FITTING AN AFTERMARKET AXLE

At some point the majority of sports ATV riders will want an aftermarket axle, to prevent damage to the stock axle, or to make the quad wider and stronger for racing purposes. We asked Peter Wilhelms to give us a step-by-step how to.

For this process of the guide we’re fitting a new Lone Star Racing Axle to a  2006 Honda TRX450ER.

Once your ready to go, this whole process should only take about one hour, or maybe two if you have too many mates over to help. Making sure you have the right tools is important too. Here’s what you’ll need:

* A good socket set from 10mm to at least 27mm

* A good set of metric Allen keys

* A 600mm shifting spanner (or something big enough to get the lock nut undone)

* Internal circlip pliers

* Long-nose pliers and

* A rubber mallet.

Before you begin, clean the quad. It’s easier to see what you’re doing if the machine is clean, and less messy.

Step 1

Place the quad on a suitable stand. Our scissor lift style stand is perfect for this kind of operation because you can tie the quad to the stand to stop it moving.

Step 2

Place the quad in gear so that the axle won’t rotate while you’re working on it. Remove the rear wheels and swingarm skid plate. Remove the wheel hubs by taking out the split pin and undoing the hub bolt. If you’ve never had your hubs off they may be tight on the axle and need some persuading. If this is the case, use a RUBBER mallet on the back of the hub to knock it off the axle.

Step 3

Remove the brake caliper. Let it sit on the top of the swingarm or tie it to the heel guard.

Step 4

Loosen the pinch bolts on the swingarm to allow you to release the tension on the chain.

Step 5

Now for the fun bit. Loosen the inner lock nut and turn back as far as you can then you can turn the outer lock nut on the threaded part to uncover the circlip. (Remember that on the 450R, the axle lock nut is a lefthand thread.) Using good circlip pliers, pop the circlip out of its groove and slide it off the axle. You can now remove the lock nut and the brake disc carrier from the axle.

Step 6

Undo the bolts that hold the sprocket to the sprocket carrier. (The LSR axle for the Honda comes with its own sprocket carrier already installed.)

Step 7

Remove the axle through the sprocket side of the swingarm. Once again use a rubber mallet if it needs help to come out.

Step 8

Before you install your new axle, it pays to grease the bearings and around the bearing seals with good waterproof grease.

Step 9

Now it’s time to put the new axle in. Use a bit of anti-seize paste on the axle bearing races, to make it easier to get out if you need to do maintenance on the bearings later on. Use a rubber mallet on the end of the axle to help get it into position.

Step 10

Now re-install the sprocket on the sprocket carrier, (make sure you use some loctite on the bolts) set your chain tension and do up the pinch bolts on the swingarm.

Step 11

Time to put the disc carrier back on and also the locknut and circlip. Then you can do the outer lock nut up until the axle is firmly seated. Do up the inner lock nut tightly.

Step 12

This axle is an adjustable one and so comes with spacers for the hub-splines to set the final width of the axle. Since we’re setting up this quad with plus-2 A-arms, I’m putting all the spacers on each side to give us maximum width.

Step 13

When fitting the hubs, it’s a good idea to place waterproof grease on the splines, to aid removal down the track. Do the hub nuts up tight (use a little loctite too), and use the R-clip provided to retain it.

Step 14

Now the brake caliper can go back on. As can the skidplate and wheels. Now take your quad for a test ride. When you get back, re-check all the bolts to make sure everything’s tight.

Lone Star Racing Axle's are available from all good ATV dealers and are distributed in Australia by Hardiman ATV (02) 4353 3622 or check out their website www.hardimanatv.com.au