Torque specs

[lee]

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

 

[RAW Blue Rider]

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

 

[alhall88]

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

 

[Moespeeds]

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.

 

[MARV]

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

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.

 

[lee]

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

 

[BWG56]

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

 

[Raywood]

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

:flag: :2thumbs:

 

[RRRUFF]

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

 

[barhopper]

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

 

[MARV]

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

1/8th of a turn

















approximately

 

[LDO]

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

 

[lee]

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

 

[ChimesCFL]

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

Thanks!

 

[98sporty]

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.

 

[LDO]

Primary drain plug??

 

[lee]

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.

 

[Staffy]

????

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...

 

[thexaulted]

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

 

[LDO]

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!