How to remove frozen axle

[Paul_E_D]

OK, This is bizzarre. Ever since new the axle on my KTM has been a bitch to remove. Every time I take sandpaper to it to lower any high spots and it goes back in easily enough. This time I cannot budge it. I can't even move the wheel fore/aft without a hammer. I could break my prybar or the fixed axle adjuster to no avail. What next???

[typeone]

wow, no shit, that sucks. didn't you have an axle issue on the Kawi too? ever check alignment of your chain with a tool or straightedge? wondering if the axle could have been a bit crooked at one point then caused some issues once snugged down.

i guess if it were me, i'd try to soak it real good with some penetrating oil first at least before you really start hammering on it.

[loudbeard]

Does your KTM have adjuster blocks, if so can you remove those?

At the point of repeated trouble with this, I'd go ahead and replace all related items. Axle, axle nut, wheel bearings, adjuster blocks. Of course, you do have to get the old shit out first.

[SRTie4k]

Take it for a ride with the axle nut loose and hit a couple stumps/jumps.

[ZX-12R]

Can you remove the axle nut or is that stuck too? I had a similar issue with my KTM and managed to motivate it by loosening the axle nut and rapping it several times with a drilling hammer. Now I grease my axle and haven't had a problem since.

[breakdirt916]

Soak found, impact driver to knock her loose, block of wood and a dead blow hammer?

Or

[MUZ720]

Paul cam you use heat or try dry ice If heat would hurt other parts?

[MUZ720]

Sorry auto correct can you use heat on it or try cooling it with dry ice or just ice for that matter! Had the same issue with a buell axle ( go figure ) and was able to break it free after chilling it..

[Paul_E_D]

So far i have done all those things. No love

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[onenut]

If its hollow maybe pour some liquid nitrogen through it, as I always wanted to try that.
But in all my years with shitty rusty dirt bikes I never had an axle so stuck that I couldn't get it out with some PB blaster and a BFH, I usually make a shouldered punch that fits inside the axle to hit on.

[tls25rs]

As has been suggested, if the axle is hollow and most dirtbike axles are, try stuffing it with ice or dry ice and cooling it way down relative to the slots in the swingarm and the inner races of the bearings.

If you do resort to impacts from a hammer see if you can block the opposite side of the swingarm such that you aren't putting all of that force into the swingarm pivot or linkage bearings. A large screwdriver with a handle that is bigger than the end of the axle makes a nice target for a deadblow hammer that is less likely to mushroom the end of the axle.

If it is the wheel bearings that are tight on the axle pounding it out wont do them any favors either.

Good Luck!

- - - Updated - - -

So far i have done all those things. No love

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Sawzall it is!

[Paul_E_D]

I don't even know what to do. Nut is off adjuster is off. The other side adjuster is fixed to the axle. I have prised it off in the past but this time ir would break the adjuster and pry bar

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[Rada]

Guessing the axle has been upset at the bearings. If that is the case then you need brute force. As Joel says, back up the swinger so that all the energy is transferred to the axle vs bearing interface.

[aldend123]

Soak everything in PBBlaster and wait a day?

[jasnmar]

Maybe build yourself a little press with some all thread, some nuts, washers and pipe?

Run the all thread through the axle add washers and nuts. Add a piece of pipe larger than the axle, touching the swing arm, then washers and a nut, with the pipe being farther out than the axle. Tighten nuts to pull the axle out?

Plan on replacing the bearings when done.

[typeone]

^ i like that idea +1

[Paul_E_D]

Hmmm, The pipe would have to be pretty big to allow the adjuster plate though. But this would at least get it started. But what happens when the washers get to the bearings? I'm thinking it will be tough to find washers with EXACTLY the right diameter to both keep a hold of the hollow axle, and pull through the bearings

[ZX-12R]

Once the axle is broken loose from the compression and/or rust, you should be able to tap it out with conventional methods.

[typeone]

right, you could create some other sort of 'bridge' on the left side rather than a big pipe since the adjuster is large. you won't have to screw it all the way through, just use the easing force of tightening down on the threaded rod to break it free as ZX points out.

def a smart solution... before the BFH comes out.

[Paul_E_D]

Once the axle is broken loose from the compression and/or rust, you should be able to tap it out with conventional methods.

I found in the past is was really hard to get it through the bearings. I'm afraid this time it will be a no go. I'm going to try heating the bearings then icing the axle, followed by the deadblow hammer treatment.

[Pittenger5]

Have you tried melting the ice?

[breakdirt916]

aaaaand the seal is broken for ridiculous responses!!

get a few guys and lift it?

buy a yamaha?

okay, okay, I'm done...resume productivity and constructive responses

[Kurlon]

Air hammer?

[ZX-12R]

...followed by the deadblow hammer treatment.

Heating and cooling are definitely good. Your bearings are likely to be toast anyway and they are easy to replace so heat the shit out of them. A deadblow hammer isn't the best tool in this situation. You need the very high peak impulse of a traditional hammer to break the bond that's holding the axle in place. Thread the axle nut all the way on and then back it out a turn or two. Hit the axle nut with a ball peen or drilling hammer and check to see if it moves. A deadblow delivers a lower impulse over a longer period of time which isn't ideal for breaking seized components free.

[ZX-12R]

Air hammer?

In my original situation, my shitty air chisel wasn't enough to break my axle loose. Once I did with a drilling hammer, the air chisel with a flat anvil made short work of pushing it the rest of the way.