How to Replace CV Boots on Your 1997 Polaris Xplorer 500 4X4
Shop parts for a 1997 Polaris Xplorer 500 4X4 ATV.
How Both Axle Boots Wear Out
The four CV boot positions on the 1997 Polaris Xplorer 500 4X4 each face distinct stress conditions, but all four are subject to the same underlying failure causes. The front axle outer boots endure the highest flex demand: at full steering lock combined with a suspension bump, the boot is flexed to its maximum range simultaneously in two directions. The rear boots handle the sustained torque loads and repetitive flexing that come with drive under load. All four positions age under UV exposure and are subject to impact damage during off-road and field work on the Xplorer 500 4X4.
When UV degradation hardens the rubber at the fold lines, the crack that eventually forms may not be immediately visible from the outside—the interior surface of the fold can crack before the exterior shows any evidence. A grease sling on the inner wheel or brake components is often the first visible sign of a boot that has been failing for multiple rides. On a 4WD machine like the Xplorer 500 4X4, a failed boot at any position affects the reliability of the whole drivetrain, which is why catching boot damage early matters.
As a 4WD machine, the Xplorer 500 4X4 drives both the front and rear wheels. CV boots are present at both axle sets—two boots at the front and two at the rear. All four positions should be inspected and serviced together whenever one is found to be damaged.
Spotting Boot Failure Before Joint Damage
The signs of boot failure on the 1997 Polaris Xplorer 500 4X4 are specific to the axle end affected. A front boot failure often produces a clicking or popping during turns under power—the sound is most pronounced at or near full steering lock because that’s where the joint angle is greatest and where wear shows earliest. A rear boot failure tends to produce its noise during acceleration under load rather than during turning. In both cases, grease on the inner wheel or brake components near the axle is the earliest visible evidence, appearing before the noise becomes consistent.
With the Xplorer 500 4X4 on jack stands and the wheel removed, inspect each boot directly—feel for tears, cracks, punctures, and clamp gaps while rotating the axle slowly. The fold lines and clamp transition zones are the most likely failure locations. A boot that appears intact but has visible surface crazing at the folds should be replaced proactively. The distinction between front and rear noise helps narrow down which axle end to inspect first on the Xplorer 500 4X4, but checking all four positions in the same session is the most efficient approach once the machine is raised.
On the Xplorer 500 4X4, all four CV boot positions—front inner, front outer, rear inner, rear outer—use the same inspection and replacement process. Check all four when servicing any one of them.
Getting Set Up Before You Start
Stage the following before working on the 1997 Polaris Xplorer 500 4X4: floor jack and jack stands; axle nut socket in the size correct for the Xplorer 500 4X4; torque wrench; snap-ring pliers; boot clamp tool; and shop rags. A separate CV boot kit—boot, two clamps, and CV grease—is needed for each axle position being serviced. CV grease is engineered for CV joint contact conditions and is not substitutable with off-the-shelf lubricants. The molybdenum compound in CV grease is what provides the film strength the joint needs under load.
Set a drain pan under the work area before starting disassembly. MotoSport.com carries CV boot kits and replacement axle assemblies for the Xplorer 500 4X4.
Axle Disassembly and Boot Access
Get the 1997 Polaris Xplorer 500 4X4 on jack stands and remove the wheel from the side being worked. Remove the cotter pin and axle nut. Push the axle spline inward to free it from the hub, using a hub puller if the Xplorer 500 4X4 requires it. Release the snap ring at the differential inboard end and pull the axle free. Set it on a clean surface, cut the old clamp bands, and slide the torn boot free. For the front axle on the Xplorer 500 4X4, check whether tie rod or steering component clearance is needed before pulling the axle. Clean the clamp groove areas on both the shaft and housing before fitting the replacement boot.
Joint Condition Check While Exposed
Clean the CV joint on the 1997 Polaris Xplorer 500 4X4 after boot removal and work it through its full designed articulation. Smooth motion throughout indicates a serviceable joint. Roughness or catching at any angle points to ball or race wear. Test for play by stabilizing the shaft and pushing the outer housing side to side and along the shaft axis. A healthy joint on the Xplorer 500 4X4 is firm in its articulation range with no rattle or looseness outside it. Play or clunking in non-articulating directions means the axle assembly needs replacement—sealing a worn joint behind a new boot produces a short-lived repair.
Fresh Grease and Boot Fitment
Before repacking the joint on the 1997 Polaris Xplorer 500 4X4, remove all old grease and contamination from every internal surface. Thread the replacement boot onto the shaft before reconnecting the joint end. Pack the CV grease from the Xplorer 500 4X4’s kit into the joint completely, rotating the housing for even distribution. Use the full kit quantity. Position the boot with both ends seated in the clamp grooves, crimp both clamps to full engagement, and tug each to confirm it’s locked. MotoSport.com carries CV boot kits for this ATV.
Final Assembly and Function Check
Seat the inboard axle end in the differential on the 1997 Polaris Xplorer 500 4X4 until the snap ring clicks into place—a pull test should show it locked. Guide the outboard spline into the hub, install and torque the axle nut to the Xplorer 500 4X4’s specification. Secure with a new cotter pin or re-stake as appropriate. Reinstall the wheel and torque the lug nuts. Lower the Xplorer 500 4X4 and steer through lock-to-lock range to verify the boot clears all surrounding components. A short test ride completes the service. MotoSport.com carries CV boot kits and axle assemblies for this ATV.
Related Shopping Categories
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Shop Wheel Bearings for a 1997 Polaris Xplorer 500 4X4 ATV.
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Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your ATV's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.