Topic: Flush axle and fork lower cap (Read 4186 times)

porthole · « **on:** March 16, 2008, 12:11:15 PM »

I put my new flush axle kit and the billet fork cap on last night.

Couple of observations.
About 10 minutes after admiring it it seemed like it was there all along? Lost its glory quickly!

Now I can't wait to get the bike next to some other big bikes with the big Ugly Betty knobbers sticking out the sides so it will look slim and trim again.

Another thing is the install.
I would strongly suggest you have a bolt with about 2.5 inches of thread to draw down the left side flush cap "before" you start.

I don't see how you can draw the flush cap into the lower with the axle as suggested in the directions.

Fortunately, from all my years in the auto field I had a wheel bearing puller that had the correct size thread, and it is hardened to boot.

I also had a couple of roller and ball bearing thrust washers that made the job a little easier.

Finished up it looks great

Thanks to Puzzled for making these available to us.

Talon · « **Reply #1 on:** March 17, 2008, 10:04:33 AM »

I really like mine too, does make the front end look much cleaner. I pulled the threaded flush mount cap in with the axle, used my 1/2 drive, had to use a little pressure, but wasn't bad. Good price too!

porthole · « **Reply #2 on:** March 17, 2008, 08:20:10 PM »

Quote from: Talon on March 17, 2008, 10:04:33 AM

I really like mine too, does make the front end look much cleaner. I pulled the threaded flush mount cap in with the axle, used my 1/2 drive, had to use a little pressure, but wasn't bad. Good price too!

I must have been missing something. I don't see how the threads are long enough to draw in the cap, unless, and I didn't look inside the fork tube, there is a boss on the inside the opening.

Did you run the axle through the spacers and the wheel maybe?
That I didn't try.

Talon · « **Reply #3 on:** March 19, 2008, 02:40:50 PM »

Quote from: porthole on March 17, 2008, 08:20:10 PM

I must have been missing something. I don't see how the threads are long enough to draw in the cap, unless, and I didn't look inside the fork tube, there is a boss on the inside the opening.

Did you run the axle through the spacers and the wheel maybe?
That I didn't try.

Yea, There's a shoulder on the axle, I put it all back together, left the fork cap loose and tightened up the axle until the threaded cap was flush on the other side, then backed off the axle and re-tightened it to spec, tightened the BAHFC and was done.

porthole · « **Reply #4 on:** March 19, 2008, 04:09:47 PM »

OK, that makes sense. But, I have to say, the way I did it has to be better. Using a bolt, nut and "bearing" thrust washer takes puts all the load on the tube and not on the threaded cap.

I'll post a picture later of what I used.

Talon · « **Reply #5 on:** March 19, 2008, 04:23:02 PM »

Quote from: porthole on March 19, 2008, 04:09:47 PM

OK, that makes sense. But, I have to say, the way I did it has to be better. Using a bolt, nut and "bearing" thrust washer takes puts all the load on the tube and not on the threaded cap.

I'll post a picture later of what I used.

It never tightened up on the bearings, the shoulder on the axle went flush against the back side of the far side hole in the lower tube, it's solid there, then I threaded the cap on the end, hand tightened the axle to get it threaded as far as I could. Then I just tightened the axle, the shoulder on the far side held the axle and pulled the cap in. I would agree, is you had a puller you could get in there without marring the cap or fork tube It would be nice. I didn't have anything like that, I talked to Puzzled, (Mike) before installing, and he recommended the way I did it.

porthole · « **Reply #6 on:** March 19, 2008, 04:32:11 PM »

When I take the pics I'll also measure the bolt I used.

Just a suggestion to anyone else trying it, I would definitely use the bolt and get one before you start the job.

I just don't like the idea of the steel axle using the aluminum tube (the boss on the inside ) as a thrust washer.

I thought that my end cap was very tight going in, I'm sure it is not going to pop out!

Puzzled · « **Reply #7 on:** March 19, 2008, 08:10:08 PM »

It won't pop out, lol they are a bugger to get back out though. I've had to take several out lately in order to lower their bikes. Sure wish they would have thought of that first.

I use the axle to draw the cap in. I like the wheel to be in place along with the spacers. The cap will draw in before the wheel bearings move or before anything else bad happens.

I removed a set of wheel bearing tonight and let me tell you those bastids' are in there. Even with the Jim's tool I had to pust some a$$ behind the wrench. That cap is MUCH easier to pull in.

porthole · « **Reply #8 on:** March 20, 2008, 08:56:13 AM »

Quote from: Puzzled on March 19, 2008, 08:10:08 PM

It won't pop out, lol they are a bugger to get back out though. I've had to take several out lately in order to lower their bikes. Sure

As tight as that was going in, I think I would put it on a press to pop it back out. I thought about that while installing.
With the wheel off I have a puller that would probably work, just use a spacer that grabs the outside of the insert, instead of pushing on the center.

Do you put new end caps on or just reuse the originals?

Are the ends available in case you bugger it up?

