CV Boot Maintenance on the 2000 Polaris Xplorer 400 4X4: Front and Rear
Shop parts for a 2000 Polaris Xplorer 400 4X4 ATV.
Boot Failure Front and Rear
The four CV boot positions on the 2000 Polaris Xplorer 400 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 400 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 400 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 400 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.
Symptoms to Watch For
The signs of boot failure on the 2000 Polaris Xplorer 400 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 400 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 400 4X4, but checking all four positions in the same session is the most efficient approach once the machine is raised.
On the Xplorer 400 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.
Organizing for the Job
CV boot replacement on the 2000 Polaris Xplorer 400 4X4 requires: floor jack and two jack stands; axle nut socket in the correct size for the Xplorer 400 4X4; a calibrated torque wrench; snap-ring pliers for the differential-end retaining clip; boot clamp pliers or an ear-crimp tool; and shop rags. Each boot position needs its own kit including the replacement boot, both clamp bands, and the correct quantity of CV grease. CV grease is a specialized molybdenum-based compound that maintains its lubricating film under the high contact pressures inside a CV joint—it’s not interchangeable with standard bearing grease or chassis lube.
Work over a drain pan to capture old grease during removal. Contaminated grease from a torn boot is abrasive and needs to be fully cleared from the joint before new compound goes in. MotoSport.com stocks CV boot kits and axle assemblies for the Xplorer 400 4X4.
Disassembly: Front or Rear
Raise the 2000 Polaris Xplorer 400 4X4 on jack stands and remove the wheel on the side being serviced. Remove the cotter pin and axle nut. Separate the outboard axle spline from the hub by pushing the shaft inward—use a hub puller on the Xplorer 400 4X4 if the spline fit is tight. At the inboard end, compress the snap ring at the differential 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. At the front axle on the Xplorer 400 4X4, steering components may need to be repositioned for clearance before the axle can be fully withdrawn. Clean the clamp groove areas before installing the new boot.
Joint Wear Inspection
With the boot off the 2000 Polaris Xplorer 400 4X4, clean old grease from the joint and articulate it through its full range—compression, extension, and full angular rotation. The joint should move smoothly and consistently throughout. Roughness or grinding at any point in the range indicates bearing wear that repacking won’t resolve. Hold the shaft and push the outer housing in non-articulating directions—any clunking or play outside the designed articulation means the axle needs replacement rather than just a new boot on the Xplorer 400 4X4.
Installing the Replacement Boot
Clean every internal surface of the CV joint on the 2000 Polaris Xplorer 400 4X4—housing, bearing balls, inner race—before adding fresh grease. Slide the replacement boot onto the shaft before reconnecting the joint. Work the CV grease from the Xplorer 400 4X4’s kit in by hand, rotating the housing to distribute it through all bearing pockets. Use the full quantity. Seat the boot with both ends in the clamp grooves, crimp both clamps fully, and verify neither can rotate. MotoSport.com stocks CV boot kits for this ATV.
Post-Installation Verification
Push the inboard axle end into the differential on the 2000 Polaris Xplorer 400 4X4 until the snap ring seats positively. Confirm it’s locked with a hand-pull. Guide the outboard spline into the hub, install the axle nut, and torque to the Xplorer 400 4X4’s specification. Secure with a new cotter pin or re-stake the nut. Reinstall the wheel and torque the lug nuts. Lower the Xplorer 400 4X4 and cycle the steering and suspension through their full ranges to verify boot clearance. A brief test ride confirms the axle is seated and the boot is holding. MotoSport.com stocks CV boot kits and axle assemblies for this ATV.
Related Shopping Categories
Shop CV Joints for a 2000 Polaris Xplorer 400 4X4 ATV.
Shop Axles for a 2000 Polaris Xplorer 400 4X4 ATV.
Shop Lubricants & Solvents for a 2000 Polaris Xplorer 400 4X4 ATV.
Shop Wheel Bearings for a 2000 Polaris Xplorer 400 4X4 ATV.
Shop Skid Plates for a 2000 Polaris Xplorer 400 4X4 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.