250r Axle Removal 1983 1984.

[greythorn3]

In case you're still having problems removing the axle (and all the useful information got lost/hidden in the fighting) here are the exact steps you need (and a picture of the rear end of my '84 250r with '83 swingarm as a reference)



Spray everything attached to axle with lots of PB Blaster the day before you start the removal process. Then:

Try to loosen the two large nuts on the left hand side with large crescent wrench. Apply heat and more PB blaster if necessary. I like to apply pb-blaster after applying heat, as it seems to "wick" the pbblaster into the threads. If you can loosen them this way, take a large flat-head screwdriver and a and try to "chisel" them loose - basically a manual impact wrench method. After getting them loose:

-Remove hub nut
-Remove wheels
-Remove hubs

LEFT SIDE:
-Remove the two large nuts
-Remove spacer between two nuts and brake disc
-Detach caliper from mount (2 bolts I believe) then lift caliper up and tie to frame to keep out of the way
-Remove brake disc from mount
-Tap the brake mount off of the axel with
-Remove snap ring holding caliper mount in place, then remove the caliper mount

RIGHT SIDE :
Not really necessary to remove anything since the axle slides out from left to right, but you might as well remove the sprocket and mount. That way it won't be damaged should the axle slide out quickly and drop to floor!

Now, once you have removed all that, again, spray PB blaster like crazy into where the axle meets the swingarm/carrier and let it work its magic. Then:

Screw the left-side axle hub nut on BACKWARDS so that the flat side faces outwards. Screw onto the axle far enough so that the flat part meets flush with the axle head. Then as gently as possible, start slamming away with a large sized sledge . If all goes well, your axle will pop out easily enough. If not, keep applying as much PB blaster as possible, wait a day, then try again. Try not to get impatient and damage the end of the axle!

Good luck, and keep us posted!

-Xhum

this is good info thank you!!! working on mine today, wow!! them large nuts are a real bugger mine are stick good! im gonna heat them with my mapp gas tourch if they dont come off after soaking in the pb blaster today.

Ray

[Dirtcrasher]

If you guys absolutely, positively cannot get those nuts off, use a Dremel or 3" cut off wheel and make a groove in them as far as you can without hitting the axle threads. Sometimes you have to cut at a 45 to the nuts face or you'll damage other components. At this point, the pressure is usually released and sometimes they'll wrench off or a tapered punch will finish the nut splitting job.

I find MAPP gas to succeed ever so often and I can't count on it. Oxy/ Acet works nearly all the time but some people don't have access to them.....

Sometimes it's better to cut things off and replace them (unless they are discontinued) Otherwise I've seen axles ruined even worse as people try to hold the axle still while attempting to remove the seized nuts. You end up seeing ruined splines or pipe wrenches all over the axle. I have one of those from an 87 200X and it's a shame, if the guy cut it off or used heat he wouldn't have chewed the hell out of the axle..........

[greythorn3]

i could just weld some beads on the hex flat that should heat it up PLEANTY to get it off.. thats wha ti will try so i can reuse the nut before cutting it off

[RodKnockRacing]

hell i just pulled my axle out today so i can get my swing arm prepped and painted

[greythorn3]

i had to do the cold chisel with teh trick to get them started comming off.. worked great!