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Old 12-02-2012, 02:56 PM   #11 (permalink)
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If you look closely at the end of the axle you can see where it is bent in and touching the first thread.
http://www.Harley-Davidsonforums.com...ey-axle-1.html

http://www.Harley-Davidsonforums.com...ey-axle-2.html
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Old 12-02-2012, 03:10 PM   #12 (permalink)
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Your link to the images does not work Red, but we all know what the problem is. There is no magic fix or trick to divulge for your problem. I understand you want to do this yourself...short of grinding off the offending end (or take a band saw to it) then cleaning up the threads again, there is little else that can be done. Hide the hammer and if you must, use a very small rubber mallet sparingly next time.
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Old 12-02-2012, 03:39 PM   #13 (permalink)
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So should the front axle pull out easily once the hardware has been removed or should it be a tight fit and need to be knocked out with a mallet?
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Old 12-02-2012, 03:56 PM   #14 (permalink)
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To ease removal/installation use your lift to position the wheel so it is barely in contact with the ground. You may use a mallet to help get the axle started on it's way if needed, but only sparingly and never on the threaded end...use a pointed drift in the center of the axle instead.

Going back together rarely needs that much effort and again use a rubber mallet only if needed. A skim coat of grease on the shaft will help. The most likely culprit for difficulty will be the right-side lower leg where the pinch bolt clamps the axle shaft, followed by simple misalignment of the hub.

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Old 12-02-2012, 04:03 PM   #15 (permalink)
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Hmmm Something wrong with the axle then. When I installed the axle, and it got to the part of the axle where it steps up I had to smash it good with a hammer to get it all of the way through. The axle is brand new and it sounds like I shouldn't have had to do that.
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Old 12-02-2012, 05:05 PM   #16 (permalink)
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Originally Posted by Redrooster66 View Post
Hmmm Something wrong with the axle then. When I installed the axle, and it got to the part of the axle where it steps up I had to smash it good with a hammer to get it all of the way through. The axle is brand new and it sounds like I shouldn't have had to do that.
Use a micrometer on the threaded end of the axle to rule out expansion due to impact. They're not hardened steel and even using wood can damage them. Not saying its your problem but ive seen it more than once. A micrometer and a few measurements will let you know.

You should never need more than a rubber mallet or nylon hammer to TAP an axle into a bearing set. If you have to force it there's something wrong.
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Old 12-02-2012, 05:29 PM   #17 (permalink)
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If you have to force it there's something wrong.
Sounds like my ex wife ...
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Old 12-02-2012, 05:48 PM   #18 (permalink)
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Sounds like my ex wife ...
I hear ya. I didn't have to force anything in with my ex, once the chloroform kicked in.....
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Old 12-02-2012, 05:51 PM   #19 (permalink)
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Question - Why was a new axle needed in the first place? What year model is your Sportster? Last of the 3/4" axles was in '07...from then on they became 25mm. I'm also assuming you did remove the pinch bolt on the right-side fork lower leg.
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Old 12-02-2012, 05:53 PM   #20 (permalink)
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Use a metal file on the edge of the shaft until 1 thread is slanted a bit

RIDE IT LIKE A MOTORCYCLE
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