IMPORTANT: Park your ATV on a flat, level surface and apply the parking brake. Ensure that the ATV is turned off and the keys are removed before beginning the procedure.
1. Disconnect the battery:
- Locate the battery under the ATV's seat.
- Disconnect the negative (black) cable from the battery terminal.
2. Remove the rear wheels and brake calipers:
- Jack up the rear of the ATV.
- Remove the lug nuts and take off the rear wheels
- Remove the brake caliper bolts and set aside the brake calipers.
- Secure the brake caliper with a zip tie to prevent damage during axle removal.
3. Remove the cotter pin and axle nut:
- Locate the axle nut on the end of the axle shaft.
- Use a cotter pin puller to remove the cotter pin from the axle nut.
- Use a socket wrench to loosen and remove the axle nut.
4. Pull out the axle:
- Locate the axle tube on the ATV frame.
- Slide a pry bar or an axle removal tool between the axle tube and the axle shaft to pry it loose from the final drive housing.
5. Once the axle is dislodged from its housing, gently pull the axle out from the other side of the ATV.
6. Inspect the axle for any damage, such as wear, cracks, or deformation. If the axle is damaged, replace it with a new one.
7. Reassemble everything in the reverse order of disassembly.
TIP: Apply a small amount of grease to the axle splines before reinstalling the axle to ease the reinstallation process.
Make sure to tighten the axle nut and other bolts to the proper torque specifications mentioned in your ATV's service manual. Reconnect the battery once everything is reassembled and properly tightened.
