Recentry installed a new axle in the left rear of my 2002 Polaris Sportsman, took it on a short ride tonight and the axle popped out of the rear center section!!! Does anybody know what would cause this to happen??

 

Have heard this several times before especially on after market drive shafts.Sounds like the circlip at the end of the plunging joint isn't locking into the gear groove correctly or possibly it may be a little smaller than the oem circlip.You might see if a dealer has one in stock and give it a try.Hold the drive shaft straight,splines lined up and have someone pop the end of the shaft with a dead blow hammer or block of wood and a hammer to seat the circlip.1350042 SPRING-RING

 

Thank you for the reply, I will order a new one and give it a try.

 

If you have the old axle you can try the circlip off that. I always save them since you never know when one will pop off when working with them and it will bounce in to oblivion...

 

This same exact thing happened to me. I figured it out finally and it WAS NOT the clip. It turned out to be a slightly shorter CV axle that was sold to me as a replacement part. I took off the still functional CV axle and did a measurement. Sure enough the cheapy ebay replacement was significantly shorter! I should have done a video on this to help ones out in the future. But I'd be willing to bet this is your issue.

 

Thanks, I will look into that closer. I've put it back together and haven't rode it in weeks. Will see.

 

Hmmm, could be either or with the circlip or the length. Probably worth in the future using reliable aftermarket manufacturers and resellers, like Rocky Mtn or ACV. Hope you've been able to figure it out over the last few weeks.

 

Yes all figured out. It was the axle bearing that was actually junk to. Replaced that and been good ever since.
thank you