Something this picture isn't showing is that there is also a metal bushing inside the rubber grommet. Could this be the problem? Ricks69 and I still think the new bolts have a different pitch thread.
I actually just went through all of this, I had to press out the new rubber grommets because they were too long and replace with the older ones. You can search for a DIU on how I pressed them out with a simple vise, C-clamp and a 1 1/2 inch nipple. (Hope you guys don't mind, it was on the XLForum: http://xlforum.net/vbportal/forums/s....php?t=1614501)

 

I got them on yesterday........

took a tap and cleaned out the hole where the upper bolts screws into. Some gunk was in there, more than likely thread lock or something. It was still tough as hell. On the other side, the bolt came out and went back in like I expected.........

On a side the note, I like the 444 shocks. I wouldn't say night and day difference but definitely smoother.

Just ordered the fork springs this morning. I think I'll let the dealer install those.

 

Changing out the front springs is pretty easy, as long as you have a bike jack to lift the bike with. I bought the front springs from Dennis Kirk as well as the socket they sell - which is not a requirement, but is much nicer for the job than a regular socket or wrench.

Just swapped out the rears for Progressive 440's and replaced the front springs on my '98 in less than an hour - not counting the break I took to give the front forks some extra "drip" time.