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SAS-99 on 2003 BD Chopper

Discussion in 'Metal Fab' started by raeggis, May 18, 2017.

  1. raeggis

    raeggis Member

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    Regarding the assembly of sas-99 on 2003 Big Dog chopper. Pin bolt on gearbox destroys assembly. Can i replace the pin bolt with 3/8 "* 1" unc machine screw?
     
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  2. Th3InfamousI

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    I don't think anyone has done this as everyone said it didn't fit.

    Pin Bolt on the transmission? Not sure I know what you are talking about never seen a Pin Bolt on a BigDog other than the Brake Caliper
     
    #2 Th3InfamousI, May 18, 2017
    Last edited: May 18, 2017
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  3. Mr. Wright

    Mr. Wright Guru
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    Picture please.
     
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  4. raeggis

    raeggis Member

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    It's the bolt on the bottom of the right side I describe on transmission. Possible wrong name on this (pin bolt)
     
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  5. Th3InfamousI

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    It's just a hex bolt, yes? I'm not sure what you would replace it with that would be more low profile?

    Sent from my 2PS64 using Tapatalk
     
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  6. raeggis

    raeggis Member

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    I want low profile om that bolt, so i Will try to use Hexagon Socket Countersunk Screw. Screenshot_20170518-223526.png
     
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  7. Th3InfamousI

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    Except the hole isn't counterbored to accept this kind of bolt. You won't get much of a bite.

    How many do you need to swap out? To get it to fit?

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  8. raeggis

    raeggis Member

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    I will try this anyway. The head of the screw must be at the same level as the underside of the mounting plate.
     
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  9. raeggis

    raeggis Member

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    Is there anyone who can describe the problem. Will cylinders hit the gear box plate? IMG_20170601_223541.png
     
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  10. Mr. Wright

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    Still not sure on what your doing. can you get a picture of where it goes.
     
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  11. Th3InfamousI

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    This unit goes in place of the shocks.

    I am nearly certain the tubes are much too big to fit regardless of bolts. We already run slim shocks on Big dogs and these air rides were made for Harley softails which can accept a larger Diameter shock.

    I believe the diameter of the shock body is going to be too large that the shock eyelets won't bolt up.

    I had an old thread on this unit and I think someone tried it and won't fit.






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  12. Mr. Wright

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    Ok, I see.
     
  13. raeggis

    raeggis Member

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    I apologize for late response, but now sas-99 is mounted on my mc. Pictures show sample assembly. I will come with more pictures later.
     

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  14. Th3InfamousI

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    Well that's neat I'm Curious what you had to do there

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  15. raeggis

    raeggis Member

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    What was needed was to remove nut and bolt number 5 on the right side under transmission mount plate (see picture number 2) . New lining must be rotated in metal pulley.
     
    #15 raeggis, Aug 31, 2017
    Last edited: Sep 7, 2017
  16. Th3InfamousI

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    We're you able to replace the bolt or just now only have 5 bolts holding your transmission on?

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  17. raeggis

    raeggis Member

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    I remowed this bolt
     

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