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Front axle rusted in place...

tkent02

tkent02

Forum LongTimer
Past Site Supporter
1981 GS 1100E, has sat for 23 years, got it running, brakes, electrical system, every thing working well, time for tires.
The front axle is having no part of it.
Put a bolt through the hole in the left end of the axle, twisted the axle with a pipe wrench, not even a budge. Pounded the right end pretty good with the axle nut on backwards, nothing. It's been soaking in PB for two days. I'm thinking maybe pull the forks down from the bike and twist them apart, I could at least determine which end of the axle is stuck. Maybe heat up the fork legs and whack it harder?
Any better ideas before I make this into a much bigger project than it is?
 
Use a snug 6-side socket and a cheater bar then pray for the best!!
 
Most likely it's stuck in the wheel bearings. Sounds like time to brace the fork against a wall with a chunk of wood and wack the axle with a sledge.:twistedevil:
 
Please do not pound on that nut, you'll ruin the thread. Take a piece of aluminum ( it could be a block, or a round stock) put it to the end of the axle and hit it with a hammer, but please don't hurt yourself doing this.
 
Don't worry too much about damaging the front axle threads. Cycle Recycle II here in Indy has a box of used axles that one can sift through and match up to one's own damaged axle and purchase for $4.

If you really mess it up getting it off, give me the length and diameter, adn I can find you another one.
 
Griffin said:
Don't worry too much about damaging the front axle threads. Cycle Recycle II here in Indy has a box of used axles that one can sift through and match up to one's own damaged axle and purchase for $4.

If you really mess it up getting it off, give me the length and diameter, adn I can find you another one.
Click to expand...

I actually have another axle. at least if it's the same as a GS 1000...
Just thought I would be civilized and try not using too much blunt force if another option were available.
On the other hand, I do have a really nice splitting maul. :-)
 
Have you thought about taking the whole wheel off? Undo the clamps and speedo cable from the drive and take it all out in one go. Take discs off and lay wheel down on some sort of spacing and bash the crap out of the axle that way.
 
Kroil works better than PB blaster. Heat might help but I vote for the big hammer too (using Sharpy's method as no chance of damaging the forks).

Dan :)
 
sharpy said:
Have you thought about taking the whole wheel off? Undo the clamps and speedo cable from the drive and take it all out in one go. Take discs off and lay wheel down on some sort of spacing and bash the crap out of the axle that way.
Click to expand...

Suzuki put a leading axle fork on the early 1100's for those of us in the US so your technique won't work for us.:mad:
 
Use an air chisel with a blunt bit and hammer on it for a few minutes. :mad:

I've taken things apart that you'de swear would never see the light of day, with this method. Works very well... :-\\\
 
Nessism said:
Suzuki put a leading axle fork on the early 1100's for those of us in the US so your technique won't work for us.:mad:
Click to expand...

Opps sorry, thought only the very first model had them. But hitting the axle while its just "hanging" there isnt much good as you need a solid backing to shock it free when your swinging that brass/alloy hammer. Still strruggling?. Might be the bearing that are rusted so taking the fork with the clamp off should it lets you swing the axle out with the wheel attached then do plan A. But having said that the speedo drive and axle mightnt let you take the LHS disc off, Bugger
 
Last edited:
I am in the same situation with a swingarm bolt on my KLX. I have been using PB Blaster all week and a few love taps with my 2lb hammer. I am going to either enlist a larger hammer or start up the torch. I figure either way I am going to have to replace the bearings.

One other radical solution I read about was to sawzall through the bolt and then use a press to remove remaining pieces, Just a thought...
 
Have you tried whacking it nice and hard from the other side (as if you are knocking it in). You can hammer on the fat end until the cows come home and you won't damage it. This may be enough to rattle it free, then you can knock it out from the other end. I agree about bracing it against something too. Just be careful you don't split those aluminium forks. :eek:
 
Weekend Update...

It is only stuck on the left side, we braced it with a big fence post for an anvil and swung the big sledge, the axle was moving inside the right side fork leg. Not stuck in the bearings because if that was it we could twist the axle, and we can't. I guess it could be stuck in both the bearings and the left leg, but I hope not.

So on to plan B, remove the fork tubes from the triples and twist the right fork leg off the axle, remove the wheel and should be able to press the axle out of the left leg... NO.
There is an air fitting on either fork leg just above the lower triple clamp, it is stuck to the fork tube big time, so cannot get either fork leg to slide down...

I'm thinking it might be time to roll it back into the corner and wait until I have the parts and enough time to disassemble and rebuild the entire front end one piece at a time, bearings, fork seals, all of it.

Sucks, it was almost ready for a longer ride.
 
it's dirty but just heat up the bottom of the fork with some propane and zap out the bolt that holds the inner tube to the outer tube at the bottom of the fork assembly. Granted all the fork oil will dump on every thinkg but at leat you will have the lower free.
 
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