Help with 250sx Front Axle/Hub/Shock

[zainyD]

I'm trying to do some work on the front end of my 85 250sx and I've run into a roadblock that seems to be fairly common with these trikes if the other threads I've read are any indication.

I have removed the front end of my 250sx and was able to remove one of the forks, the wheel, and the brake drum, however, I cannot get the axle to budge from the left fork. As I understand it, I must first remove the axle before I can remove the hub and brake backing plate, correct? Is it also correct that the front axle threads into the right fork? Is it standard threads, i.e. right-tight, left-loose?

My backing plate is cracked and I would like to replace it with one I purchased recently from dirtface. The service manual is a bit vague on how to separate the hub, axle, and right fork so would somebody be able to post some pictures or a brief tutorial?

So far I have tried a breaker bar with a long cheater bar slid onto it and have sprayed the axle with WD-40 with no success. I don't have a torch at the moment. If possible I would like to avoid breaking or destroying anything, but I realize that may not be an option.

Any help, pictures, or words of wisdom would be most appreciated. I'm sure the axle has never been removed since this trike was new so I have an uphill battle ahead of me.

[Dirtcrasher]

Yep, standard threads, just corrosion.

Many will not come apart without cut off wheels and complete destruction.

Why no one greases them from the get go is beyond me..................

[aldochina]

i had one like this!! deffinately need a tourch, and a ton of tourque! mine finally broke loose, ended up pulling a few of the aluminum threads from the fork leg, but was still very much usuable!!

[zainyD]

I put some heat on it yesterday and then proceeded to break my 17mm socket trying to get it loose. I had no idea this would be such a challenge. I'll keep at it and try some more heat. So far this thing is kicking my behind.

[dirtface]

If the backing plate is already cracked and junk, then destroy it and save the axle. Where I have seen them froze up is the metal sleeve that is pressed into the center of the backing plate, the axle seizes to it. I have personally ran into this numerous time, so your definately not alone on this one. Like DC said, grease the heck out of it when you do go to put it back together.

[zainyD]

I'm going to stop by Sears tomorrow and get a new socket and then hit the axle with some more heat. Hope it comes loose.

[Headsup]

Is your front end still on? You can maybe get some more leverage if it is. Stop it from moving around while trying to break it free. Heat it and smack on it with a rubber mallet while the front end is still on the frame then give it a go with some force

[atc007]

You said the fr end is OFF. Take it to a press. Simply move on with your life! PAY someone with a press to do this one for you. you have a great attitude and work ethic,,but this one better off letting someone else deal with. If it was still in the bike,I'd say keep fighting. But take it and have it pressed. They are a real Bear. You will prolly just break your new Craftsman 17 again. been there done that : )

[atc350xer]

If the backing plate is already cracked and junk, then destroy it and save the axle. Where I have seen them froze up is the metal sleeve that is pressed into the center of the backing plate, the axle seizes to it. I have personally ran into this numerous time, so your definately not alone on this one. Like DC said, grease the heck out of it when you do go to put it back together.
X2... I was very lucky, mine eventually came out fairly easily, but most of them don't, from what I've heard.

[3wheely]

Can't wait to see what mine is like. The only thing I hate about getting a new old bike is not knowing how well they were maintained. I make it a habit to grease everything I take apart and put back together.

[zainyD]

I just realized that I had a typing error in my original post. The axle will not unscrew from the left, front fork, not the right. The hub and backing plate aren't my problems at the moment.

The whole point of taking the front end apart was to replace the brake backing plate. I purchased a replacement from dirtface a while back. Unfortunately, this has opened up a whole new can of worms that I'm trying to work through.

Today, after applying ample heat and lubricant to the portion of the fork where the axle threads into it I bent and cracked a 17mm wrench. Now the bolt end of the axle is pretty marred up. I am contemplating cutting the axle so that I can remove the hub and backing plate then devise some method to remove the threaded end from the left fork. I may have to drill it out, but the axle is very hard steel so I'm not sure I have the quality of tools necessary to do that.

So far this has been very frustrating, but I'm going to keep at it.

[aldochina]

you must use a 6 point socket only!! alittle late for that, i actually twisted the head of the bolt a bit, but ground and filed back to anice tight fit!! if your bolt is toast on the end, and you have access to a welder, weld a large 3/4 nut or something on the end and keep at it

[Dirtcrasher]

It's not that hard or it would snap. Drilling it straight is most peoples issue.....

I'm willing to bet if you chop the axle off and have some to put in a vice, you can unthread it from the fork.

Use a cutoff wheel on the spacer and hope it pounds out of the hub.

[zainyD]

I have a welder, an angle grinder with lots of cut-off wheels, and a drill press so worse comes to worse they'll be put to use.

Before I cut it though I think I may take it to a guy in my church who has a auto repair shop to see if he can work any magic on it.

This thing has been a bear, but I'm determined to not let it beat me.