Puzzled · « **Reply #9 on:** March 20, 2008, 09:23:02 AM »

Quote from: porthole on March 20, 2008, 08:56:13 AM

As tight as that was going in, I think I would put it on a press to pop it back out. I thought about that while installing.
With the wheel off I have a puller that would probably work, just use a spacer that grabs the outside of the insert, instead of pushing on the center.

Do you put new end caps on or just reuse the originals?

Are the ends available in case you bugger it up?

To remove the knurled end cap I use a blunt end brass punch and a decent sized hammer. Sounds crude when typed I know. If your trying to get the 6MM bolt out for the fork tube internals the axle cap does not have to come all the way out. It has to be moved about 3/16 of an inch. This is just enough to squeak the bolt by and not remove the cap from the lines left by the knurls.

As far as a replacement cap, good question. I'll inquire. I found a set on eBay once and they were as much as a new axle!

Chief · « **Reply #10 on:** March 20, 2008, 09:36:58 AM »

Couldn't you press the end cap in with a suitable clamp? Protect the surfaces on both sides and press it in that way?

RJ749 · « **Reply #11 on:** March 20, 2008, 09:44:17 AM »

If you install the flush axle and BadAss caps, does this impact removing the wheel for tire replacement (or fender replacement, don't ask) ?

Puzzled · « **Reply #12 on:** March 20, 2008, 09:48:15 AM »

Quote from: Chief on March 20, 2008, 09:36:58 AM

Couldn't you press the end cap in with a suitable clamp? Protect the surfaces on both sides and press it in that way?

It would have to be a pretty big clamp as it takes a little bit of a$$ to draw the cap in. This is why I like the axle as it is 1" round and you can get a 1/2" drive ratchet on it.

Puzzled · « **Reply #13 on:** March 20, 2008, 09:49:35 AM »

Quote from: Rjob749 on March 20, 2008, 09:44:17 AM

If you install the flush axle and BadAss caps, does this impact removing the wheel for tire replacement (or fender replacement, don't ask) ?

No it does not as the stationary cap we're talking about would not have to come back out. I saw the fine print!

porthole · « **Reply #14 on:** March 20, 2008, 09:52:07 AM »

Quote from: Rjob749 on March 20, 2008, 09:44:17 AM

If you install the flush axle and BadAss caps, does this impact removing the wheel for tire replacement (or fender replacement, don't ask) ?

I think the only impact would telling whoever is doing the removal how to do it.

Only difference is; instead of removing a nut and washers on the left side (stock) you loosen the cap on the right side and remove the axle. The axle has a hex head and screws into the cap.

As neat as this is you should already have had it in the tool box awaiting the arrival of the bike

You know Roger, with as long as it took to get the bike here, the "boxes" should have been pretty well stacked up.

RJ749 · « **Reply #15 on:** March 20, 2008, 09:54:39 AM »

Quote from: porthole on March 20, 2008, 09:52:07 AM

I think the only impact would telling whoever is doing the removal how to do it.

Only difference is; instead of removing a nut and washers on the left side (stock) you loosen the cap on the right side and remove the axle. The axle has a hex head and screws into the cap.

As neat as this is you should already have had it in the tool box awaiting the arrival of the bike

Yo know Roger, wit as long as it took to get the bike here the "boxes" should have been pretty well stacked up.

I have it on the SEUC, it's still rain season out here and tomorrow they're predicting snow, it gives me something to do if I spread it out.

Like the battery yesterday along with some waxing and touch up

porthole · « **Reply #16 on:** March 20, 2008, 09:54:56 AM »

Quote from: Puzzled on March 20, 2008, 09:23:02 AM

To remove the knurled end cap I use a blunt end brass punch and a decent sized hammer. Sounds crude when typed I know. If your trying to get the 6MM bolt out for the fork tube internals the axle cap does not have to come all the way out. It has to be moved about 3/16 of an inch. This is just enough to squeak the bolt by and not remove the cap from the lines left by the knurls.

As far as a replacement cap, good question. I'll inquire. I found a set on eBay once and they were as much as a new axle!

Is this 6mm bolt something that comes out when doing the Traxxion upgrade?
If so, I think I'd like to have a spare cap. Maybe you could check into that Mike. if it is not unreasonable ......................

Puzzled · « **Reply #17 on:** March 20, 2008, 09:57:35 AM »

Quote from: porthole on March 20, 2008, 09:54:56 AM

Is this 6mm bolt something that comes out when doing the Traxxion upgrade?
If so, I think I'd like to have a spare cap. Maybe you could check into that Mike. if it is not unreasonable ......................

I will say yes as if anything has to come out of the tubes that 6MM bolt has to be loosened.

I'll check on replacement caps.

porthole · « **Reply #18 on:** March 20, 2008, 10:07:09 AM »

Quote from: porthole on March 20, 2008, 09:54:56 AM

Maybe you could check into that ............ if it is not unreasonable ......................

