Suspension Arm Removal on 2001-2005 Honda TRX250EX Sportrax TRX250EX ATVs
Removal Steps:
- Remove the wheel hub.
- Remove the bolts and brake hose clamps from the upper arm.
- Remove the cotter pins from the upper and lower arm ball joint studs.
- Remove the knuckle ball joint nuts.
- Remove the cotter pin from the tie-rod ball joint stud. Remove the joint nut by holding the joint stud flat surfaces.
- Remove the tie-rod ball joint from the knuckle.
- Release the ball joints of the upper and lower arms off the knuckle, using the special tool according to the following instructions.
Special Tool Required:
Ball joint remover 07MAC-SL00200
Instructions for Using the Special Tool:
- Apply grease to the ball joint remover at the point shown. This will ease installation of the tool and prevent damage to the pressure bolt threads.
- Insert the jaws carefully, making sure that you do not damage the ball joint boot.
- Adjust the jaw spacing by turning the pressure bolt.
- Once the tool is in place, turn the adjusting bolt as necessary to make the jaws parallel.
- Hand-tighten the pressure bolt and recheck the jaws to make sure they are still parallel.
- Tighten the pressure bolt with a wrench until the ball joint stud pops loose.
- Remove the knuckle from the upper and lower arms.
Additional Removal Steps:
- Remove the upper arm pivot nuts, bolts, and upper arm.
- Remove the shock absorber lower mounting nut and bolt.
- Remove the lower arm pivot nuts, bolts, and lower arm.
