Got me a '03 Harley - Torx sizes??? When did they start using TorxPlus?

[mrborohachi]

Currently borrowing a T27 from a GJ'er Mohawk Dave. Just wanted to ask what sizes I will need.

Funny I'm looking at Japanese Koken bits and sockets on https://palmac.net/ (the crappiest tool website in the world) they just happen to have the best stock of Koken in the US. They sell to all the Colleges in the east coast. At my work we've been using Koken hex sockets and I have to say they show less wear than SO socketed Allens.

Searching Harley forum posts with Google I see in the mid 2000's (post said 2007 model) Harley started using TorxPlus. Are their head-bolts XZN triple-square or just 12pt SAE?

^from https://store-h2bpv89yys.mybigcommerce.com/content/Docs/Koken/KOKEN_201908ENSP.pdf

 

[Aquamoose]

I’ve used Torx Plus as far back as 1992 for seat belt bolt anchors.


Sent from my iPhone using Tapatalk

 

[dusterdude]

My 94 sportster had 12 pt head bolts if iirc

Sent from my LM-X420 using Tapatalk

 

[mrborohachi]

I’ve used Torx Plus as far back as 1992 for seat belt bolt anchors.


Sent from my iPhone using Tapatalk

Good thing Hogs don't have seatbelts, doors, or Steering wheels (which I saw 'murican cars use security Torx head bolts on airbags)

 

[ChefRex]

T-27,T-40 and T-45 will take care of most your needs.
The head bolts ar 12 point 1/2". Throw a T-25 in there too.

 

[tdkkart]

Day 1 take the damn torx bolts out of the primary cover and replace them with socket heads. Being flat back button heads
they tend to bond themselves in place and the torx WILL strip out the next time you try to take them out. Replace them now, or drill them later, almost guaranteed.

Ungodly expensive motor cycles and they use cheap *** cad coated socket heads all over the engine. I replace mine with a stainless
using a kit from these folks. https://alloyboltz.com/

 

[lardy1]

Some of the compensator sprockets need a T70.

 

[ChefRex]

Tdkart, I think you have that backwards, honestly with quality tools I almost never have a problem and if I do someone else started it.
SS bolt kits are sweet but pricey.


Sent from my iPhone using Tapatalk

 

[ChefRex]

Some of the compensator sprockets need a T70.

That’s late into Twin Cams.


Sent from my iPhone using Tapatalk

 

[Htscheg]

Ok, I work on these bikes on a daily basis, so get yourself a GOOD set of torx sockets, bits whatever your choice, being that its an 03 id bet the majority of torx fasters are damaged by previous owners/tech's. Replace them with faster of your choice, I hate allen fasters with a passion lol

T25/27 both used on handbcontrols, primary screws, etc

T40 & 45 are also found in various plces, any of the larger ones are specialty and get when you need them

 

[mrborohachi]

I'm shocked I grabbed a Eklind T-handle T-27 from work and it was as sloppy as a socketed Gearwrench Taiwanese T27. The SO socketed T27 was solid as a rock, nearly no play.

 

[Neggy]

Jeeps and Harleys are the only things I have ever worked on that have T27 hardware.

On both my Harley's I have replaced the Torx hardware whenever possible

The Head bolts on my TC88 and 103 are 12 point SAE, the brake caliper bolts (because of the SHOWA forks) is IIRC 10mm 12 point.

 

[mrborohachi]

Hahahah thanks for the heads up Neggy. I knew the starters on all late 90's and up Harley's are ND just like any corolla and I knew about the SHOWA forks. Should I be buying Honda fork oil?!?!? I believe I remember seeing Nissin made the brake calipers too.

 

[Neggy]

rip the Showa internals out (they are junk) and slap in a set of Progressive fork cartridges and solve the problem

rip off the air shocks and get BiTubo shocks from DK Customs

As to the stock fork oil, there are all sorts of threads over on HDForums.com about using different weight oil in the forks and shocks to make them tolerable.

PS 03 Harleys are NOTORIOUS for the cam chain tensioners failing some as early as 20K miles, and almost all by 35K
Cyclo makes replacement shoes that last longer, but it is still a check every 25K mile item, I have S&S 509 gear drive cams in my 2003 bike eliminating the chains. I have Progressive suspension front & rear, the HD ECM was tossed and I have a Thundermax ECU with O2 sensors that self tune....