[Thorpe]

A 6 point socket and an AIR IMPACT WRENCH... Cheater bars are a great way to destroy the axle, and fork... Slow twisting ruins stuff thats corroded together. Get a better for of penetrating oil than wd-40 as well. Both of my axles came out on BR and SX that way...

[TatTooL23]

^^^^ exactly what I was gonna say. Have u tried an air impact wrench with 6 point socket only?? It's the hammmering of the impact that can usually break it free. With the hammmering it "scares" it free rather then tons of slow pressure. If u have a real good strong impact and press into the axle as hard as u can with it I think it would come out. I did 2 SX front ends like this no problem.

[aldochina]

i have to say i had no luck with an impact on mine!! i did use a 1/2" breaker bar with rigid pipe extension + 6 POINT SOCKET!! I'm a rather strapping lad though!! lol. like i said the head did twist alittle, but did not ruin the axle. I actually sold that axle to a member here. as far as i know it has worked out for him!!

[aldochina]

Also if you dont have a nice brass hammer, get one, they are great. i use mine all the time on frozen stuff. apply heat, penetrant, torque, tap the bolt, tap the fork lower. patience, and persistence, and i usually win!! I like to use the brass hammer as a buffer between the axle, or bolt, and a good wack with the minni sludge!! they sell cheap ones at harbor freight that work good, but the brass isnt of the best quality, and is a bit brittle, so always wear your safety glasses. a more expensive one will be softer brass, and less likely to send little pieces of brass flying!

[zainyD]

Put an impact on it today with no change in results. I'm going to get some PB Blaster and try some more heat. Someone I spoke with today said that WD40 is a lubricant only, not a penetrating oil.

I took a flat file and dressed up the end of the axle. I have a brass punch and gave the axle a couple good whacks using the punch as a buffer.

My wife is getting impatient for me to have my trike out of her parking spot in the garage, lol.

[atc007]

Did you try your buddies garage? A 3/4 gun with an impact socket will almost surely bring that out of there. Working by hand is,,well,,just not the way to do it. Anyplace that changes tires or works on bigger stuff should yank that right out of there for ya. Then see if the real fun starts : (

[Dirtcrasher]

Put an impact on it today with no change in results. I'm going to get some PB Blaster and try some more heat. Someone I spoke with today said that WD40 is a lubricant only, not a penetrating oil.

I took a flat file and dressed up the end of the axle. I have a brass punch and gave the axle a couple good whacks using the punch as a buffer.

My wife is getting impatient for me to have my trike out of her parking spot in the garage, lol.

Slash her tires and fix the trike :lol: She has to YAMAHONDAMAN

[zainyD]

Slash her tires and fix the trike :lol: She has to YAMAHONDAMAN

haha, I'd have to find a new place to live. She's actually very patient with me and my "inconvenient" hobbies.

[DSHOT59]

When my front bearings went bad I had the same problem.With a bit (quite a bit) of heat and an impact it finally came out ,heat is key. The axle didn`t survive however but every thing else did and I was able to pick one up on e-bay for like $10 I think it was. Good luck man and keep at it you`ll get it.

[zainyD]

IT'S OFF!!!!!!

Here was the problem, there is a steel sleeve which runs through the center of the brake backing plate. This sleeve acts as a retainer for the left side of the hub. As it turns out, the threaded end was not binding in the fork as I had originally suspected, it was that steel sleeve which had completely welded itself to the axle. Since the axle has to run through the hub and backing plate before entering the fork it was impossible to turn the axle.

I took it to my friend's auto repair shop yesterday and we removed the ears from the back side of the backing plate enabling us to spin the axle, hub, and backing plate together and we removed them as one unit from the left fork. Then, we put it on the press, but the axle wouldn't budge; we were just bending he flange of the hub. I ended up totally destroying the backing plate to get to that metal sleeve. After cutting through the sleeve down to the axle, beating on it, and putting some heat on it with a torch I was finally able to break the sleeve free from the axle. Even at my friend's well equipped shop this took over two hours.

Since the whole point of this project was to replace the backing plate I already had another one on hand. I also have new hub seals, but I found that the bearings needed to be replaced so I'll order those today. The hub and axle received minor damage during the removal process, but nothing that would prevent them from being reused, mostly just some nicks and gouges which I took care of.

Thank you for everyone's help and support! This was a bear of a project, but at least it's nearing completion and I won't have to worry about it anymore. Everything will receive a liberal coat of grease and anti-seize when it's re-assembled.

[atc350xer]

That is exactly where mine was frozen... glad you finally got it apart!

[3wheely]

If I run into this problem with mine Zainy, I'll be giving you a call!

[atc007]

If I run into this problem with mine Zainy, I'll be giving you a call!
That means yours hasn't been out. I strongly recommend going out and trying to get it out and grease it. It is more than likely seized,,if your brakes and bearings are good,,worry about it later. But if you can get it apart now and grease her up,you'll be a much happier camper later.