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remove the wheel and brake drum then remove rear diff. cover put transmission in neutral roll rear diff. around until you see an 8 mm bolt , remove bolt then diff. pin then push axle in to un key axle key then pull axle out to get to seal remove seal with seal remover tool
remove the calipers and rotors if rear disk and then remove the ebrake shoes/cables.
If rear drums remove the drums. remove the shoes and the e brake cable. remove the backing plate bolts. remove backing plate from axle and support with a piece of wire from the frame being careful not to distort the brake line.
remove the bolt that holds the breather an brake junction to the axle.
remove the break line from the tabs (may not have them).
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KTM Torque settings
Collar screw, front wheel spindle Front axle nut 40Nm 30ft lbs
Brake Caliper front Brake Caliper front Loctite 243 2 19ft lbs
Brake Disk, front Brake disk front Loctite 243 1 11ft lbs
you will have to remove the differential cover. Take care not to bend it and watch out for the oil as it drains. Once that is done there is a pinion shaft locking bolt that has to be removed. Then you slide the pinion lock out. After that you push the axle IN and remove the "C" clip. The axle will then slide out. BE SURE the whole rear of the vehicle is supported on jack stands. If not the other axle will slide in and you won't be able to install the axle you took out.
The locking bolt will be recessed and it will face across the vehice (like an axle) and the pinion lock will be face front to back and slide out towards the back.
pull wheel and drum then pull back cover. Then find the eight mm bolt on the carrier pull that out then the pin it holds in. Now push the axle in to access the c clip that holds the axle in and pull axle out.
to remove the rear axle you will need to put the rear of the jimmy on jack stands off the ground and remove the wheels
then remove the rear drums or if you have disc brakes the caliper and rotor
next you will need to remove the rear differential cover
once you have removed the rear differential cover you will need to rotate the differential by just turning the rear axle to gain access to the lockbolt
using an 8 mm socket you should be able to fairly easily remove the lock bolt
once you have removed the lock bolt you will need to push the axle in from the side that the wheel gets mouted to and then in the rear differential remove the locking 'c' clip
once the locking 'c' clip is removed you should be able to pull the axle right out
installation is the reverse of the removal
keep in mind that after romoving the lock bolt you must make sure not to rotat the axle if you do you will mess up the allignment with the differential and axle and you will spend loads of time trying to re-allign it again