Can someone tell me why 2 wheels, same shaft size, same diameter, same width, brakes bolt on the same, won't fit the same bike? The only difference is that one wheel is cone and roller style bearing, and the other is a sealed bearing style. Both measuring 3/4" i.d.

 

Generally speaking, they should fit, but you'll typically need to change the spacer sizes (width). Assuming your talking about your Sporty, and pre vs post 2000 wheels.
With sealed bearings, the spacers press against the outside on the inner bearing race and the bearing itself is wider. With non-sealed bearings, the spacers fit inside the the bearing dust seals.
I'm running a 19" 1998 HD Thunderstar wheel on my 2004 and just had to change the spacer sizes to make it fit. Finding the right size spacer can take a bit of trial and error, but buying an assortment pack of axle spacers helps, unless you're equipped to machine you're own.

 

Yes, I'm sorry, I was referring to my sportster. Of course, the HD dealer said it would work IF I changed my left fork tube to a different caliper mount, caliper, and rotor. They didn't know if the rear would work or not. I was hoping to put a set of the seven spoke mags on my ride to get rid of the 13 spoked ones. Dang it, I knew I should have asked on here first!

 

The only change required for the caliper was installing a couple of small washers on the caliper mounting bolts between the the fork tube and the caliper, to move the caliper away from the leg and a little bit closer to the wheel so that it was centered with the rotor.

 

Any idea on the rear one?

 

No, I haven't changed the rear.
Also, you didn't say what year you're bike is, so I don't know if you're going from sealed to non-sealed or the other way around. If your bike is pre 2000 and you're trying to go to a sealed bearing wheel, your caliper may wind up too close to the wheel (the opposite of my situation) and that might mean a new leg or some machine work.

 

Mine is an '02, I was wanting to go from sealed to old school cone and roller type.

 

IMO, unless the wheel you want is only available with non-sealed and the price is a steal, I wouldn't go that route again.
Non-sealed bearings should be re-packed every 10,000 miles and that means pulling the wheels and bearings. I get about 25,000 miles out of a front tire, but I still have to pull the front wheel off every 7-8 months (that's 10,000 miles for me) to grease the bearings. I got a steal of a price on the wheel, but the bearing service is a pain in the *** if you put on a lot of miles.

 

My friend, you just made me go from mad as hell at the dumb dealership to happy as a pig in slop!! The repacking issue would have been a HUGE ordeal for me, as I don't have the equipment to remove the wheels myself, or the know how! SO, next time you're near Myrtle Beach, hit me up, the drinks are on me!

 

Hehe, no problem.
You can use any wheel with sealed bearings from 2000 - 2008? (before HD went to the hollow axle with the crappy 25mm bearings). If the bearing axle size is wrong, just change out the bearings for the correct axle size. The bearing OD size is the same for both 3/4 and 1" axles.