Tools and Materials Needed:
• 10mm socket wrench
• 12mm socket wrench
• Pry bar
• Flat-blade screwdriver
• Wire cutters
• Replacement drive shaft (if necessary)
Step-by-Step Guide:
1. Prepare the ATV:
- Park the ATV on a level surface and engage the parking brake.
- Turn off the engine and allow it to cool down completely.
- Disconnect the battery to prevent any electrical accidents while working.
2. Locate the Drive Shaft:
- The drive shaft is located under the ATV, running from the transmission to the rear differential.
3. Remove the Rear Axle Cover:
- Use a 12mm socket wrench to remove the bolts securing the rear axle cover.
- Carefully remove the cover, noting the gasket or O-ring behind it.
4. Disconnect the Driveshaft:
- Locate the U-joints at both ends of the drive shaft.
- Use a flat-blade screwdriver and a pry bar to carefully pry the U-joints apart, disengaging them from the transmission output shaft and the differential input shaft.
- Be careful not to damage the U-joints or the splined ends of the shafts.
5. Detach the Drive Shaft Support Bracket:
- If your ATV has a drive shaft support bracket, use a 10mm socket wrench to remove the bolts holding it in place.
- Carefully remove the bracket, noting any shims or spacers behind it.
6. Remove the Drive Shaft:
- Slide the drive shaft out from the rear end of the ATV.
- Be careful not to lose any parts or hardware during removal.
7. Inspect the Drive Shaft:
- Inspect the drive shaft for any signs of damage or wear, such as cracks, bends, or excessive play in the U-joints.
- If the drive shaft is damaged, it must be replaced with a new one.
8. Install the New Drive Shaft:
- If installing a new drive shaft, insert it into the ATV from the rear end.
- Reinstall the drive shaft support bracket, shims or spacers, and any bolts removed earlier.
9. Reconnect the U-Joints:
- Carefully reengage the U-joints at both ends of the drive shaft.
- Ensure they are properly seated and secured.
10. Reinstall the Rear Axle Cover:
- Reinstall the rear axle cover, ensuring the gasket or O-ring is properly seated.
- Secure the cover with the bolts removed earlier.
11. Reconnect the Battery:
- Reconnect the battery terminals, being careful to match positive to positive and negative to negative.
12. Test the ATV:
- Start the ATV and test the driveline by shifting through all gears and driving the ATV in a safe area.
Remember, if you are not comfortable performing these steps or encounter any difficulties, it is best to consult with a professional mechanic to ensure the proper and safe removal and installation of the drive shaft on your Honda Rincon ATV.
