Front axle rusted in place...

[Zooks]

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.

[tkent02]

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.

[first timer]

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.

[chef1366]

I'd love to have a whack at that!

[tkent02]

I'd love to have a whack at that!

Come on up, feel free to whack to your heart's content!
I have couch space and beer, and a nice tight GS for you to ride when the Whacking is complete!

[chef1366]

Come on up, feel free to whack to your heart's content!
I have couch space and beer, and a nice tight GS for you to ride when the Whacking is complete!

Uh thanks.

[tkent02]

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.

Well, I thought of that one as well, these forks have a damping adjustment wheel at the bottom of the slider where the bolts should be, I'm not sure how they come apart...
Anyone who has had this style fork apart is welcome to chime in...
I'm thinking I may need to post a few pictures.

[Zooks]

Does 'whacking' have the same colloquial meaning in the U.S that it does over here. LOL

[first timer]

I had a set of those fork, from what i remember you just yank the dials off. Well you might have to carefully pry them off but I am pretty sure they are just pressed on. Then you have a do some tinkering and remove some clips then you are good to go. Try this link below for the factory instructions

http://www.quickfilepost.com/download.do?get=41cae9bedc9e83787cc9d7e4dfb897b9

[chef1366]

Does 'whacking' have the same colloquial meaning in the U.S that it does over here. LOL

It may be universal.

[tkent02]

Nother update,
Got the forks off by taking the entire triple clamp assembly apart, the right fork leg came off the axle OK, the spacer between the wheel and the right fork leg is completely solid, as if one piece with the axle.
The axle will turn in the left fork leg, takes maybe 100 ft. lbs. of torque to move it.
Who has another idea to try?
Hydraulic press?

[tkent02]

Anyone around Denver have a big hydraulic press?
There's beer in it for you.

[Hammered]

Is this the offset style of forks or the inline?

[first timer]

keep rotateing it back and forth adding penatrating oil. some thing will break free eventually

[reddirtrider]

Anyone around Denver have a big hydraulic press?
There's beer in it for you.

If you want to drive 2 hours southwest into the mountains I've got a press and I'll do it for nothing.