Hello all,
I have been going through old posts and learning about the Polaris I bought used, And I have not been able to find anything on the problem I am having. (this is my first ATV I bought it to use for hunting so I wouldn't be ready for a nap when I got to the top of the mountain lol)
The front end just didn't feel right I aligned it but it only helped alittle. Watched alot of youtube videos and lurked around and read everything I could on the 2002 sportsman 700.
Then I got it up on jack stands Changed all of the fluids, then started poking around and found the axle was out of the differential about 1/2 an inch. (Picture 1)

disconnected everything and got it all the way out, it seamed to pop in and out very easily so I figured it was the Circlip, ordered a new clip and replaced the ball joints as they were sloppy put it back together, looked at it later that evening and it was popped out again. looking into in deeper this was a newer CV axle than the other side which seemed to original (was rusted in place took me 3 days and a can of PB blaster to get it out). The newer one has ATVPC PO-0418 stamped on the shaft. I found a article online saying that 2002 had to different axles depending on whether manufacture date was before or after 05.20.2002 Called a company on Amazon (Niche) Lady was very nice looked up my vin and I bought 2 new axles, installed them this afternoon and they really don't work they are to long for the front wheel hub and don't fit in place at the back of the hub.





Any help or insight would be greatly appreciated.

 

Well being that that brand is one of the very cheap Chinese knock off manufacturers I would not be surprised if she just didn’t tell you she looked up your vin and then just sold you what they had.
I would measure the original axle s and find a match too them.
according too Partzilla the axles after 5/01/02 are no longer available .
Now that is the original axles from Polaris but there is most likely still a company out there that makes the later version for your machine but it is still best to have the actual dimension you are looking for.

 

Quad Logic is listing axles for your machine.
They are listed by year
02/04
05
07 and 08 X2
I think it would serve you well to call them rather than some eBay or Amazon company because most of the stuff on those sites are junk or fakes.

 

The same axle was used on the 2003 Magnum 330 so you may be able to search for one under that machine also.

 

This is going to be a problem. Polaris has a nasty habit of discontinuing parts about ten years after production stops on machines.
Yours is a machine they only made for about 6 years in total and probably not slit if them.
I checked with three of the sellers I use and only Quad zloguc even listed axles for your machine and it does not specify about tge early on r Kate production model either.

 

I returned the wrong axle's, the hub ends are entirely wrong and will never work. Yet they are the axle's almost everyone else sells.


I think I have found a set of the correct axle's I will call the company tomorrow.


My biggest concern now is why did/how did keep popping out (it was the newer axle replaced by the previous owner) even after replacing the circlip I bought from Polaris. Maybe it was a bad knockoff that the groove for the circlip was wrong, maybe the shaft is 1/2 inch to short? I am at a loss.

Let me know what you think
Thanks for your help

 

If the axle is too short it can pop out since the circlip is not seating in the housing in the correct location.
it is getting difficult to find parts for your machine and the fact that nearly no one is even making that type of axle does not bode well for it. I do know there are companies out there that can and do make custom axles but they can get very pricey . I believe a company called Turner makes them but not sure at the moment.

 

I got the new axles, They look great, but when I installed them same problem with the right side as I tightened up the hub nut the last few turns the axle popped out of the differential 1/4 to 1/2 inch it is still sitting inside the differential not up tight. the A arm has no adjustments and is a solid piece.
I had the parts guy show the picture to one of the mechanics he said that the ridge/groove inside the output hub piece (new piece pictured) might be worn and the is why the circlip is not holding the axle in. I really don't want to rebuild the front differential (taking it out looks to be the hardest part) but I am not sure what else to do?

 

What you call a differential is actually just a gear case. They really are not that hard to repair. I think the most difficult part is getting them out of the machine.
This really looks like it is your only option because the other option is to out the machine up for salvage or part it out.
for the cost of a new machine or an overpriced someone else’s problem I would fix it.
If the parts are available to fix it.
I think that is going to be the deciding factor here..

 

I will put new output hubs and seals in. The question is do order a full rebuild kit? AWD was working fine and when I changed the fluid it looked good. If nothing is damaged when I open it up will the rebuild kit be worse quality than the OEM?
Let me know your thoughts please.
Thanks for all your help