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  #11  
Old 23rd September 2018
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Quote:
Originally Posted by lucag View Post
Thanks for the tips, you are very kind, but... I live far far away in that beautiful but messy place called Italy :-)))

Anyway I used a metric, the 8... not easy to disconnect the igntion module
connector from the wiring... it is under the black metal base once you remove the module... I think I will remove the battery too...

To be continued
As far as I know, all the bolts and screws on a Sportster are S.A.E. except the battery bolts which most are 10mm. 5/16in.=8mm. 5/8in. = 16mm, the some are kinda close and some just aren't. You'll need an S.A.E. set of tools.
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  #12  
Old 23rd September 2018
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Quote:
Originally Posted by Toejam503 View Post
As far as I know, all the bolts and screws on a Sportster are S.A.E. except the battery bolts which most are 10mm. 5/16in.=8mm. 5/8in. = 16mm, the some are kinda close and some just aren't. You'll need an S.A.E. set of tools.
Two others are 10 mm:

10 mm horn mounting nut (don't know why)
throttle cable adjustment jam nut (cause the Keihin is a Japanese carb?)
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  #13  
Old 23rd September 2018
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Good catch!
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  #14  
Old 23rd September 2018
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Quote:
Originally Posted by Toejam503 View Post
As far as I know, all the bolts and screws on a Sportster are S.A.E. except the battery bolts which most are 10mm. 5/16in.=8mm. 5/8in. = 16mm, the some are kinda close and some just aren't. You'll need an S.A.E. set of tools.
Yep, for SAE hex head bolts/nuts, 5/16 = .325 inch = 7.93 mm, so 8 mm works fine, especially if using 6 point sockets.

3/8 = .375 = 9.5 mm, so a 10 mm is rather sloppy. The other way around, using SAE on metric, a 3/8 is too tight and 7/16 usually too loose

7/16 = .4375 = 11.11 mm

9/16 = 14.29 mm, so they usually interchange well.

3/4 = 19.05 mm

Using metric on SAE works for most, but not well on 1/4 inch (6.35 mm) as a 6 is too tight and 7 rather loose, to the point of often slipping.

However, trying to use metric on SAE Allen heads is a recipe for disaster.
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  #15  
Old 23rd September 2018
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The front forks are Showa........... all metric.
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Originally Posted by Graywolf View Post
The front forks are Showa........... all metric.
Any other than Allen or Torx?

This list came from the Technical section of Sportster.org. It may need updating for newer bikes (04 and up)

Torx
T25 control housing screws
T27 clutch inspection cover
control clamps
T40 front brake disk
front wheel hub plate
T45 rear brake disk mounting bolts
fork bracket pinch screws
Allen
4.5 mm ball head mounting screw for front directionals
6 or 7 mm fork damper tube screw
5/32 sissy bar mounting screws
primary chain inspection cover screws
3/16 primary cover screws
rocker box cover screws
gearcase cover
sprocket cover
sissy bar side plate mounting screws
1/4 front fender bolts
handlebar clamp bolts
eyebrow bolts
coil bracket bolt
left footpeg mount screws
rear master cylinder mounting screws
belt guard mounting screw
intake manifold to head
primary adjuster screw
5/16 upper engine mounts
air cleaner mounting screws
front axle pinch bolt
3/8 timing plug
Hex Head
5/16 heat shield worm drive clamps
brake line mounting clips
horn mounting bracket screws
3/8 voltage regulator mounting screws
7/16 coil mounting screws
battery strap nut
brake pedal adjustment screw
10 mm horn mounting nut
battery terminal screw
throttle cable adjustment jam nut
1/2 front fender bolt nuts
enricher bracket
front directional signal mounts
mirror mount
coil bracket bolt
brake pedal adjustment screw locknut
9/16 lower front engine mounts
front axle pinch bolt
upper shock mounting bolt
belt tension adjuster screws
upper front engine mount screws
rear engine mount bolts
5/8 front directional swivel nut
spark plugs
11/16 lower front engine mount flange nuts
3/4 front axle nut
lower shock mounting bolt
headlight mounting bolt
7/8 primary chain adjuster screw locknut
15/16 rear axle nut
stem bolt
1 1/8 crank sprocket inside primary
1 3/16 clutch mainshaft nut
1 3/8 fork tube cap
Twelve Point
3/8 caliper banjo bolts
rear master cylinder banjo bolt
7/16 front master cylinder banjo bolt
1/2 head screws
Phillips
#1 headlight clamp ring
directional signal lens screws
taillight lens screws
#3 ignition module cover screws
#4 air cleaner cover screws
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  #17  
Old 23rd September 2018
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Hey Doc, nothing about the nut between the seat and the handle bar ????
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  #18  
Old 23rd September 2018
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Hey Doc, nothing about the nut between the seat and the handle bar ????
I suppose that depends on helmet size!
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