Join Date: Nov 2012
Location: upper east side ... of Texas
Once my parts arrive, I'm needing to replace the rear inner boot on my 02 Sportsman 500. Researching online, I believe there are three methods.
One is to remove the outer hub, and CV boot clamps, push the outer boot out of the way and whack the outer CV off with a rubber mallet (I guess there's a spring clip in the splines?). From there, you remove the outer boot, then inner boot, install inner boot and then outer boot and press the outer CV back onto the half shaft.
Another method starts out similarly, but you yank (or wedge/pry) the inner cup out of the transfer case (also has a spring clip in the splines) to remove the entire axle where you can put it on a workbench and continue as follows
The third method leaves the inner cup in place, but you remove the half shaft from the innter CV by finding a snap ring which goes around the halfshaft. This snap ring has ears in a recessed portion of the bearing holder (the kind of star shaped bit that is inside the bearing cage). Anyway, push those ears apart, and the halfshaft should slide on out.
I think I'm going to start with method 2, and if too much effort, go to method 3. And finally method 1 if the other two fail.