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POC for this page — Bert Linson 2016/01/20 20:03

• Axle Nut: 50 ft-lbs / 67.79 Nm
• Brake Disc Mounting Screw: 35 ft-lbs / 47.45 Nm (1973)
• Brake Disc Mounting Screw: 10 ft-lbs / 13.5 Nm (1974 & later)
• Fork Stem Pinch Bolt: 20 - 25 ft-lbs / 27.11 - 33.89 Nm
• Handlebar Clamping Bolt: 20 ft-lbs / 27.11 Nm
• Front Caliper Bolt: 35 ft-lbs / 47.45 Nm
• Front Brake Disc Bolt: 35 ft-lbs / 47.45 Nm

• Gear Shaft Nut: 100 - 120 ft-lbs / 135.6 - 162.7 Nm
• Sprocket Shaft Nut: 100 - 120 ft-lbs / 135.6 - 162.7 Nm
• Crank Pin Nut: 150 ft-lbs / 203.37 Nm
• Rocker Arm Cover Screw: 20 ft-lbs / 27.11 Nm
• Cylinder Head Bolt: 65 ft-lbs / 88.12 Nm
• Carburetor (Tillotson) Inlet Seat Assembly: 40 - 45 in-lbs / 4.519 - 5.084 Nm
• Carburetor (Tillotson) Accelerator Pump Channel Plug: 23 - 28 in-lbs / 2.598 - 3.163
• Clutch Hub Nut (1971 & later): 150 ft-lbs / 203.37 Nm
• Gear Cover Screws, Chain Cover Screws, and Oil Pump: 100 in-lbs / 11.298 Nm

• Spark Plug: 20 ft-lbs / 27.11 Nm
• Starter Motor Thru Bolt (Prestolite): 20 - 25 in-lbs / 27.11 - 33.89 Nm
• Starter Motor Thru Bolt (Hitachi): 20 - 25 in-lbs / 27.11 - 33.89 Nm

• Fit in Guide (EX): .0025 - .0045 in
• Fit in Guide (IN): .0015 - .0035 in
• Spring (outer)
  • 55 - 66 lbs. @ 1-9/32 in. (valve closed)
  • 152 - 168 lbs. @ 15/16 in. (valve open)
• Spring (inner)
  • 30 - 36 lbs. @ 1-3/32 in. (valve open)
  • 76 - 88 lbs. @ 3/4 in. (valve closed)
• Spring free length:
  • 1-1/2 in. (outer)
  • 1-23/64 in. (inner)

• Fit in bushing: .001 - .0025 in. Loose

• Fit in cylinder: .003 - .004 in. loose
• Ring Gap: .015 - .025 in.
• Ring side clearance: .0035 - .005 in.
• Piston pin fit: Light hand press fit at 70 degrees Fahrenheit.

• Piston pin fit: .0008 - .001 in. loose
• End play between flywheels: .005 - .001 in.
• Fit on crank pin: .0005 - .001 in. loose

At 60 MPH in high gear (oil hot).

• Minimum: 10 lbs. / sq. in.
• Maximum: 20 lbs. / sq. in.

• Guide fit: .0005 - .001 in. press
• Fit in guide: .0005 - .001 in. loose
• Roller fit: .0005 - .001 in.
• Roller end clearance: .008 - .010 in.
• Tappet clearance: Just free (no lash) - Engine cold

• Intake
  • Opens: 79 - 85 degrees BTC
  • Closes 79 - 85 degrees ABC
• Exhaust
  • Opens: 81 - 89 degrees BBC
  • Closes: 76 - 84 degrees ATC

• Intermediate gear shaft
  • In bushing: .0005 - .001 in.
• Cam gear shaft in bushing: .0005 - .002 in.
• Cam gear shaft
  • In needle bearing: .0005 - .003 in.
• Cam gear end play
  • 1976 & earlier: .001 - .005 in.
  • 1977 & later: .003 - .007 in.
• Cam gear backlash: .000 - .0005 in.

• Gear shaft nut torque: 150 ft-lbs
• Sprocket shaft nut torque: 150 ft-lbs
• Crank pin nuts torque: 150 ft-lbs
• Runout (flywheels): .003 in. maximum at rim
• Runout (main shafts): .002 in. maximum

• Cup fit in crankshaft: .0005 - .0025 in. tight
• Cone fit on shaft: .0002 - .0015 in. tight
• End play: .001 - .007 in.

• Shaft fit in roller bearing: .0005 - .0015 in.
• Shaft fit in cover bushing: .0005 - .0015 in.

• Breaker point gap setting
  • 1970: .020 in.
  • 1971 & later: .018 in.
• Dwell
  • 1970 & 1971: 90 degrees @ 2000 rpm
  • 1972 & later: 140 degrees @ 2000 rpm
• Spark plug gap setting: .025 - .030 in.
• Ignition timing - Advanced
  • 1971 & earlier: 45 degrees (11/16 in. BTC)
  • 1972 % later: 40 degrees (17/32 in. BTC)
• Ignition timing - Retarded
  • 1971 & earlier: 15 degrees (5/64 in BTC)
  • 1972 & later: 10 degrees (1/32 in BTC)