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400 Front Driveline
Difficulty 2.5 out of 10, not a big deal, no special tools. remove plastic cover, left side (covers the coolant bottle).remove front left wheel, then jack up front of quad.remove all 3 bolts holding the front differential to the frame (14mm socket and box end wrench).locate the small coupler boot near the front of the drive shaft. Slide it rearward (there are no clamps) until you can see the c-clip. loosen c-clip and slide it rearward.loosen rear clamp of the front boot and slide the coupler rearward on shaft.at this point you should see a split in the shaft and a spring inside the shaft. Do not try to remove the spring yet. Using prybar, pry the rear of the differential upward and/or backward until there is enough clearance between the two halves of the drive shaft to get the spring out.using a screwdriver or prybar, gently pry the front or the rear drive yoke off of it's shaft and remove whichever shaft (front or rear) that you are working on.Replace the ujoint, boot or whatever else is wrong with the driveline.Installation is the reverse. Use a rubber mallet to pop the driveline yokes back on. Good luck.I got the parts from www.ronayers.com. They were cheaper than the dealer. Gil told me he got the Ujoints cheaper. He said: "THE PLACE THAT MY LOCAL KAWI DEALER ORDERED THE U-JOINT FROM IS TUCKER ROCKY DIST. THEY ARE A WHOLESALE OUTFIT AND MOST ANY DEALER CAN ORDERPARTS FROM THEM.I AM TOLD BY THIS DEALER THAT THEY HAVE A WAREHOUSE IN NY. THE TOLL FREE # 1-800-347-1010"
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