Front axle sticking out a bit to the right

[BenAlpha]

So A few days ago I put my bike in the shop to replace the fork seals.
So I picked my bike and went home and decided to install my new 5-0dro
axle sliders when I noticed the front axle is sticking out a bit to the right.

Went back to the shop, the guy says "It's supposed to be like that".
I showed him a few pictures of other XB's and also a few vague photos
of my XB (didn't have any close ups) so he decided to take out the front
wheel to see what's up (at that moment I noticed he isn't using a torque
wrench) he took out the wheel, showed me that that bearings are ok, that
the axle is ok, and that if he does not tighten the wheel up to the point
where the axle sticks out, the wheel is wobbling between the forks - so it
must be like that. I asked him how is it possible that it wasn't like that before
the bike came in but it is now? he said he doesn't know, and that he can add
a spacer there for me or cut and re-thread the tip of the axle if all I want it to
"flush"

Needles to say I didn't like these answers and went to another mechanic.
The new guy agrees that this is not normal, but also says that the axle and
wheel bearings all seem OK. he also checked the forks and says they are not
effecting this problem. He thinks that the mechanic before him, over tightened
the wheel to the wrong side (front axle is has reversed threading) thus deforming
the axle somehow. We do not have another XB's axle to compare it to nor any
XB bike at all around here actually.

What do you guys think?

some pics (sorry for the size):

 

[Negative]

Well ... Just to add a comparison from another XB ... I literally just walked into the living room to stare at my front axle for about 10 seconds and see if mine was like that .... it's not .... mine is flush on both sides ...

 

[BenAlpha]

Yup, supposed to be "flush" on both sides. [sad]

 

[50dro]

Been talking w/ Ben on this issue...It has me stumped. Here's the only things it could be IMO:

1) Damaged bearing spacer (from over-torquing)
2) Damaged right fork where it rests against the bearing. (from over-torquing)

I feel that the threads in the fork would probably strip before you could stretch the axle...What do you guys think? Have any of you seen this before? I've seen some variation on the "flush-ness" of the axle but never this much. [confused] Thoughts?

 

[03Firebolt9R]

Was the spacer put back in?

 

[user_deleted]

work the problem logically. your axle and front end assembly appeared "normal" to you prior to visit to shop for fork seals and upon picking up the bike things have changed? the problem occurred while at this shop. proper front wheel assembly will yield axle head being approx. 2mm in from fork leg and threaded axle end flush with other leg. i absolutely positively would not ride it until a pro looks at it and diagnoses what's going on there. these front ends are beautifully simplistic in design but improper assembly, bearings being compressed by sideload, defective axle or spacer installed incorrectly or defective will usually result in your problem. the axle cannot compress or stretch but from your pics yours is in bad shape and must be replaced. a likely culprit is crossed threads in the lower axle leg. they are left-hand threads. i suspect someone was installing the wheel, started to thread the axle into the leg, crossed the threads and continued to tighten the axle resulting in what you now see. just a hunch

 

[user_deleted]

benalpha: diagnosis from pics and text difficult to say the least but upon looking once again at the pic you have of your axle, it appears the machined face of the axle flange....the part right below the threaded end...is destroyed and quite possibly the source of your problem. this "face" or machined surface is what generates sufficient side-load upon the bearings and spacer when the axle is torqued. being bitched up as it appears would allow the axle to pull itself into the inner bearing race resulting in among other things threads sticking out of the lower fork leg. IMO

 

[BenAlpha]

@03Firebolt9R - Yes, the spacer is in there properly (was never been taking out)

@Lunaticfringe - A "pro" did look at it, the second guy I went to. But, as I said, he thinks
the problem lays in the axle, but because he's never seen one like this before and because
he can't compare it to another one side by side, he suggests we replace it. He's not sure if it
will fix it though and suggested (as did Sandro) that I ask more Buell riders. I'm actually glad
to hear you think it's the axle.

He also said I can ride with it like that with no fear because the bearings and wheel are spinning
freely and there doesn't seem to be any issues other than the axle sticking out a bit. Do you not
agree with him?

Thanks for the answers and opinions so far!
More ideas and inputs will appreciated !

*And if someone has a good condition front axle for sale, please let me know.

 

[50dro]

Biggest thing is to make sure there are no issues with the alignment of the rotor and the caliper and of course that the rest of the assembly is torqued properly.

 

[netty2424]

possible bent fork?

 

[TooFst]

Well not much help her but I will agree DON'T RIDE IT until you get it figured out. I hate to say it but I'd bring it to a HD stealership, have them figure it out and send the bill to the "shop" that did the axle seals.

 

[BenAlpha]

We don't have HD dealerships in Israel.
The dealership that used to sell Buells (all 7 of them) is gone.

 

[user_deleted]

then do this

http://www.ebay.com/itm/03-Buell-XB...ies&hash=item27d2b317e8&vxp=mtr#ht_1576wt_917

 

[BenAlpha]

Thanks for the link!
The seller does not seem to ship world wide.
I will PM him. also, emailed a few buell parts sites.

 

[BenAlpha]

So.. the new axle fixed the issue.
Attached are photos of the old and new axle side by side.

looks like my new mechanic was right, the mechanic before him torqued the
axle while trying to open the front wheel (not realizing it has reversed threads)
and "stretched" the axle. Look closely, you can actually see the middle of the
old axle is thinner because that's the point where it got "twirled".

The new axle fixed the issue.
Stupid people can do amazing things with power tools.

Case closed.

 

[Cooter]

WOW!
I own a bolt stretch gauge, and I have NEVER seen one go +-.350"(?)!!

Just Wow.

 

[thrstrmech]

cases like this is why I choose to do my own maintenance

 

[sparky300]

^[up]

 

[Matteson]

[up]

 

[konarider94]

wow thats impressive. Must have missed that giant L and arrow that's cast into the fork leg.