How to remove frozen axle

[aldend123]

I've been trying heat-cycling instead of just temp differences when I get stuck. Heat, apply ice. Wait till ice is melted. Repeat several times.

If you're ready to call the bearings and maybe the axle casualties of war, put the nut back on 75% of the way with a little threadlocker. Once threadlocker dries, start wailing on it with a sledge. Shock-and-awe approach also likely to bust up corrosion. Might need a helper to brace the bike to make sure you're getting the most out of the impacts.

If this thing has been apart within the past year, hard to believe it's sledge-hammer stuck.

[breakdirt916]

Might need a helper to brace the bike

this helped me think of this....

I had a axle stuck so bad one time that I had to take the whole swingarm off the bike with the wheel attached and I had to use a press to push the axle through.

[jasnmar]

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

Either drill out the ID of some washers or hole saw the OD to fit. Something, somewhere will work.

Worst case someone with a lathe can turn a part for you that matches the ID of your all thread and the OD of your axle (or, just under).

[caloots]

Press is your best bet if you have to take the swing arm off.. otherwise an air hammer and try to get pb blaster in there while hammering.. otherwise cutting it off isn't a bad idea..

Sent from my Pixel using Tapatalk

[Paul_E_D]

OK, good ideas in here guys. Thanks. I'm going to try heat/cold + regular hammer with swingarm blocked first. If it doesn't budge, I'm going threaded rod puller/press route. I also have to replace a blown turbo hose on the van ASAP, so not sure I will succeed tonight. Gonna pick up a new axle and wheel bearings in the meantime. It is not corrosion as I service the bike all the time, it has to be the axle/bearings. I do ride in sand all the time, which helps nothing.

[R7]

It is not corrosion as I service the bike all the time, it has to be the axle/bearings. I do ride in sand all the time, which helps nothing.

Not sure what year your bike is, and if/when KTM stop coating axles, but all my past KTM's had teftlon coated axles. Any grease or oil on the axle, would cause the coating to swell and make the axle near impossible to remove. I learned this the hard way on my 06 525 exc. My 2011 xcw200 had the same coating, I ended up sanding it off both those bikes and never had an issue after that

[Paul_E_D]

No coating on this one, and I have sanded it every time I removed it. I have tried both greased and dry. I cannot win with this thing.

[typeone]

what a bitch. wonder if a fresh, perfectly round axle + SKF wheel seal kit and bearings would last longer for you in the sand. there must be imperfections in the axle allowing some seep then corrosion each time.

ever slather it with anti-seize rather than grease? your conditions aren't going to change, that's some BS to go through even twice.

[Paul_E_D]

Also, the reason I need the axle out is that I flatted an UHD rear tube. I don't even have rocks where I ride FFS. Whyyyyyyyyyy?????

[Falko]

I don't know how wide the swing arm is, but I have a ball joint clamp/press that is pretty large.

[typeone]

Also, the reason I need the axle out is that I flatted an UHD rear tube. I don't even have rocks where I ride FFS. Whyyyyyyyyyy?????

are you getting slippage like i've been dealing with lately? valve stem straight?

[Paul_E_D]

I don't think so, but I'll check the stem.

[breakdirt916]

Flat UHD! The f? I'm running one...I thought that was the last tube I needed per tire!

[Paul_E_D]

Ok. Heat, ice and the carpentry hammer did the trick.

Sent from my SM-G930V using Tapatalk

[ZX-12R]

Any galling or corrosion? Did you chowder-up the wheel bearings?

[Paul_E_D]

Any galling or corrosion? Did you chowder-up the wheel bearings?

Lots of galling on the axle and even some on the spacer. Bearings weren't smoked. Lots of debris behind the seals though.

Sent from my SM-G930V using Tapatalk

[Stromper]

Biggest threaded rod that will go through the axle

Take pipe fittings on the opposite side like a nipple with a cap nipple big enough for the head etc to fit in

2 nuts and its a press just around the axle itself

[tls25rs]

Lots of galling on the axle and even some on the spacer. Bearings weren't smoked. Lots of debris behind the seals though.

Sent from my SM-G930V using Tapatalk

Wonder if somehow the spacers are being deformed and pinching things when trying to move the axle?

[Paul_E_D]

I think the spacers are the culprit. there is some kind of coating that is peeling and the axle is galling there.

I bought a bearing kit that includes the seals, the sleeve, and spacers, but the damn things are the wrong size. Doh. Back to Valley tomorrow.

This whole thing ran me 200 bucks. Axle, nut, bearing kit, rear pads and a tube. Grrr.

[caloots]

Try lubing everything that is touching that axle bolt with synthetic grease when you put it together?? Maybe that will help

Sent from my Pixel using Tapatalk

[Paul_E_D]

Tried that. Didn't work. I think in my case a dry setup is best. I ride in wet sand usually, and it infiltrates everything. Grease will just trap more of it.

[breakdirt916]

Eek hidden costs of dirty maintenance I am sure 95% of CL riders don't do

[Stromper]

My threaded rod press would work

maybe upgrade higher carbon stuff from mcmaster.com

[ZX-12R]

My threaded rod press would work

Did you miss the part where he got it out using heat, ice, and a hammer?

[Chippertheripper]

He does not read.


Paul, I'm a little disappointed we have yet to see pictures of this mauled axle.
I'd be lying if I said I wasn't mildly freaked out by this. I go back and forth between a cheap set of wheels and the stock wheels all the time, and now I'm a little weirded.