i have a 2002 500 and ive heard the rear axels making a noise usually when i go from reverse to forward.( how it kinda pops into drive). the same when i goforward to reverse. i never though much of it though. from time to time ill hear it while riding. i tried to find out where the noise was coming from but i couldnt pin point it exactly. didnt know if it was axel,drive shaft,front or rear. now ill check it out and see what the dealer has to say. plus they still need to fix my brake lever that dont work.

 

Different axles and CV joints.

 

bear
you keep saying the axels are beefer but im not sure that they are.
tell us what part of the axel is stronger.
because i was looking at the new cats and they look the same to me.
if your so sure there bigger give us some sizes of the old ones and the new ones.
because i cant see the differance.
when they replaced the ones on my 03 500 they said they were stronger.
but the new axel was taperd in the middle but the same thickness on the ends as the old ones.
and i found the new one broke befor the left side old one.
the old one was the same thickness all the way from one end to the other.
i think there pulling our leg by saying there better.
because i here there still braking.

 

I did the axle part number thing. The 2004, 400 and 500 axles are different than the 2004, 650s. But in 2005 they all have the same axles. The 2004 and 2005, 650's run the same axles so the axles must be the heavy duty ones. And the 2004, 400 and 500 axles number updates to a different number than the 2004, 650 or the 2005s.