02 300 EXC rear wheel removal

lowflyer · 02-02-2009, 08:57 PM

I hate to admit it, but I am stuck. I just bought a bike that has apparently never had the rear wheel off since new and the chain has never been adjusted. I can get the cap nut off of the axle and the adjuster block that is under it off, but that is as far as I can get. Both of the adjuster bolts are frozen. I am wondering if I should try gently heating the bolts with a propane torch. I am also wondering how this axle is supposed to come out. The manual has not been very helpful as it assumes this stuff comes apart when you disassemble it. Any help would be appreciated.

Thanks.

bajadog · 02-03-2009, 08:43 AM

Quote:

Originally Posted by lowflyer

I hate to admit it, but I am stuck. I just bought a bike that has apparently never had the rear wheel off since new and the chain has never been adjusted. I can get the cap nut off of the axle and the adjuster block that is under it off, but that is as far as I can get. Both of the adjuster bolts are frozen. I am wondering if I should try gently heating the bolts with a propane torch. I am also wondering how this axle is supposed to come out. The manual has not been very helpful as it assumes this stuff comes apart when you disassemble it. Any help would be appreciated.

Thanks.

I'd get some triflo or any penetrating oil, soak the adjuster bolts overnight,
then try turning them.
If you put the axle nut back on the axle, and tap the nut with a
mallet, it should start to move out, then get a long drift pin and
keep working it out.

Once the axle is out, you can get a socket on the adjuster bolts. You will
round them with a wrench.

lowflyer · 02-03-2009, 09:50 AM

Quote:

Originally Posted by bajadog

I'd get some triflo or any penetrating oil, soak the adjuster bolts overnight,
then try turning them.
If you put the axle nut back on the axle, and tap the nut with a
mallet, it should start to move out, then get a long drift pin and
keep working it out.

Once the axle is out, you can get a socket on the adjuster bolts. You will
round them with a wrench.

Thanks! I will try the penetrating oil next. I had used WD-40 and let it sit for a couple of hours to no avail.

The axle is seized up as well. I put a 2x4 on the end and tapped it with a 2.5-lb sledge and it hasn't budged. I can get it to wiggle fore and aft on the threaded side, but it won't budge at all on the other. The chain has never been tightened, so it is not holding the axle against the adjuster bolt.

I have never had this much trouble with a rear axle. I use anti-seize on my other bikes. I picked this bike up used, but it still has the OEM tires on it. I am fairly confident that this has not been apart since new.

In the picture, you can see how loose the chain is and you can almost make out that the top of the chain is worn flat.

bajadog · 02-03-2009, 09:58 AM

Quote:

Originally Posted by lowflyer

Thanks! I will try the penetrating oil next. I had used WD-40 and let it sit for a couple of hours to no avail.

The axle is seized up as well. I put a 2x4 on the end and tapped it with a 2.5-lb sledge and it hasn't budged. I can get it to wiggle fore and aft on the threaded side, but it won't budge at all on the other. The chain has never been tightened, so it is not holding the axle against the adjuster bolt.

I have never had this much trouble with a rear axle. I use anti-seize on my other bikes. I picked this bike up used, but it still has the OEM tires on it. I am fairly confident that this has not been apart since new.

Try doing an overnight soak on the axle (use a straw on the can) and
SOAK the heck out of the axle as much as possible.

Next day, give it some hard hit with the 2X4. If nothing budges, get
a can of aerosol duster, and spray the can upside down, into the
hollow end of the axle. This should contract the axle a bit, then
whack it with the hammer and 2 X 4.

Good luck.

Remember to anti-seize the adjuster bolts (like you mentioned).

lowflyer · 02-03-2009, 08:15 PM

Success! I used a product called Freeze-Off. I followed the instructions on the can and it worked on both the axle and the bolts. I got the axle out by hitting it harder with the sledge and wood block. I switched to a socket and then a t-handle and tapped it lightly with the sledge until it worked its way out. After the axle was out of the way, I was able to get a 6-point socket on the adjuster bolts and took my time working them in and out until they broke free. Whew!!!

bajadog · 02-03-2009, 08:55 PM

Quote:

Originally Posted by lowflyer

Success! I used a product called Freeze-Off. I followed the instructions on the can and it worked on both the axle and the bolts. I got the axle out by hitting it harder with the sledge and wood block. I switched to a socket and then a t-handle and tapped it lightly with the sledge until it worked its way out. After the axle was out of the way, I was able to get a 6-point socket on the adjuster bolts and took my time working them in and out until they broke free. Whew!!!

Kewl!

Where did you get Freeze-off?

lowflyer · 02-03-2009, 09:27 PM

Quote:

Originally Posted by bajadog

Kewl!

Where did you get Freeze-off?

I found it at Autozone this evening. I was a little skeptical, but thought it sounded plausible. You squirt it on through the red straw for 10-20 seconds and then tap it for a minute or two while it sets up. Worked like a charm.

bajadog · 02-04-2009, 06:38 AM

Quote:

Originally Posted by lowflyer

I found it at Autozone this evening. I was a little skeptical, but thought it sounded plausible. You squirt it on through the red straw for 10-20 seconds and then tap it for a minute or two while it sets up. Worked like a charm.

Nice.

Thanks for the tip.

I'll keep some in my garage.