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Discussion Starter #1
I found the dreaded crack at the axle hole in the swingarm of my 2000 Roadglide. It's a known issue with '99-2001 baggers, happened to a couple other guys I know.

Rather than weld mine, I want to replace it with a later model, stronger swingarm and 1" axle from an '05. Anybody done this swap?

I got a deal on the '05 swingarm, wheel, axle, brake caliper, etc. from a friend who did a trike conversion. One thing I'm not sure about is the pivot shaft. Anybody know if it's the same size on the '00 and '05?

And, can I use the original '00 wheel with 1" bearings?

I will be replacing all bushings and bearings, etc. while I'm in there. Anything else I should know or look out for?

Thanks in advance.
 

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I had a broken swing arm on my '01, but ended up replacing with the same style swing arm so I have no experience with upgrading to a newer one.

However, Howard at Motorcycle Metal would be the guy to ask - his web page should also answer most of your questions:

http://www.motorcyclemetal.com/gpage14.html

I have not dealt with Howard myself (yet). But I have heard good things (on this site) about him and that he is very knowledgeable in Harley suspensions.
 

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There are some companies that do the rear swing arm bushing kits that allow you to do that.
http://www.motorcyclemetal.com/gpage14.html
https://www.ccesd.us/index.php?main_page=index&cPath=192&zenid=03f9dbaa1601abde0157394b5cdc9b8c
I welded mine on my 99 Ultra. The first time it broke again, looking at it I realized where the problem was & changed that. The axle is tappered so on one side of the left arm the axle is 3/4" but as it goes through the arm it is 5/8". So I took my axle nut to my machinist & had him turn the nut down to the 3/4" (like the old mag lug nuts) on the end with out the crown for the cotter pin. I think I have around 40K on it now with no problems, but I also reinforced it there big time.
http://imageshack.com/a/img251/2037/1000816z.jpg[/IMG




Good luck
 

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From the part numbers, the Pivot Shaft and shaft spacers changed in 2002 model year.
If you do use the newer year parts, be sure to replace the later year shaft too.

A good way to make sure of the correct parts is to get a Part Catalog from the year of parts used.
 

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Discussion Starter #5
I had a broken swing arm on my '01, but ended up replacing with the same style swing arm so I have no experience with upgrading to a newer one.

However, Howard at Motorcycle Metal would be the guy to ask - his web page should also answer most of your questions:

http://www.motorcyclemetal.com/gpage14.html

I have not dealt with Howard myself (yet). But I have heard good things (on this site) about him and that he is very knowledgeable in Harley suspensions.
Thanks for the info, I'll check his kit out.
 

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Discussion Starter #6
There are some companies that do the rear swing arm bushing kits that allow you to do that.
http://www.motorcyclemetal.com/gpage14.html
https://www.ccesd.us/index.php?main_page=index&cPath=192&zenid=03f9dbaa1601abde0157394b5cdc9b8c
I welded mine on my 99 Ultra. The first time it broke again, looking at it I realized where the problem was & changed that. The axle is tappered so on one side of the left arm the axle is 3/4" but as it goes through the arm it is 5/8". So I took my axle nut to my machinist & had him turn the nut down to the 3/4" (like the old mag lug nuts) on the end with out the crown for the cotter pin. I think I have around 40K on it now with no problems, but I also reinforced it there big time.
http://imageshack.com/a/img251/2037/1000816z.jpg[/IMG




Good luck
Thanks for the info!
 

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The swing arm on my 99 road glide broke as well...and like you I found tons of info about this issue but my understanding is when Harley changed their swing arm construction in 84 to box beam HSS that is when the issue started. In 02 they reverted to a style not unlike the 83. Only issue, is in 02 they changed the wheel axle and pivot axle diameters and though there are a couple places that sell bushing retrofit kits, they are pretty pricy not to mention you would have to get a new swing arm regardless. I applied the parameters of my swing arm dims into a 3D parametric solid modeler and queried what the strength would be if I were to weld 4140 chrome moly to three sides of the swing arm and shorted the axle spacer by the same 125 thou I added in CM. The mathematical results were good as the math says with the torque being applied (and my torque is high having a jims 120 with all sorts of s&s and sqreaming eagle race stuff) that the strength would be about 5 times stronger than the default... so that what I did...I welded chrome moly to three sides of the swing arm (.125 inches thick) and shortened the wheel spacer by the same amount and the bike is good as new...actually better. I am lucky I didn't get dumped.

more pictures are available if anyone cares to see
 

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