By unreasonable I mean in price, not in you doing it

skreminegul07 · « **Reply #19 on:** March 21, 2008, 04:21:09 PM »

I finally got to use this

porthole · « **Reply #20 on:** March 21, 2008, 10:54:52 PM »

Puzzled already has plenty of good pictures of the axle and cap on his "axle and cap thread", as well as his two different "wheels for sale" threads.

porthole · « **Reply #21 on:** October 04, 2009, 09:59:17 AM »

Quote from: Puzzled on March 20, 2008, 09:57:35 AM

I will say yes as if anything has to come out of the tubes that 6MM bolt has to be loosened.

I'll check on replacement caps.

Mike - any updates on replacement caps?
Will probably be pulling the forks out over the winter and send back to Georgia.

Puzzled · « **Reply #22 on:** October 04, 2009, 11:14:28 AM »

WOW this is an old thread.

You can take the left side cap out without damaging it as I have done this a few times.

With that said YES I have replacement caps.

They run something like $30 plus shipping.

porthole · « **Reply #23 on:** October 04, 2009, 01:46:27 PM »

Alright, just checking. Would rather know they are available now instead of "then"

I'll be taking the bike to the shop soon for tires, remember the axle & cap torques?

09S/E roadglide · « **Reply #24 on:** October 04, 2009, 09:15:44 PM »

Quote from: porthole on October 04, 2009, 01:46:27 PM

Alright, just checking. Would rather know they are available now instead of "then"

I'll be taking the bike to the shop soon for tires, remember the axle & cap torques?

how bout some pics of the new shiny stuff !!

Puzzled · « **Reply #25 on:** October 04, 2009, 09:23:32 PM »

See reply #20.

porthole · « **Reply #26 on:** October 04, 2009, 10:08:14 PM »

Quote from: 09S/E roadglide on October 04, 2009, 09:15:44 PM

how bout some pics of the new shiny stuff !!

Flush axle kit and Bad As Hell lower cap.

porthole · « **Reply #27 on:** October 04, 2009, 10:26:30 PM »

Quote from: 09S/E roadglide on October 04, 2009, 09:15:44 PM

how bout some pics of the new shiny stuff !!

This is one of those upgrade you really don't appreciate - until your next to another bike that doesn't have the flush axle and cap.

09S/E roadglide · « **Reply #28 on:** October 05, 2009, 07:14:20 AM »

Wow !!! thx for the pics. once again thanks for spending more money on the bike !! Is that a HD part?

Fired00d · « **Reply #29 on:** October 05, 2009, 07:21:54 AM »

Quote from: 09S/E roadglide on October 05, 2009, 07:14:20 AM

Wow !!! thx for the pics. once again thanks for spending more money on the bike !! Is that a HD part?

I believe these two threads will hold the info on those parts...

Flush mount hidden front 1" axles

Bad AS Hell fork end cap

Ride Safe,
Fired00d

porthole · « **Reply #30 on:** October 05, 2009, 10:37:01 AM »

Quote from: 09S/E roadglide on October 05, 2009, 07:14:20 AM

Wow !!! thx for the pics. once again thanks for spending more money on the bike !! Is that a HD part?

Rick - You didn't notice all the caps at Maggie Valley?

Mike aka "Puzzled" on this site sells them. Nice - kinda stealth upgrade.

Of course Gary doesn't have though

Fired00d · « **Reply #31 on:** October 05, 2009, 11:12:04 AM »

Quote from: porthole on October 05, 2009, 10:37:01 AM

Rick - You didn't notice all the caps at Maggie Valley?

Mike aka "Puzzled" on this site sells them. Nice - kinda stealth upgrade.

Of course Gary doesn't have though

Nope, sure don't... When everyone is getting the same aftermarket parts then their bikes look stock... and my stock looks custom.

Ride Safe,
Fired00d

Twolanerider · « **Reply #32 on:** October 05, 2009, 11:17:39 AM »

Quote from: Fired00d on October 05, 2009, 11:12:04 AM

Nope, sure don't... When everyone is getting the same aftermarket parts then their bikes look stock... and my stock looks custom.

Ride Safe,
Fired00d

Part number 99999-09. Custom SE OE Butt Ugly Tour Pak Hinges.

Fired00d · « **Reply #33 on:** October 05, 2009, 11:20:22 AM »

Quote from: Twolanerider on October 05, 2009, 11:17:39 AM

Part number 99999-09. Custom SE OE Butt Ugly Tour Pak Hinges.

Yes sir!!!!! Love them!!!!

Ride Safe,
Fired00d

Twolanerider · « **Reply #34 on:** October 05, 2009, 11:23:32 AM »

Quote from: Fired00d on October 05, 2009, 11:20:22 AM

Yes sir!!!!! Love them!!!!

Ride Safe,
Fired00d

No one really needs fancy bike parts when they've got a flamed pimp daddy hat and a Screamin' Eagle thong

.

Fired00d · « **Reply #35 on:** October 05, 2009, 11:28:45 AM »

Quote from: Twolanerider on October 05, 2009, 11:23:32 AM

No one really needs fancy bike parts when they've got a flamed pimp daddy hat and a Screamin' Eagle thong .

Pimp'n ain't easy.

Ride Safe,
Fired00d

Talon · « **Reply #36 on:** October 05, 2009, 03:12:36 PM »

Author Topic: Flush axle and fork lower cap (Read 4186 times)