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Torque specs

Discussion in 'Technical' started by lee, Mar 14, 2009.

  1. lee

    lee Well-Known Member

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    This might be useful for some of you. I'm printing and laminating this and its going on the garage wall.

    2005 Big Dog Bulldog - Torque specs

    Motor mount bolts 35 ft-lbs
    Spark plugs 18 ft-lbs
    Cam cover bolts 120 inch-lbs
    Tappet screen plug 120 inch-lbs
    Transmission mounts 45 ft-lbs
    Air cleaner to carb 10-12 ft-lbs
    Air cleaner to head bolts 8-12 ft-lbs
    Intake flange bolts 16 ft-lbs
    Carb to manifold bolts 18 ft-lbs
    Neutral switch 10-15 ft-lbs
    Pulley nut 50 ft-lbs + 40 degrees
    Trans drain plug 7-9 ft-lbs
    Pulley cover bolts 18-20 ft-lbs
    Ball ramp cover bolts 35-40 in-lbs
    Trans main / clutch hub shaft nut 80 ft-lbs - red loctite
    Engine drive sprocket nut 150-165 ft-lbs - red loctite
    (Primary fluid 32 oz)
    Outer primary bolts 9 ft lbs
    Inspection cover bolts 9 ft lbs
    Inner primary bolts 15 ft lbs
    Exhaust flange bolts 60-80 in lbs
    Brake rotor mount bolt 50 ft lbs
    Rear pulley bolts 60 ft lbs
    Rear axle 55-65 ft lbs
    Front axle 45 ft lbs
    Front axle pinch bolts 12 ft lbs
    Forward control mount 25 ft lbs
    Lower triple tree pinch 16 ft lbs
    Brake caliper mount bolts 25 ft lbs
    Rear fender strut bolts 25 ft lbs
    Rear shock mount bolts 100 ft lbs
    Upper engine mount to cylinder 35 ft lbs
    Upper engine mount to frame 45 ft lbs
     
    The Dog likes this.
  2. RAW Blue Rider

    RAW Blue Rider Active Member

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    :cheers:
    Thanks for the legwork Lee.:flag:
    Here's the list, alphabetized for quick reference.

    Torque specs

    Air cleaner to carb 10-12 ft-lbs
    Air cleaner to head bolts 8-12 ft-lbs
    Ball ramp cover bolts 35-40 in-lbs
    Brake caliper mount bolts 25 ft lbs
    Brake rotor mount bolt 50 ft lbs
    Cam cover bolts 120 inch-lbs
    Carb to manifold bolts 18 ft-lbs
    Engine drive sprocket nut 150-165 ft-lbs - red loctite
    Exhaust flange bolts 60-80 in lbs
    Forward control mount 25 ft lbs
    Front axle 45 ft lbs
    Front axle pinch bolts 12 ft lbs
    Inner primary bolts 15 ft lbs
    Inspection cover bolts 9 ft lbs
    Intake flange bolts 16 ft-lbs
    Lower triple tree pinch 16 ft lbs
    Motor mount bolts 35 ft-lbs
    Neutral switch 10-15 ft-lbs
    Outer primary bolts 9 ft lbs
    Primary fluid 32 oz
    Pulley cover bolts 18-20 ft-lbs
    Pulley nut 50 ft-lbs + 40 degrees
    Rear pulley bolts 60 ft lbs
    Rear axle 55-65 ft lbs
    Rear fender strut bolts 25 ft lbs
    Rear shock mount bolts 100 ft lbs
    Spark plugs 18 ft-lbs
    Tappet screen plug 120 inch-lbs
    Transmission drain plug 7-9 ft-lbs
    Transmission main / clutch hub shaft nut 80 ft-lbs - red loctite
    Transmission mounts 45 ft-lbs
    Upper engine mount to cylinder 35 ft lbs
    Upper engine mount to frame 45 ft lbs
     
  3. alhall88

    alhall88 UAW

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    Brake rotor mount bolt 50 ft lbs

    I don't think this is correct. You'll strip out those button head allens. I thought it was 17 to 19 on the 5/16 bolts and 25 to 27 on the 3/8 bolts
     
  4. Moespeeds

    Moespeeds Well-Known Member

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    Chrome cap head and button heads are supposed to be grade 8, so I just follow a standard grade 8 chart. I think I actually got mine here somewhere. I usually use wet torque because I generally clean bolts and loctite them before installing.
     
  5. MARV

    MARV Well-Known Member

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    it does state Al's specs in the brake section of my 05 service manual.

    then in the chasis section it says 50 ft/lbs like Lee said.

    :bang: :bang: :bang:



    looks like you's found another mistake in the manual.
     
  6. lee

    lee Well-Known Member

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    you're right. I just looked again. Not great is it. Thanks fellas.
     
  7. BWG56

    BWG56 Guru

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    Hasn't the clutch hub nut been bumped up to 100ft/lb?
     
  8. Raywood

    Raywood The Pirate
    Staff Member Supporting Member Calendar Participant

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    Made this a sticky for quick/easy reference.
    Thanks guys,
    Ray

    :flag: :cheers: :2thumbs:
     
  9. RRRUFF

    RRRUFF Well-Known Member

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    Thanks Lee, this is something I have been wanting to do for a while now but never thought of when I had time.:2thumbs:
     
  10. barhopper

    barhopper Another round please

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    What does plus 40 degrees mean? Just a stupid fuck here.
     
  11. MARV

    MARV Well-Known Member

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    1/8th of a turn

















    approximately :rolleyes:
     
  12. LDO

    LDO The Cleaner
    Staff Member Supporting Member

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    What about handlebar riser bolts? Been going by the bolt grade spec sheet since I've never found anything specific to them...:angry:
     
  13. lee

    lee Well-Known Member

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    nice and snug with some blue loctite...I guess
     
  14. ChimesCFL

    ChimesCFL Member

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    :2thumbs: Great info, I've already copied, pasted and printed it to hang in the shop.

    Thanks!
     
  15. 98sporty

    98sporty Member

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    If you look in the service manual in the chassis section, the table shows that the 5/16 x 18 bolts (if they are grade 8) is about 29 ft Lbs. not the 50 that is shown at the top of the page. I retightened mine to the 29 ft lbs.
     
  16. LDO

    LDO The Cleaner
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    Primary drain plug??:confused:
     
  17. lee

    lee Well-Known Member

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    I just do nice and snug with some paste / tape. My Haynes manual for the HD says .160" to .180" protrusion. Don't know if that helps.
     
  18. Staffy

    Staffy Active Member

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    ????

    Thank Lee - Not sure....My manual says "Upper engine mounting screw to frame 80- ft-lbs with 2760 (Red) loctite" it is a 1/2" bolt so makes sense...
     
  19. thexaulted

    thexaulted Member

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    Does anybody know what the steering head bolt (I guess thats what you call it) on an 03 Chopper should be torqued at?
     
  20. LDO

    LDO The Cleaner
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    On my 03 Mastiff, you tighten the bolt using the 'fall away' method.

    Using a centerline of your tire, measure how much you have to manually push your bars before they fall away on their own. I believe the measurement is 2 inches.

    Do a search on posts by dogvet and I believe he explained it.

    To be very honest with you, I did this after changing out my neck bearings and found that (of course) the left side will always drop sooner since the caliper is on that side!

    I got it close, took it for a ride then tightened it up a bit more until if 'felt' right.

    Also, I found that it was better (and recommended) to tighten it up really good as it helps everything 'set' then loosen up a bit until the proper fall away or your own personal preference.

    Hope this help. Sorry for the lengthy post!:D
     
    JoeHawkins likes this.

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