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Hi , Just joined about 10 minutes ago! have a 02 300ex that needs new rear axle bearings(at least). having issues removing right side axle nuts , do you have to remove completly to pull axle thru to left side? says to use honda wrenches 45mm and 56 mm, any other way to remove them? they are loose but dont rotate very far - lubed with pb blaster to help loosen up. wire brushed what threads I could, have a Hayes manual that came with quad. Thanks for your help!
PS Boys race go karts also so were always in the shop doing something.
 

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A large open-end or adjustable wrench does not provide enough torque to remove seized axle nuts and those wrenches can round off the nuts, making them even more difficult to remove. The solution is to build a long socket that fits over the axle to allow the use of a large breaker bar, or better yet, an air impact wrench.

Here are close-up pics of the nuts in question. These are from a TRX300 but the Rancher 420 setup is very similar.


To build your axle-nut socket, get yourself a 41mm impact socket and use a chop saw to cut it in half. Next, find yourself a length of pipe and weld both parts of the cut socket onto the pipe, one on each end of the pipe. Grind the welds, paint the modified socket, and you’re in business. The total length of the socket should be aproximately 12 inches. Here’s what it should look like (the lines show where the cut socket was welded to the pipe).

Here is the drive end of the socket.

This is the business end of the socket. Just remove the ATV’s hub, slip your new socket over the axle, and easily remove those stubborn axle nuts in a matter of seconds. It works incredibly well. It also makes rear brake maintenance a breeze as the right side axle nuts must be removed to access the rear brake assembly on the TRX300 and Rancher 420. If you don’t have the welding skills or equipment to fabricate this socket, ask a friend or family member who does. It is well worth it.
 
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