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I just got this 2002 foreman 450 and started it up and put it in gear the rear end kinda hops a little then just stop pulling so my first thought is the ring gear or pinion gear so I start tearing it down and I have hit a brick wall. I can not get the pinion joint/coupler off. Any ideas to get it off
 

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I got a 2002 450 but have never had to take the pinion out yet , from looking at the print the pinion coupler could be held onto the shaft with a clip as I see no nut on the end of the pinion , it is hard to tell by the print , did you view the break down print here is a link below , on that link if you click on the complete diff part , you will see the coupler comes as part of the complete diff and 2002-04 is the only years that diff fits , I am as curious as you on how it comes apart

Honda ATV Parts 2002 TRX450FM A FINAL DRIVEN GEAR Diagram
 

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According to the FSM the pinion joint is held on by a nut up thru '01 models. On 2002 models the pinion joint simply pulls out... it has an o-ring on it. That o-ring should be the only thing holding it in place unless it has bound up on the splines somehow.
 

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they don't show a nut on the print of a 2002 , they do show a clip , seems there would have to be a way to achieve pre-load on the pinion bearing
 

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Behind the pinion joint is (supposed to be) the oil seal then a staked nut holding the outer pinion bearing down. The FSM doesn't say anything about a retainer for the joint on the '02 though, just says to pull it off. There may be an error or omission in the FSM... dunno.
 

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