Rear Axle CV Boot Service on the 2002 Bombardier DS650
Shop parts for a 2002 Bombardier DS650 ATV.
The Root Causes of Boot Failure
CV boot failure on the 2002 Bombardier DS650 starts at the rubber compound and works outward from there. The boot is clamped at both ends of the rear CV joint and must maintain a watertight seal while stretching and compressing through suspension travel on every ride. Age and UV exposure work against it constantly—the rubber loses elasticity, stiffens, and eventually cracks at the fold points where it flexes most.
Trail debris is the other main failure path for the DS650. The inner boot at the differential end of the rear axle sits close to the ground and is directly exposed to rocks, roots, and branches during off-road riding. A puncture from a single impact can open a tear that the owner may not notice until grease appears on a nearby component. Either way, a torn boot means grease loss and contamination entry with every flex cycle, and the CV joint that was running clean begins to carry abrasive grit in its grease from that point forward.
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.
What to Look and Listen For
Finding a failed boot on the 2002 Bombardier DS650 early is largely about knowing what grease sling looks like. When a boot tears, the spinning axle distributes CV grease onto the inner wheel face, the rotor, the brake caliper, or the lower frame rail. CV grease is visually distinct from road grime—it’s thick, sticky, and dark, and it accumulates in specific locations rather than coating surfaces evenly. Seeing this pattern on the DS650 near the rear axle means the boot has already been open long enough to lose a measurable amount of grease.
Confirm the boot condition with a direct inspection. Raise the DS650 on jack stands, remove the wheel, and examine each boot thoroughly while rotating the axle. Look and feel for splits, cracks, punctures, and clamp gaps—any opening in the boot means the joint behind it is running contaminated grease. Pay particular attention to the fold areas and the zones just inside each clamp band. A boot that has visible crazing or feels hard at the folds should be replaced proactively. A clicking sound during acceleration that wasn’t present before indicates joint wear that needs evaluation during the boot replacement.
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.
Gathering the Right Equipment
For the 2002 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.
Taking the Axle Apart
Raise the 2002 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.
What to Look for in the Joint
With the boot off the 2002 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.
Installing the New Boot Correctly
Clean the CV joint completely on the 2002 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.
Completing the Job
Push the inboard axle end into the differential on the 2002 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 2002 Bombardier DS650 ATV.
Shop Axles for a 2002 Bombardier DS650 ATV.
Shop Lubricants & Solvents for a 2002 Bombardier DS650 ATV.
Shop Wheel Bearings for a 2002 Bombardier DS650 ATV.
Shop Skid Plates for a 2002 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.