Hello, I have a 2001 Polaris Sportsman 500 HO that has been ripping rear axle boots. The rips seem to happen within a few months after replacing the axle. The rips are on the inner boot and start on the first rib almost always. They are cheaper axles as I have a feeling something is wrong and causing this and expensive axles/boots will have the same issue. I'm lucky if the Axels last a few months depending on how often it gets used. The rips happen on both sides randomly and are not cause by sticks or rocks. There is no lift kit, rear shocks are OEM. Anybody have any ideas what could be causing this repeated failure?

Here is the Vin 4XACH50A71C594976
4/12/2001 build
Model A01CH50AA

 

I don't know Polaris quads at all, we used to service one old Diesel but even that has now gone. However, the usual killer is wire or string, gets wrapped round the shaft and cuts the boot as it tightens. If there isn't an obvious culprit, it could be low quality boots. Quality control on pattern parts is patchy, price is nothing to go by either, same poor quality Chinese part may come in a well known aftermarket sellers packaging at three times the price. Buy a replacement boot from a different maker, and see if it lasts longer.

 

Cheap axles use very cheap materials for the boots. Only thing that can be done is either buy better axles or buy boot kits from the makers of the better axles and install them. Cheaper to buy a good boot that it is to buy a much better axle. I tend to stay away from the high strength axles because I prefer to break an axle than a differential or gear case. The axle is designed to be the weak link in order to protect the more important parts.

 

I feel like this is something deeper then cheap axles. I seem to have to replace both rear axles at least every 6 months do to the rear boot ripping. They always start ripping in the same spot. I have noticed that there is a clicking in the rear end even with new axles. Is it possible that there is something going to with the rear diff that could cause repeated ripping of the boots?

 

Yeah don’t know. Is it possible the boots are getting cut by something when the suspension is under full compression? Like under a heavy load or a big bump when the rear end comes down? Have you tried watching the machine through its range of travel. My thinking is it’s fine when sitting there but once it’s under load some part is coming into contact with the boots and cutting them.