This is not a step-by-step install instruction. It is rather an explanation of the principles involved in placement of the bearings & spacers plus the overall concept of alignment.

Here is a general diagram of the front wheel in the forks with various parts identified. The illustration uses sealed-bearings but the concepts apply to use of Timken bearings (with shims) as well.

When installing bearings, install the brake-side first so that the bearing is fully seated in the hub. This helps to keep the brake rotor alignment while using the previous external bearing spacer. Then place the internal hub spacer into the wheel and install the other bearing. Be sure that the internal hub bearing spacer is a few thousandth longer than the spacing of the hub bearing seats - this guarantees that the internal spacer will be in full contact with the inner race of the 2nd bearing. The outer race of the 2nd bearing should NOT fully seat against the hub cavity - You must stop the bearing insertion when the inner race of the 2nd bearing comes in contact with the inner spacer.

Notice in the diagram that there is a small GAP between the outer race of the 2nd bearing (right-side of forks) and the seat of the hub cavity. This is important to maintain as described above.

When re-installing the wheel to the forks, the axle will slip completely thru the right-side fork. It will clamp the external spacer, the right-side bearing inner race, the inner spacer, the left-side bearing inner race and the second external spacer to the left-side fork. At this point, when you tighten the nut on the axle, the wheel assembly is only clamped to the left-side fork. The right-side fork is then clamped to the wheel assembly by the Pinch Bolt which now allows both forks to support the front wheel assembly.

If you are changing from a stock wheel, be sure your external and internal spacers are properly sized. The inner spacer must be a few thousandth longer than the measured distance between the two bearing cavities of the hub. The external spacers need to be the correct length to properly align the brake rotor with the brake caliper and also to center the wheel between the forks.

Take Note:

• Custom bearings can be found to match a wheel to an axle size (and there are OEM kits for 2000-later wheels) but the original bearings varied in width (Timken, Double-Row Bearing, Single-Row Bearing) - This also means that internal & external spacer lengths varied.
  • The difference between two 15mm bearings & two 21mm bearings is 12mm = .472“
• If placing a 21mm width bearing in a wheel designed for bearings of 15mm width, you will have 6mm of the bearing outside the hub face (meaning the centerline of the bearing is 3mm more outward). There is no collected data on whether this configuration represents a problem, but it would seem that, when properly spacered and clamped on the axle, this variation should be functional. Safety is the responsibility of each rider.
  • See this XLForum thread.

Timken Tapered Bearings are a 2-piece angular roller bearing. This type wheel bearing was used up thru 1999, after which, unitized sealed bearings replaced them.

The first part is a simple outer race while the second part is not only the inner race but includes the roller bearings in a cage. When installed, in addition to using the two bearing sets, there is a hub spacer, a spacer washer and, possibly, SHIM washers. Because there must be a precise space between the inner & outer races of each bearing set, shims are used in setting that precise distance.

The outer races are simply installed fully into the hub cavity on each side of the wheel. Then, on the brake rotor side, the selected shims are installed, followed by the spacer washer, then the inner bearing race (with rollers) and the oil seal. On the opposite side of the wheel, you must insert the hub spacer (to fully contact shim washers), then the 2nd inner bearing race (with rollers) followed by the oil seal. Then the proper wheel spacers are inserted through the center of the oil seals to make contact with the inner races on each side.

When assembled, between the front forks (or rear swingarm), the axle clamps the assembly together. You must then check the End Play (the gap between the inner & outer races) to be sure you are within the specs (typically, .002” to .006“ combined total for End Play of the assembly). Check your factory manual for the recommended procedure.

