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
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
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
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.
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.
Thanks Lee, this is something I have been wanting to do for a while now but never thought of when I had time.:2thumbs:
What about handlebar riser bolts? Been going by the bolt grade spec sheet since I've never found anything specific to them...:angry:
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.
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.
???? 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...
Does anybody know what the steering head bolt (I guess thats what you call it) on an 03 Chopper should be torqued at?
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!
