing from the inner joint assembly. Take note of the orientation and placement of any components inside.
Step 5: CV Joint Inspection:
- Inspection: Thoroughly inspect the removed joint for any damage, excessive wear, or cracks. If severe damage is found, consider replacing the CV joint rather than just the boot.
Step 6: CV Joint Assembly:
- Grease: Apply grease to the ball bearings, grooves, and surfaces inside the joint housing according to the manufacturer's instructions.
- Rebuild Process: Reassemble the CV joint by placing the inner joint assembly into the housing and installing the ball cage and circlip. Ensure proper alignment.
Step 7: Reinstall CV Joint:
- Check Orientation: Double-check the orientation of the joint to ensure it matches the original position.
- Joint Installation: Carefully insert the joint back into the differential and secure it in place. Consult your ATV's manual for specific installation steps.
Step 8: Install New CV Boot:
- Install New Kit: Install a new CV boot kit, which typically includes the boot, clamps, and grease. Follow the instructions provided with the kit for proper installation.
- Grease Injection: Inject grease into the installed boot using the provided injection port.
Step 9: Reassembly and Testing:
- Reinstall any components that were removed during disassembly.
- Double-check all connections and ensure the CV joint moves freely without binding.
- Test the ATV by riding it slowly to ensure proper functionality.
Note: This guide is a general overview of the process. Please refer to your specific ATV's manual or consult with an experienced mechanic if you're unsure about any step or encounter any issues during the replacement.
