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New KDX 220 Owner: KX 500 Wheel Question

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I recently bought a 1998, KDX 220. :worthy: This is the third bike in my stable, and the first Kawasaki I have ever owned. After bringing the bike home, I discovered my bike has 43mm, USD forks, which are apparently from the 94-96, KX 500 bike. The first owner installed new fork seals on these forks.

KDX220repairsession1006.jpg

KDX220repairsession1007.jpg

I have obtained the KDX 200 service manual, and the KDX 220 Supplement to that manual. I have also obtained a KDX 220 Owners Manual. In addition, I have obtained a KX 500 Owners Manual, which contains a lot of information regarding fork maintenance. :worthy: However, the KX 500 Owners Manual does not address changing the front wheel. 👍

I also acquired a spare, KX 500 front wheel with this motorcycle. However, I have discovered that the axle is rusted into the axle nut on both my KX 500, front wheels. :ride: I can change the wheels by removing the axle clamps on both forks. However, I presume the correct procedure is to first loosen the axle clamp bolts on the right fork, and then to unscrew the axle from the axle nut. Am I correct?

In any event, I need to break the axles from the axle nuts before I can inspect the wheel bearings on both my front wheels. Can anyone offer any advice on the best way to accomplish this? Thank you. :worthy:

Spud :worthy:

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First saturate the thread area with Liquid Wrench penetrant, let sit, and try again. If it still won't break, heat the nut with a torch (not the axle so much, the idea is to expand the nut away from the axle) and try again.

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I would not be afraid to pull both axle caps off, and work on the axle away from the forks. Then you can apply heat if needed without risking fork damage.

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First saturate the thread area with Liquid Wrench penetrant, let sit, and try again. If it still won't break, heat the nut with a torch (not the axle so much, the idea is to expand the nut away from the axle) and try again.

Thank you for your reply, Sputter. :ride: As you can see in the photograph below, today I successfully removed the front wheel that was mounted on my bike! :worthy:

KDXWheelandBrakerotorrepair007.jpg

However, I now need to persuade the axle out of my spare, KX500 wheel, shown below. 👍

KDXWheelandBrakerotorrepair004.jpg

I have saturated the axle and axle nut with PB Blaster Penetrating Oil. I have also applied heat from my propane torch. However, I will now also give the Liquid Wrench a try. :worthy:

Spud :worthy:

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I would not be afraid to pull both axle caps off, and work on the axle away from the forks. Then you can apply heat if needed without risking fork damage.

Thank you for your reply. 👍 Now that I have successfully removed the wheel mounted on the bike, I can safely try a variety of methods to "persuade" the axle out of my spare wheel. :worthy:

Spud :ride:

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