Harley-Davidson Sportster: Tool sizes overview, torque information

Since I’ve not found this information in rather complete and readably form anywhere, I am starting to document those informations here – for my own use and in the hope that this will be useful to others.

The information should apply to any so called “EVO Sportster” – these are the bikes with the “more modern” motor that’s still frame-mounted. My bike is a 2001 Sportster Custom (so a XL1200C), that means all data in this list will be accurate at least for the model years 2000, 2001, 2002 and 2003 of any 883 or 1200 sportster. I believe the only real difference between those bikes and any Sportster that was built 1993-2000 would be the brake calipers, so the rest of the information should be accurate for these older models as well.

I’ll go ahead and publish it directly – although being far from complete at the beginning – so parts can and will be missing. However, the information included should be accurate, as I verified it all on my very bike.

Area/groupItemImperialMetricTorque
FrontFront axle nut3/4
Brake Caliper Mount Nut10
(12 point!)
28-38ft/lbs
38-51.5 nm
Brake Pad Slide Pins1/4
(12 point!)
180-200 in/lbs
20.3-22.6 Nm
RearRear axle nut15/16
Brake Pad Slide Pins1/4
(12 point!)
180-200 in/lbs
20.3-22.6 Nm
Transmission, primary, beltprimary chain adjuster screw locknut 7/8

As said, I’ll be updating this from time to time whenever I work at certain parts and have a chance not only to look this data up, but mainly to verify it – because incorrect information I found in the web was my main issue.

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