Author Topic: Brake hub removal  (Read 222 times)

Offline Surlyman

  • Jr. Member
  • *
  • Posts: 11
Brake hub removal
« on: June 02, 2017, 12:52:30 AM »
2003 model.

How in the hell does a guy get the thing off without the special tool?

Ive called BRP, special tool #529 035 695 has been discontinued =[ I should have round'ed up that type of stuff years ago.

Ive got my rear end half way apart for a bearing replacement and I'm stuck not being able to remove the brake hub.

Thanks in advance for any advice.

Offline Dirk1616

  • Full Member
  • **
  • Posts: 40
  • Little Do A Little Good, Lotta Do A Lotta Good
Re: Brake hub removal
« Reply #1 on: June 02, 2017, 03:51:50 AM »
That brake hub can be a bastard. The easiest way I have found to get it off is to slide the axle all the way to the right (looking at the back of the machine). This presses the brake hub against the carrier and the swing arm. Now take a Deadblow (Rubber Mallet), and hit the left side of the axle with a few solid hits. If it's still being tough, wiggle the axle and try to get it as center and as straight as you can with everything. You may have to hit it several times if it really doesn't want to cooperate. But it's probably the easiest way.

I would always fight with it until I did it this way and it popped off with a couple hits. I wouldn't recommend using a regular hammer to hit the axle with. I know they changed the design of the wheel nut threads on the ends of the axle so the threads don't go all the way out to the end of the axle. The redesign now stops the threads about 3/8" before the end, which is how it is on the 2003. In the earlier years, like 2000, the threads went all the way out to the end, which meant if you messed them up using a regular hammer, good luck getting the nut back on without messing up more threads. I'm not sure what year this change happened.

After it comes off, you'll notice an O-Ring seal inside the hub, it'll have some grooves in it from forcing it over the splines of the axle. It isn't too big of a deal, they will still seal and keep most stuff out. What I normally do is put grease in all the splines on the axle, even the wheel hub splines, just helps keep junk out and prevents wear.

This is getting to be a lengthy post. But what I have also done, and some others have done I'm sure, is put a grease zerk in the carrier housing. I found where the carrier would be with putting as much slack in the chain as possible, finding a spot in the center of the carrier I could easily get to, drilling a small hole, tap, screw in a zerk, and drilling a hole through the swing arm (big enough to get a grease gun into).
The only thing I would say about doing this is, once you use half a tube of grease to fill the carrier and all the air is out, don't pump it until you see grease, by then, your carrier bearing seals will pop out and you'll have to tear it all apart again to put the seals back in place. I think there is a post of this somewhere on here, could be wrong. If anyone wants, I can post this up with pics for a DIY project.

Hope this helps!
« Last Edit: June 02, 2017, 03:57:10 AM by Dirk1616 »
2003 DS Baja         Riding at Bundy Hill and Silver Lake
Big Gun CDI, 11.5 JE Piston, Port/Polish, OMR Carb Mods,
Custom Mod End Cap, UNI Filter, More To Come?


* Calendar

October 2017
Sun Mon Tue Wed Thu Fri Sat
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 [17] 18 19 20 21
22 23 24 25 26 27 28
29 30 31

No calendar events were found.

* Recent Posts

Polyethelene high molecule shock bushings. For ds factory shocks by persom55
[October 12, 2017, 06:45:15 AM]

[September 19, 2017, 06:54:44 PM]

water pump seal by persom55
[August 30, 2017, 02:20:17 PM]

charging system problems! by bob
[July 14, 2017, 05:56:28 PM]

Ds 1000 by romanrsx
[June 17, 2017, 06:17:58 AM]

what size shim do i need and where can i get them by BigRay800
[June 05, 2017, 10:14:46 PM]

Running Hot by Dirk1616
[June 05, 2017, 04:45:57 AM]

Brake hub removal by Dirk1616
[June 02, 2017, 03:51:50 AM]

Silver Lake Memorial Day Weekend 2017 by bob
[May 31, 2017, 05:47:20 PM]

dune trip in the planning by badge
[May 28, 2017, 03:11:42 PM]

Float settings by Oldmanracing
[May 24, 2017, 07:34:38 PM]

Forced Air Intake With A Fan by Dirk1616
[May 22, 2017, 08:42:24 AM]

Need help by kevinpd1987
[May 18, 2017, 01:13:58 AM]

Can anyone help me with a VIN? by kevinpd1987
[May 18, 2017, 12:52:21 AM]

Front shock bushings by Jamielukas
[May 13, 2017, 09:03:37 PM]

New ds650 owner from Syracuse ny by Jamielukas
[May 13, 2017, 08:58:15 PM]

rotax F800 twin swap? by BigRay800
[May 13, 2017, 01:50:08 PM]

Where to start with jetting by Stvo
[May 09, 2017, 03:03:42 AM]

Geo referenced may of the Dunes by MRDS650
[May 06, 2017, 07:08:39 AM]

timeing and gapping... by BigRay800
[May 04, 2017, 09:24:03 AM]

What's the REAL deal with direct mount filters? by Oldmanracing
[April 20, 2017, 11:07:27 AM]

IMS tank leaking around gasket by persom55
[April 16, 2017, 05:07:05 PM]

PRM rear skid by Toddwick
[April 16, 2017, 05:43:52 AM]

[April 14, 2017, 11:05:30 PM]

June 2015 by Dirk1616
[April 14, 2017, 07:33:41 PM]