BA Torque Specs - BonnevilleAmerica.com

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Notes. Clutch cover to crankcase bolts. 9. 6.633. Bonneville, Bonneville T100, and Bonneville America. Clutch cover to crankcase bolts. 12. 8.844. Speedmaster.
Application Camshaft cover to cylinder head bolts Camshaft bearing caps to head bolts Camshaft oil feed pipe to bearing cap bolts Cam chain tensioner body to crankcase bolts Cam chain tensioner centre bolt Cam chain drive gear shaft retaining bolt Cylinder head nuts Cam chain guide blade to cylinder head bolts Cam chain tensioner blade to cylinder head nut Oil cooler feed pipe to cylinder head banjo bolts Low oil pressure warning light switch (oil feed pipe to cylinder head) Spark plug Exhaust pipe stud Application Clutch cover to crankcase bolts Clutch cover to crankcase bolts Gearchange level clamp bolt Clutch centre nut Clutch release plate to pressure plate bolts Clutch level mounting clamp bolts Starter (sprag) clutch housing to crankcase bolts Centrifugal breather to crankshaft screws Application Front and rear upper mounting bolts Frame-downtube to frame bolts Frame-downtube to frame bolts Frame-tube brace bolts Cylinder head to frame mounting bracket bolts: Frame bolt Cylinder head bolt Cylinder head to frame mounting bracket bolts: Frame bolt Cylinder head bolt Application Crankcase bolts Connecting rod big end bolt nuts Centrifugal breather to crankshaft screws Starter (sprag) clutch housing to crankshaft bolts Balancer shaft lock washer to crankcase screw

Cylinder Head/Camshaft Torque(Nm) Torque(FtLb) 10 7.370 10 7.370 8 5.896 9 6.633 20 14.740 10 7.370 * 10 7.370 10 7.370 30 22.110 13 9.581 20 14.740 18 13.266 Clutch Torque(Nm) Torque(FtLb) 9 6.633 12 8.844 9 6.633 105 77.385 9 6.633 15 11.055 16 11.792 12 8.844 Engine Mountings Torque(Nm) Torque(FtLb) 80 58.960 45 33.165 55 40.535 22 16.214 22 80

16.214 58.960

Notes Lubricate threads with engine oil. See note 2 below for tightening sequence

See Note 1 below

Always replace the sealing washer

Notes Bonneville, Bonneville T100, and Bonneville America Speedmaster

Tighten upper bolt first then lower bolt Fit new bolts if removed Fit new bolts if removed Notes Bonneville/T100 America/Speedmaster Bonneville/T100 Bonneville/T100 Bonneville/T100

80 58.960 America/Speedmaster 80 58.960 America/Speedmaster Crankshaft/Connecting Rods Torque(Nm) Torque(FtLb) * Too involved for this document * Too involved for this document 12 8.844 Fit new screws if removed 16 11.792 Fit new bolts if removed 12 8.844 Fit a new screw if removed

Notes

Application Gearchange mechanism cover bolts Selector fork shaft retaining plate screw Selector drum cam retaining bolt Gearchange shaft abutment bolt Detent arm retaining bolt Neutral switch Sprocket cover to crankcase Chainguard to swinging arm Application

Sump drain plug Oil filter Oil filter adaptor to crankcase Low oil pressure warning light switch Oil cooler mounting bolts Oil feed pipe to cylinder head banjo bolts (M14 bolts, upper pipe) Oil feed pipe to oil cooler banjo bolt (M18 bolt, upper pipe) Oil return pipe to sump banjo bolt to cooler (M18 bolt, lower pipe) Oil return pipe union to sump adapter Oil return pipe union sump adapter Oil pick-up strainer screws Sump to crankcase bolts Oil pump to crankcase bolts Oil pressure relief valve Application Fuel tank mounting bolts Fuel tank mounting bolts Warning light plinth to tank Airbox mounting bolts Airbox mounting bolts Secondary air injection system control valve to frame screws Exhaust header pipe to cylinder head nuts Exhaust header pipe mounting bolts Exhaust header pipe mounting bolts Exhaust header balance pipe clamp Silencer mounting (passenger footrest) nut Silencer mounting (passenger footrest) fixing Silencer clamp Low fuel warning light sender to fuel tank Fuel tank badge to tank