The Pre-1992 models used a selection of different length center hub spacers but without the SHIMs. See the Center Hub Spacers listed below.

http://xlforum.net/vbportal/forums/showthread.php?t=1973858
http://xlforum.net/vbportal/forums/showthread.php?t=1457354
http://xlforum.net/vbportal/forums/showthread.php?t=257343

Also:

ReddTigger - http://xlforum.net/vbportal/forums/showthread.php?t=1608830
Decman - - - http://xlforum.net/vbportal/forums/showthread.php?t=1788732
Folkie - - - http://xlforum.net/vbportal/forums/showthread.php?t=1635642

(From HD Parts Catalogs and online fiche sources ¹⁾ unless noted otherwise)

• The same axle is used for dual disc / single disc wheels as well as cast / spoked wheels within the same wheel year models (not bike year models).

Click on a pic to enlarge:

Used 1988-1996 Front Steel Axle 43895-87 19)

Used 1998-1999 3/4“ Front Stainless Steel Axle 43895-87B 20)

Used 2000-2007 3/4” Front Stainless Steel Axle 43895-00 21)

Front axle comparison: 98-98 (back) vs 00-07 (front) 22) Pics skewed / Same overall length w/ longer head

*Ref: https://cad.timken.com/item/tapered-roller-bearings-ts-tapered-single-/tapered-roller-bearings-ts-tapered-single-imperi-2/item-27295

(From HD Parts Catalogs and online fiche sources ⁷²⁾ unless noted otherwise)

• Custom rear bearings can be found to match a wheel to an axle size but the original bearings varied in width (Timken, Double-Row Bearing, Single-Row Bearing) - This also means that spacer lengths varied.
  • Note: Difference between two 15mm bearings & two 21mm bearings is 12mm = .472“
• Don't forget the Swingarm slots & Axle Adjusters need to match the axle diameter. Axle Adjusters changed from '04-earlier (centered) to '05-later (flush to inside)
• NOTE: If placing a 21mm width bearing in a wheel designed for bearings of 15mm width, you will have 6mm of the bearing outside the hub face (meaning the centerline of the bearing is 3mm more outward). There is no collected data on whether this configuration represents a problem, but it would seem that, when properly spacered and clamped on the axle, this variation should be functional. Safety is the responsibility of each rider.
  • See this XLForum thread.

*Ref: https://cad.timken.com/item/tapered-roller-bearings-ts-tapered-single-/tapered-roller-bearings-ts-tapered-single-imperi-2/item-27295

Part Numbers listed below for 2000-Later Wheel Bearings & Spacers
(Based on http://www.harley-davidson.com/app-content/service/isheets/-J04069.pdf)

For 3/4” Axle - Bearing .. .. 9267
For 1“ Axle - Bearing .. .. .. 9247
For 25mm Axle - Bearing . . 9276

For 3/4” Axle . ??“ Center_Spacer .. .. .. .. 43608-00
For 1” Axle .. .. .. 4.8“ Center_Spacer .. .. 43517-00
For 25mm Axle … 133mm Center_Spacer . 41900-08*
(HD calls these Axle Sleeves)

For 25mm Axle - 5mm Brg Shim Spacer .. .. 43904-08

(?? 25mm ABS Axle Bearing .. 9252)

The axle part numbers vary somewhat by year/model - Check for your specific model.
*Some spacer part numbers may vary depending on the exact wheel

Part Numbers For Wheel Bearing Install Kits for 2000-later Wheels:
Front
2000-2007 - Using 3/4” Axle .. .. .. 43833-07A
2008-up — Using 25mm Axle . . .. 41452-08C

Rear
2000-2004 - Using 3/4“ Axle .. .. ..43854-08A
2005-2007 - Using 1” Axle . .. .. .. 43861-08A
2008-up — Using 25mm Axle .. .. 43878-08B (BUT NOT 2011-later XL883L)
(HD 43878-08B comes with 2-25mm bearings, one 5mm spacer, a 133mm & 147mm center_spacer and valve stems)

http://xlforum.net/vbportal/forums/showthread.php?t=1608830
ReddTigger commented:
Some early model wheels (made between 2000-2004?) may have a center hub hole that is only
clearanced for 3/4" axle spacers. This is not the surface where the bearings mount, but
rather the hole between left & right sides of the hub where the center_spacer goes through.

