2004 Sportsman Axle Issues - Polaris ATV Forum
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post #1 of 9 (permalink) Old 03-21-2016, 11:38 AM Thread Starter
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2004 Sportsman Axle Issues

We have a 2004 Sportsman 700 4X4 that I'm having axle issues with. We purchased the bike used in May of 2015 with the following setup. The bike has oversized tires on it which are just 1" taller and 2" wider. The front wheel has spacers installed on them. The carb as been jetted and the bike runs.

When we brought the bike home we replaced all four axle assemblies along with the wheel bearings. The axles were sixity brand axles which I have used on my other machines with no problem.

My first issue I seen was when I jacked the bike up this winter the right rear axle fell out of the differential as the wheel lowered. I was able to snap it back in with no problem and haven't had any issues until two weeks ago.

I got on the bike which was parked in my driveway as I was getting ready to burn pasture. I had just installed my sprayer with no water in it yet, as I started the bike and gave it throttle it made several loud pops then it wouldn't move. I observed that the right rear axle again had fell out and now that right front axle was out. Upon further inspection the u joint had broke on the right front axle. I was able to push the rear axle back into place and limp the bike into the garage.

Lets forward to this past weekend 3/19 I installed the new from axle and took the bike for a drive. I dropped into a small ditch that I drive thru regulary. I noticed the right rear wheel spinning trying to get traction. I get off the bike and observed that the left rear axle had now pulled out of the out CV joint. Can anyone please explain to me what is going on here!!!!!
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post #2 of 9 (permalink) Old 03-21-2016, 12:25 PM
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2004 Sportsman Axle Issues

Did someone put a lift kit on it
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post #3 of 9 (permalink) Old 03-21-2016, 12:30 PM
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Not sure if its the same but I've had issues with aftermarket axles. In particuliar them being shorter than the OEM which will cause them to fall out.
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post #4 of 9 (permalink) Old 03-21-2016, 05:47 PM Thread Starter
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Did someone put a lift kit on it
It doesn't appear so. That was my first thought.
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post #5 of 9 (permalink) Old 03-21-2016, 05:47 PM Thread Starter
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Does anyone know what the axle lengths should be.. I would like to measure mine and compare to OEM.
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post #6 of 9 (permalink) Old 03-22-2016, 05:35 AM
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I'd have to look and see if I still have one of my old stock axles around to measure, but I do know that I have 4 new to almost new Gorilla axles from back over 10yrs ago when I owned my 700. I don't hear much of Gorilla these days, but back in the day they were the best. They are double CV and very robust.

See here: https://www.polarisatvforums.com/foru...e-fitment.html

'15 Sportsman Touring 1000 LE bronze mist
'13 Ranger 900XP Browning
'07 Ranger 700XP camo-sold
'06 Honda Rincon 680 EFI
'04 Sportsman 700 carb-sold
'04 Honda TRX 90 for the little guys
'01 Sportsman 500 HO-sold

Last edited by TDMax; 03-22-2016 at 05:37 AM.
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post #7 of 9 (permalink) Old 03-22-2016, 06:45 AM
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Have these all been with sixity axles?
Last fall I remember reading a post where someone bought a new sixity axle and it kept falling out of the differential.

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post #8 of 9 (permalink) Old 03-22-2016, 08:19 AM
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Quote:
Originally Posted by TDMax View Post
I'd have to look and see if I still have one of my old stock axles around to measure, but I do know that I have 4 new to almost new Gorilla axles from back over 10yrs ago when I owned my 700. I don't hear much of Gorilla these days, but back in the day they were the best. They are double CV and very robust.

See here: https://www.polarisatvforums.com/foru...e-fitment.html
That picture looks like 4 front axles. If you have rears too I might be interested.
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post #9 of 9 (permalink) Old 03-22-2016, 08:28 AM
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Quote:
Originally Posted by TDMax View Post
I'd have to look and see if I still have one of my old stock axles around to measure, but I do know that I have 4 new to almost new Gorilla axles from back over 10yrs ago when I owned my 700. I don't hear much of Gorilla these days, but back in the day they were the best. They are double CV and very robust.

See here: https://www.polarisatvforums.com/foru...e-fitment.html
That picture looks like 4 front axles. If you have rears too I might be interested.
Sorry this is all that I have. I have no idea how I got to this point as this was 10 yrs ago, but the machine sold with front Gorillas in it too. I assume that the rears are definitely different?

'15 Sportsman Touring 1000 LE bronze mist
'13 Ranger 900XP Browning
'07 Ranger 700XP camo-sold
'06 Honda Rincon 680 EFI
'04 Sportsman 700 carb-sold
'04 Honda TRX 90 for the little guys
'01 Sportsman 500 HO-sold
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