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post #1 of 7 (permalink) Old 03-17-2010, 05:28 PM Thread Starter
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250 recon rear end...

can anyone tell me how to get the pinion out of the the gear case of a 250 recon?
I'm trying to salvage this rear end if I can, but cant seem to get the pinion out.

Thanks. Tim B.
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post #2 of 7 (permalink) Old 03-17-2010, 05:36 PM
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There's a big nut that screws into the end of the differential, where the drive shaft fits. This nut has threads on the outside of the nut that threads into the diff. The inside is hex shaped. It takes a special tool to remove it.

Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!

You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
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post #3 of 7 (permalink) Old 03-17-2010, 05:42 PM
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if you don't have the tool to remove the hex nut..you can try something i do..if you can get your hands on a sqaure piece of tubing..i can't remember the size..1 1/2 or 2 inches..it fits down inside the nut at the right angle, with a pipe wrench..you can take the hex nut out.it does work..it's just finding the right size of tubing that fits. maybe you can get a measurement across the nut..and see what size will work..sorry i can't remember the size..but..it sure beats paying a boat load of cash just for this tool..when you may only use it once in your life..lol.
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post #4 of 7 (permalink) Old 03-17-2010, 05:48 PM
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You can make the tool if you really want to. I made one for me and I made one for one of my buddies. It's easy, but you have to find a large fitting of some kind with an outer hex shape that is the same size as the inside of the nut. Then just cut it off and weld it to the end of an impact socket. Works great. I can't tell you where to get the fitting, though. I just happened to already have a bunch of fittings and already had some that were perfect. And by the way, it has to be made of steel, so you can weld it.

Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!

You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
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post #5 of 7 (permalink) Old 03-17-2010, 08:10 PM
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Quote:
Originally Posted by Helmut View Post
You can make the tool if you really want to. I made one for me and I made one for one of my buddies. It's easy, but you have to find a large fitting of some kind with an outer hex shape that is the same size as the inside of the nut. Then just cut it off and weld it to the end of an impact socket. Works great. I can't tell you where to get the fitting, though. I just happened to already have a bunch of fittings and already had some that were perfect. And by the way, it has to be made of steel, so you can weld it.
The welding thing is a given helmut.

Billy

1991 Trx250X Custom exhaust,K&N jetted,widened 7.5 inches in the back and 8 inches in the frontWarrior rear shock and z400 front shocks with custom brackets.Race cut fenders.+3 swingarm.Way more to come.
Building things makes me happy.
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post #6 of 7 (permalink) Old 03-17-2010, 08:15 PM
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Quote:
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Quote:
Originally Posted by Helmut View Post
You can make the tool if you really want to. I made one for me and I made one for one of my buddies. It's easy, but you have to find a large fitting of some kind with an outer hex shape that is the same size as the inside of the nut. Then just cut it off and weld it to the end of an impact socket. Works great. I can't tell you where to get the fitting, though. I just happened to already have a bunch of fittings and already had some that were perfect. And by the way, it has to be made of steel, so you can weld it.
The welding thing is a given helmut.
Some of the fittings are brass. I didn't won't someone to go to the trouble of buying one and not thinking about it and then getting home and realizing that they can't weld it. But if they're a welder, then they wouldn't do that I suppose. LOL.

Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!

You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
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post #7 of 7 (permalink) Old 03-17-2010, 08:16 PM
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We'd hope not anyways or they had there head in the wrong place.LOL

Billy

1991 Trx250X Custom exhaust,K&N jetted,widened 7.5 inches in the back and 8 inches in the frontWarrior rear shock and z400 front shocks with custom brackets.Race cut fenders.+3 swingarm.Way more to come.
Building things makes me happy.
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