Diagnosing and Replacing the CV Boot on a 2003 Bombardier DS650 ATV
Shop parts for a 2003 Bombardier DS650 ATV.
Why the Rear Boot Takes the Most Abuse
The CV boot on the 2003 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.
Diagnosing Boot Damage Before It Spreads
A torn CV boot on the 2003 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.
Getting Organized Before Disassembly
Stage these before starting on the 2003 Bombardier DS650: floor jack and jack stands; axle nut socket in the correct size for the DS650; calibrated torque wrench; snap-ring pliers; boot clamp installation tool; and shop rags. The boot kit for the job must include the replacement boot, two clamp bands, and pre-measured CV grease. Using the grease from the kit matters—CV joints run at high contact pressure between bearing balls and races, and the molybdenum compound in CV grease is what maintains the film strength those conditions require. Off-the-shelf grease types don’t provide equivalent protection.
Line the work area with a drain pan. Old contaminated grease needs to come fully out of the joint before new compound goes in—mixing the two means adding abrasive grit to clean grease. MotoSport.com carries CV boot kits and axle assemblies for the DS650.
Boot and Axle Disassembly
Get the 2003 Bombardier DS650 on jack stands and pull the rear wheel from the affected side. Remove the cotter pin and axle nut completely. Separate the outboard axle spline from the hub by pushing the shaft inward—a hub puller is the right tool if the DS650 has a tight spline fit. Move to the inboard end, release the snap ring at the differential with snap-ring pliers, and pull the axle free. Set it on a clean surface. Cut the old clamps off and slide the torn boot free. Wipe the clamp groove areas clean on both the shaft and differential housing before installing the replacement boot on the DS650.
Joint Inspection After Boot Removal
Once the boot is off the 2003 Bombardier DS650, wipe away all old grease and articulate the CV joint through its full designed range. The joint should move smoothly and evenly from full compression to full extension and through all steering angles the DS650’s rear axle reaches in use. Roughness or resistance at any point in the range is a sign of bearing wear. Check for play by stabilizing the shaft and pushing the outer housing in directions it shouldn’t move. Controlled articulation with no rattle or looseness means the joint is ready to repack. Any clunking or excess play in non-articulating directions means the axle needs replacement before a new boot goes on.
Grease, Clamps, and Reassembly
Before repacking the 2003 Bombardier DS650’s joint, remove all old grease and contamination from the housing, bearing balls, and inner race. Thread the replacement boot onto the shaft before reconnecting the joint—it can’t go on after. Work the full quantity of CV grease from the DS650’s kit into the joint by hand, pushing it into the bearing pockets and rotating the housing for even distribution. Position the new boot with both ends seated in the clamp grooves, crimp both clamps fully, and tug each one to confirm it won’t rotate. MotoSport.com carries CV boot kits for this ATV.
Post-Installation Verification
Seat the inboard axle end in the differential on the 2003 Bombardier DS650 until the snap ring clicks into place—a hand-pull should show it locked. Guide the outboard spline into the hub, thread on the axle nut, and torque to the DS650’s spec. Secure with a new cotter pin or re-stake as required. Mount the wheel and torque the lug nuts. Lower the DS650 and move the rear suspension through its full travel to verify the boot clears all nearby components. A short test ride through a power turn confirms the repair is complete. MotoSport.com carries CV boot kits and axle assemblies for this ATV.
Related Shopping Categories
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Shop Lubricants & Solvents for a 2003 Bombardier DS650 ATV.
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Shop Skid Plates for a 2003 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.