My front wheel alignment is off, so i'm replacing the triple tree and forks. I was able to get the front wheel off by twisting the forks, but no luck removing axle. The left side of the axle did not have a nut, it had a cotter pin (I'm only mentioning this because my manual shows a nut on the end). So, I have the left side free now, and on the end, there is a 1/2 inch of a hex shape. On the right side (the brake side), there is about an 1/8 inch of what looks to be the other end of the axle (it is threaded). From what I can see, the only thing I can do is turn the axle counter clockwise with a wrench on the 1/2 inch of hex shape on the very end of the left side of the axle. Is there another way of freeing the axle from the right fork, or does it just twist out counter clockwise? I have already tried loosening it this way, but it just won't move. I'm afraid to keep trying it this way for fear of bending the axle. Thanks in advance for any replies.

 

I had the same problem with my 85 200S and never did get the axle out of it, tried drilling the axle out so hopefully that the walls of the axle would be thin enough to twist it off, but that did not work, I ended up cutting the axle off with a sawzall, had to junk the forks, replaced with 125M's. I believe what had happened to my forks was that the front wheel bearings siezed up and galded the front axle to the fork. I would recommend that you replace the front bearings when putting the wheel on your new forks and use lots of antisieze. Apparently this was a problem with the ATC 200's

 

Hey, thanks for the reply. I guess i'm on the right track, i just got a bum deal with the axle being stuck. Well, I guess it matches just fine with the adjusting nut that is also stuck and preventing me from removing the triple tree. I'll probably have to purchase another axle assembly with the brake, or try and cut the axle, or maybe just remove the right fork with the axle and brake and use it with the new (used) triple tree I got. Thanks.

 

I don't know whether I would call it a bum deal or not, after all these machines are 23 years old now, mine had a bunch of engine parts missing, so I have had to go throught the entire top end of the engine. I have a brake assembly, but was never able to find an axle, so I put a 125M front fork assembly (rigid no front suspension) on mine with a front wheel and hub from a 110 which is a 3 lug set up without front brakes (I went retro the original ATC 90's and 110's did not have front brakes either), but I also have a 125M front brake assembly should I ever decide to install it, all I would have to do is get another 4 lug wheel that will go on the front end, kind of a Frankenstein by way of mixing and matching parts, but if you try and buy the axle new I think it costs about $60 new and it does not include any spacers of other hardware that you need, I never was able to find just the axle on ebay.

 

It was a good day in the back yard today! I was able to get the axle loose and eventually remove it. I used a 20 inch breaker bar with a 17mm socket, and the pole from a patio umbrella that I slid over the bar. The pole gave me the leverage I needed to start the axle turning. I heard a loud crack and thought something had broke, but it was just the sound of the axle turning. I was also able to get the adjusting nut off, so that I could remove the triple tree. I used some big plyers with the same pole slid over them to give me the leverage.

 

lol thats great to hear... but it sounds like the stuff I wrok on all day... lol [img]i/expressions/face-icon-small-happy.gif[/img]