Transmission Torque(Nm) Torque(FtLb) 9 6.633 12 8.844 12 8.844 28 20.636 12 8.844 10 7.370 9 6.633 7 5.159 Lubrication System Torque(Nm) Torque(FtLb) 25 18.425 8-12 5.8-8.8 10 7.370 13 9.581 9 6.633 30 22.110 45 33.165 45 33.165 15 11.055 45 33.165 6 4.422 12 8.844 12 8.844 15 11.055 Fuel System/Exhaust Torque(Nm) Torque(FtLb) 9 6.633 19 14.003 5 3.685 6 4.422 5 3.685 8 5.896 19 14.003 22 16.214 15 11.055 22 16.214 27 19.899 See rear susp 22 16.214 9 6.633 9 6.633

Notes Fit a new screw if removed Fit a new bolt if removed Fit a new bolt if removed

Notes Apply Three Bond TB1305 to threads

Apply Three Bond TB1305 to threads

Apply Three Bond TB1305 to threads

Bonneville/T100 America/Speedmaster America/Speedmaster Bonneville/T100 America/Speedmaster

Bonneville/T100 America/Speedmaster Bonneville/T100 America/Speedmaster

Notes

Application Brake caliper bleed nipple Front brake caliper mounting bolts Front brake caliper pad retaining pin Front brake caliper pad retaining pin plug Front brake hose banjo bolts Front brake master cylinder mounting clamp bolts Front brake disc bolts Rear brake fluid reservoir mounting screw Rear brake fluid reservoir mounting screw Rear brake caliper mounting bolts Rear brake caliper pad retaining pins Rear brake hose to caliper banjo bolt Rear brake pipe to master cylinder and joint block (steel pipe) Rear brake master cylinder mounting bolts Rear brake master cylinder mounting bolts Rear brake master cylinder pushrod clevis locknuts Rear brake light switch Rear brake disc retaining bolts Rear brake hose clamp to swinging arm Rear brake pedal pivot Application Top yoke fork clamp bolt Top yoke fork clamp bolt Bottom yoke fork clamp bolt Fork top cap Fork damper rod bolt Fork damper rod bolt Fork cover to bottom yoke Steering head bearing adjuster nut locknut Steering stem top nut Handlebar mounting clamp to top yoke nut Handlebar mounting clamp to top yoke nut Handlebar clamp bolts Handlebar end weight screw Application Rear suspension unit mounting bolts Swinging arm spindle nut Swinging arm outrigger clamp bolts

Braking System Torque(Nm) Torque(FtLb) 5 3.685 28 20.636 18 13.266 3 2.211 25 18.425 15 11.055 22 16.214 7 5.159 5 3.685 40 29.480 18 13.266 25 18.425 25 18.425 18 13.266 27 19.899 18 13.266 15 11.055 22 16.214 7 5.159 30 22.110 Front Suspension/Steering Torque(Nm) Torque(FtLb) 27 19.899 20 14.740 27 19.899 23 16.951 30 22.110 43 31.691 9 6.633 45 33.165 65 47.905 35 25.795 45 33.165 26 19.162 5 3.685 Rear Suspension Torque(Nm) Torque(FtLb) 28 20.636 110 81.070 45 33.165

Notes

Tighten upper bolt first then lower bolt Fit new bolts if removed America/Speedmaster Bonneville/T100

America/Speedmaster Bonneville/T100 America/Speedmaster

Fit new bolts if removed

Bonneville/T100 America/Speedmaster

Notes

Bonneville/T100 America/Speedmaster America/Speedmaster

Bonneville/T100 America/Speedmaster Tighten upper bolt first then lower bolt Notes America/Speedmaster

