Hey guys,

Add yet another 2004.5 Sportsman 500 with a torn CV joint boot. My machine only has 52 hours on it (and I baby it), but the other day I was looking it over and noticed grease on the OUTTER right-front cv boot. It has about a three-inch rip in the boot. The other three inner and outer boots look fine (for now).

I searched this forum and have read many threads about this common problem. I also have the polaris service manual and I'm ready to start the repair but I was hoping for some additional information.

What brand of replacement boot is the best? From what I've read, the Gorilla Axle boots seem to be good. Here's the web page I was looking at: http://www.gorilla-axle.com/category.asp?ID=6 Are there any other ones out there that are tougher than the OEM ones? Please let me know. I'd rather buy a better boot now if it ends up lasting longer.

I'm still riding the bike (for utility/yard work stuff), but I want to fix this as soon as possible. The joint isn't making any "clicking or popping" sound and I have also squirted more grease in the ripped boot hoping to avoid damage to the shaft.

Also, I've read about those boot protector sheilds, but those look the same as the polaris ones that came on the machine. How do these offer better protection than the stock ones? I still don't understand how a stick torn the boot in the first place?!? I don't beat on my 500 at all and mainly drive under 30 mph around my property. I guess all it takes is one little stick aimed the right way...

Thanks in advance for any advice!

RC

 

WHOOPS! Forgot to ask...

Gorilla's web site lists "A ratcheting clamp tool is also available to aid in boot installation". What exactly is this and is it worth the money? Also forgot to ask if anyone knows the Polaris part number for the boot clamp pliers....

Thanks again!

RC

 

I cant answer many of your questions but I do know it would be wise to not drive it anymore incase some small peice of rock or stick or whatever is in that torn boot. you could cause alot of damage and have to buy new spindles also. I have also heard that gorilla axles are the best but more desinged for if your putting larger tires on it. If you plan on leaving it stock you may not need to spend the extra money.

 

I have a 2002 500ho and tore my first boot a few weeks ago. My local dealer had a stock boot on hand so I replaced it with a stock boot. If he would have had to order it I was going to get a Gorilla boot. I have read some posts here about the Gorilla boot clamp being a problem. I was going to try stock boot clamps with the Gorilla boot. Do a search for boot and you will find alot of info. If you go stock, it comes with boot, two clamps and cv grease as a kit. Like I said, do a search using the search button and you will find what your looking for.

 

My buddy got creative and went to an auto parts store and just started to match up his front boot with different car boots.Its a match with an early 90's Dodge shadow I think?! It holds up just as well and its a significant $ difference compared to Polaris,apparently the front boots are much pricier than the rear, I'm not sure though I've only replaced the rear so far on mine.

As for the ratcheting clamp tool ,that just a rig about 6-7"long, the small end is bent back 90 degrees with a slit in the middle for the clamp to sit in and in the middle of the body it has a pin with a slit again and its connected to a bolt head on the other side. Then crank on it with a wrench. Works excellent, should only be a few dollars,buy them at NAPA. Maybe this is what your talking about....or not!

Maybe this is some help to you?!

 

I have replaced the rear cv boots on my 2002 polaris sp500 about 6 times and the front 1 time. So i am pretty use to changing them out. First of all the gorilla boots are not worth a crap dont buy them. The hole that fits around the axle is a perfect fit but the hole that goes around the cv is to big and that is the thermoplastic boot just to let you know. If you look on Ebay you might be able to find a diff kind of rubber boot. There is always alot of them.

 

Hey Cody,
I'd recommend the thermoplastic boot kits. They are thicker and more puncture resistant. PM me for more details. And you are right some boot application do match up to automotive but not very many (shhhh secrets of the trade). You never know who might be watching[img]i/expressions/face-icon-small-wink.gif[/img]

 

hey danny my dad bought 2 new cv joints from you today for a polaris 500 sportsman 2002. you said that your brother lives in Centerville,Ga. i live in Bonaire. i was wondering how long does it usually take for your shipping to reach Georgia? About the boots the 2 i ordered from gorilla would not fit. So i put electrical tape around the CV then it would fit. But after i ripped it there was alot of water in the CV. So i probably would not buy from them again. And for the racheting tool just use a regular pair of needle nose they work fine with polaris boots.

 

Oh Yeah[img]i/expressions/face-icon-small-blush.gif[/img],
Yes, in fact your dad and I talked for a while. He order two new outer cv joint kits and two extra boot kits. I guess he want to be sure not to have to go through this again. I'm sure you won't have any problem with mine fitting. I even have an o.e. shaft to try them before I send them to just to be sure. As for crimping the clamps, tile snips or end snips work great. I have them if you checkout my eBay store you can see a picture. If you have any problems be sure to give me a call. Let me know how it all works out. I hope that you will be spreading the word for me[img]i/expressions/face-icon-small-wink.gif[/img][img]i/expressions/face-icon-small-tongue.gif[/img]
Thanks,
Danny
"thecvman"

 

Auto Zone has a CV boot pliers for $10, get it, the clamps are a biatch!

I wouldn't drive the machine with a ripped boot, any contamination and you will be replacing CV joints too.

You need to remove the brake caliper, lower a-arm from the ball joint (a pickle fork will come in handy) and the hub, all easy.
The cv clip will release from the shaft with a quick yank towards you.
Clean it out thoroughly and dry, then add the 40ml of grease to the cv and 30ml to the boot.
The Polaris boot comes with the clamps and appropriate grease (103ml).

Jim