To use these wheels with a later axle size (ie., 1" or 25mm) you will need to bore that
center hub hole to be slightly larger than the OD of spacer being used. DO NOT BUGGER UP
THE BEARING SURFACES! The exact size of this enlargement is not critical but it must be
done well. The center_spacer must move freeling in that opening. If you have any question
of your ability to do this, find a machine shop who will enlarge that hole correctly.
Take your center_spacer along to be sure the final hole is larger than the spacer OD.
With skill, you should be able to use the proper size bit or a unibit to do this yourself.

http://xlforum.net/vbportal/forums/showthread.php?t=1788732
Decman describes converting Timken angular roller bearings to sealed ball bearings
and includes a conceptual diagram.

The following information is provided for research only
THIS IS NOT A RECOMMENDATION TO USE ANY OF THESE PARTS

3/4" Sealed Bearing - OEM 9267 --- J&P 202-182
1" Sealed Bearing --- OEM 9247 --- J&P 202-183
25mm Sealed Bearing - OEM 251571 - J&P 203-785

3/4" Timken Tapered Roller Bearing - OEM 9052 - J&P 202-169


Drag Specialties A25-1002 - Wheel Bearing/Seal Kit Front Or Rear 3/4 ID Timken
------------------------------------------------------------------------------
Advert Says: Bearings are premium EMQ quality featuring low-drag,
double lip rubber seals that keep water out and improve grease retention
Replaces OEM #9052
Contains all necessary bearings and seals required for each individual wheel application
Tapered Roller Bearing Specifications
.. (2) LM11910 Cups (1.781" OD)
.. (2) LM11949 Cones (.75" ID)
.. Width of Cone/Cup Assembly: .653"
.. (2) D5118 Seal (1.781"OD x 1.12"ID x .40"Width)


(Note: Providing information only - not recommending the use of these parts)
(The following is a sealed bearing kit as an alternative to Timken Bearings #9052)
(Applicable to 1991 to 1999 XL Rear Wheel w/Belt Drive)
(These bearings, theoretically, will also replace 3/4" front axle Timken bearings but ...
... will require a different set of hub & wheel spacers to match the front wheel hub width)

V-Twin No: 44-2995 - Rear Sealed Wheel Bearing Conversion Kit for 3/4" Axle
---------------------------------------------------------------------------
Retro fit for models with Timken bearings. Double row wheel bearings eliminate wheel play,
have a longer wear life, require no adjustment. Kit includes two bearings, center spacer
& spacers. Fits 1991-99 XL.
Double Row Sealed Wheel Bearing - OD=1.782" - ID=.747" - Width=.81"
Center_Spacer length=4.5"

2008 and up hubs are not sold separately but rather as an assembly with the rim

Introduced only for Japan model Sportsters, the Isolated Drive System improves rider comfort and ride quality by dampening the mechanical noise and vibration caused by the engine's torque pulses. The rubber compensation elements act like a cushion, absorbing the power pulses from the engine. The motorcycle feels more refined, and is quieter while accelerating, shifting and cruising⁸⁶³⁾. It uses a special sprocket (same 68T count as U.S. models), a compensator bowl, (isolators between the two) and inner and outer spacers on the sprocket on cast rear wheels only beginning in 2004 ⁸⁶⁴⁾and including laced rear wheels beginning in 2007⁸⁶⁵⁾.

• Rim size and contour are cast or stamped into exterior surface of rim.
• Example: T19x2.50 CO DOT. “T” indicates the rim conforms to 'Tire and Rim Association' standards, 19 is the nominal diameter of the rim in inches measured at the bead center diameter, 2.5 is the width of the bead seat measured in inches, CO designates the rim contour, DOT means the rim meets Dept. of Motor Vehicle Standards. ⁸⁶⁶⁾
• See also Factory Rear Wheels and Factory Front Wheels
• See also Tire 101 for decoding tire sizes, conversion, cross reference charts, etc.