2000 Bombardier DS650 Rear CV Boot Replacement: Step-by-Step
Shop parts for a 2000 Bombardier DS650 ATV.
How CV Boots Wear Out
The CV boot on the 2000 Bombardier DS650's rear axle protects a precision joint that can’t tolerate contamination. Inside the boot, a set of bearing balls and inner races transfer drive torque from the axle shaft to the wheel while allowing the suspension to move freely. The grease packed around these components needs to stay sealed and uncontaminated to keep the joint functional. The boot’s job is to make that happen across thousands of flex cycles, exposure to sunlight, mud, and water, and the occasional impact from trail debris.
On the DS650, UV radiation is a constant threat to boot longevity even between rides. The rubber compound degrades with sun exposure over time, losing the flexibility it needs to survive repeated flexing at the fold lines. A boot that passes an external inspection may have interior crazing at the folds that hasn’t opened into a full tear yet—but it will. Physical punctures happen without warning and often aren’t discovered until grease sling shows up on the inner wheel or brake components. In either case, catching the failure quickly keeps the repair at a boot kit rather than an axle assembly.
On the DS650, only the rear wheels are driven—the front wheels steer and roll freely with no driven axle or CV boot to service. This article focuses entirely on the rear axle.
Recognizing Boot Failure Early
A torn CV boot on the 2000 Bombardier DS650 announces itself through grease on nearby components before it causes audible symptoms. Once a boot opens, every rotation of the rear axle flings CV grease outward onto the inner wheel, the rotor face, the brake assembly, or the frame near the axle. The deposits are distinctive—CV grease is dark, thick, and tacky, and it builds up over successive rides. Any time this appears on the DS650 near the rear axle, stop and inspect before riding again.
Remove the wheel and work each boot by hand while rotating the axle, looking for tears, cracks, stiff fold areas, and any gap where a clamp has lost contact with the boot. A boot that looks intact from a distance may show a hairline crack at the fold that only opens under flex. Check for grease on the exterior of a boot that otherwise appears whole—a clamp that has lost its crimp can let grease escape without visibly tearing the rubber. A clicking or popping from the rear axle during turning or power acceleration means the joint is already wearing, and the inspection needs to assess whether it’s still serviceable.
Because the DS650 is a 2WD machine, the rear axle is the only location with CV joints and boots. The front wheels are not driven and require no CV boot service.
What to Have Ready Before You Start
For the 2000 Bombardier DS650 boot replacement, have the following ready: a floor jack and two jack stands; the correct axle nut socket for the DS650; a torque wrench; snap-ring pliers for the differential-end retaining clip; boot clamp pliers or an ear-crimp tool depending on clamp style; and shop rags. The CV boot kit must include the replacement boot, both clamp bands, and the correct CV grease. CV grease is a molybdenum-based compound engineered for the contact pressures inside a CV joint—substituting standard bearing grease or chassis lube is not adequate for this application and will shorten the joint’s service life.
Set a drain pan under the axle work area before pulling hardware. Old grease from a compromised boot is contaminated and abrasive and must be completely cleared from the joint before new compound goes in. MotoSport.com stocks CV boot kits and complete axle assemblies for the DS650.
Disassembly: Getting to the Torn Boot
Raise the 2000 Bombardier DS650 on jack stands and remove the rear wheel on the affected side. With the wheel off, pull the cotter pin from the axle nut and remove the nut fully. Push the axle spline inward toward the differential to separate it from the hub—use a hub puller if the DS650’s spline fit is tight rather than hammering on the shaft end. At the inboard end, compress the snap ring at the differential housing with snap-ring pliers and pull the axle free. Lay it on a clean surface, cut both clamp bands, and slide the damaged boot off the shaft.
CV Joint Condition Check
With the boot off the 2000 Bombardier DS650, clean old grease from the joint with shop rags and work it through its full articulation range—compression and extension along the shaft, plus full rotation in all directions the rear axle would reach in operation. Smooth, consistent motion through the entire range means the joint is serviceable. Any roughness, grinding, or catching at a specific point indicates bearing wear that repacking won’t fix.
Hold the shaft and try to move the joint housing in non-articulating directions—side to side and along the shaft axis. A serviceable joint is firm in its designed range with no perceptible play or clunking elsewhere. Any looseness or rattle in the DS650’s joint outside the normal articulation range means bearing surfaces have worn past the usable limit and the axle needs replacement rather than just a new boot.
Fresh Grease and New Boot Fitment
Clean the CV joint completely on the 2000 Bombardier DS650 before adding fresh grease. Wipe every internal surface—bearing balls, inner race, and housing—free of old compound and contamination. Slide the new boot onto the shaft before reconnecting the joint end, since it can’t be threaded on afterward. Pack the CV grease from the DS650’s boot kit into the joint by hand, rotating the housing to distribute it through all the bearing ball pockets. Use the full quantity from the kit.
Putting It Back Together and Testing
Push the inboard axle end into the differential on the 2000 Bombardier DS650 until the snap ring seats positively. A light pull on the axle should confirm it’s locked. Seat the outboard spline in the hub, install the axle nut, and torque to the DS650’s specification. Install a new cotter pin or re-stake the nut as appropriate. Reinstall the wheel and torque the lug nuts. Lower the DS650 to the ground and cycle through full suspension travel to check for any binding from the new boot. A brief low-speed test ride confirms the axle is seated and the boot is clear of all surrounding components.
Related Shopping Categories
Shop CV Joints for a 2000 Bombardier DS650 ATV.
Shop Axles for a 2000 Bombardier DS650 ATV.
Shop Lubricants & Solvents for a 2000 Bombardier DS650 ATV.
Shop Wheel Bearings for a 2000 Bombardier DS650 ATV.
Shop Skid Plates for a 2000 Bombardier DS650 ATV.
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.