Application Rider footrest bracket to frame bolts Rider footrest mounting bar to frame Rider footrest clevis bracket to mounting bar Rider footrest bracket locating bolt (left hand side only) Passenger footrest/silencer mounting plate to frame Passenger footrest to silencer mounting plate Application Seat to frame screws Front seat to mudguard fixing Rear seat to mudguard fixing Front mudguard to stay bolts Front mudguard stay to fork bolts Front mudguard to bracket bolts Front mudguard bracket to fork bolts Rear mudguard mounting screws Rear mudguard to bracket screws Rear mudguard to frame cross-beam screws Rear mudguard bracket to frame screws Side stand pivot bolt Side stand pivot bolt locknut Airbox cover/airbox wiring cover

Front wheel spindle fixing Front wheel spindle clamp bolt Front wheel spindle clamp bolt Rear wheel spindle nut

Application

Application Rear wheel spindle nut Chainguard to swinging arm screws Front sprocket cover bolts Front sprocket nut Rear sprocket nuts Rear sprocket nuts

Footrests Torque(Nm) Torque(FtLb) 27 19.899 30 22.110 45 33.165 9 6.633 30 22.110 27 19.899 Frame/Bodywork Torque(Nm) Torque(FtLb) 10 7.370 26 19.162 10 7.370 9 6.633 12 8.844 3 2.211 12 8.844 9 6.633 26 19.162 26 19.162 64 47.168 20 14.740 25 18.425 3 2.211 Wheels Torque(Nm) Torque(FtLb) 60 44.220 27 19.899 20 14.740 85 62.645 Final Drive Torque(Nm) Torque(FtLb) 85 62.645 7 5.159 9 6.633 132 97.284 55 40.535 85 62.645

Bonneville/T100 America/Speedmaster America/Speedmaster America/Speedmaster America/Speedmaster America/Speedmaster

Bonneville/T100 America/Speedmaster America/Speedmaster Bonneville/T100 Bonneville/T100 America/Speedmaster America/Speedmaster Bonneville/T100 America/Speedmaster America/Speedmaster America/Speedmaster

Notes

Notes

America/Speedmaster Notes Bonneville/T100 America/Speedmaster Notes

Secure in position with lockwasher Bonneville/T100 America/Speedmaster

Application Headlight mounting bolts Headlight mounting bracket to lower yoke Headlight clamp to bracket Speedometer housing to top yoke bolts Speedometer bracket to top yoke Rear light fixings Rear light fixings Rear light bracket to mudguard Front indicator mounting nuts Front indicator to bracket Front indicator bracket to hand controls Rear indicator mounting nuts Handlebar switch retaining screws Ignition switch screws Alternator rotor bolts (M10 bolt) Alternator rotor bolts (M12 bolt) Alternator stator to cover bolts Alternator stator wiring clamp to cover screw Alternator cover to crankcase bolts Regulator/rectifier fixings Starter motor to crankcase bolts Starter motor lead terminal nut Starter solenoid lead terminal nut Ignition pick-up coil screws Igniter unit retaining nut

Electrical System/Ignition Torque(Nm) Torque(FtLb) 10 7.370 27 19.899 27 19.899 9 6.633 9 6.633 9 6.633 3 2.211 5 3.685 10 7.370 15 11.055 15 11.055 18 13.266 2 1.474 5 3.685 98 72.226 120 88.440 12 8.844 12 8.844 9 6.633 9 6.633 10 7.370 7 5.159 7 5.159 10 7.370 9 6.633

Bonneville/T100 America/Speedmaster America/Speedmaster Bonneville/T100 America/Speedmaster Bonneville/T100 America/Speedmaster America/Speedmaster Bonneville/T100 America/Speedmaster America/Speedmaster

Ensure coil air gap is correctly set

Notes

Note 1 The cylinder head nuts are tightened in three stages. This is to ensure that the cylinder head gasket seals correctly to the cylinder head and barrels. The three stages are as follows: NOTE: In stages A and B a torque wrench of known and accurate calibration must be used. A. Tighten the cylinder head nuts , in the sequence shown, to 20 Nm B. Tighten the cylinder head nuts , in the sequence shown, to torque 30 Nm C. Finally tighten the cylinder head nuts, in the sequence shown , through a further 90 degrees NOTE: Use service tool 3880105-T0301 to ensure accuracy when angle-tightening

Note 2