Author Topic: Brake hub removal  (Read 505 times)

Offline Surlyman

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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

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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
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