| Author | Message | ||
     Tipsymcstagger |
I ordered the service manual for my '08 Uly two-plus weeks ago but it hasn't yet arrived. I'll be home from my travels tomorrow and would like to install the pile of parts I've ordered over the last few weeks. These include, Rox risers, Drummer muffler, Kaoko throttle control, HID low beam, PIAA 510's and an auxiliary fuse block. I'm a little apprehensive about tackling this w/o the manual but I have to travel again in a week and I'd like to get Farkling while I have the chance. Can anyone post or email the necessary torque values? Off the top of my head, I know I'll need numbers for the muffler straps and handle bar clamps. Also, I want to completely remove the airbox base plate so I can run the additional wiring as neatly as possible along the factory loom. Can I do this sans service manual without screwing anything up? How difficult is it to remove the airbox components? Lastly, I'll have to reroute the throttle cables with the addition of the Rox risers. Is disconnecting the cables from the throttle body a fairly obvious process? Of course, if you live in the NYC or Great Barrington, MA area and can lend me a service manual, that'll work too  TIA. Tipsy | ||
| Skyclad |
Tipsy, Here are your requested torque values: Muffler mount fastener, front: 16-18 ft-lbs Muffler mounting block fastener, rear: 32-36 ft-lbs, calls for Loctite red Muffler strap fastener, front: 108-120 in-lbs Muffler strap fastener, rear: 48-60 in-lbs Handlebar clamp screws: 10-12 ft-lbs, tighten front first, calls for Loctite red Removing the air cleaner base should be pretty straight forward. There is a note for the reinstallation about the breather hose coming in from the bottom. Make sure breather hoses do not extend past intake air temperature sensor tower. If hoses extend past tower, damage to sensor may occur. Baseplate fasteners are torqued to 84-120 in-lbs. If you take off the exhaust actuator, it gets torqued to 36-40 in-lbs. Looking a the throttle cables, I would recommend waiting until you get the service manual. Not a terribly difficult process, but there lots of notes and cautions. Best to have all the info for this one. | ||
| Froggy |
Tipsy, I live about an hour north of you. I have a service manual for my 06 Lightning. If you want to borrow it, you’re more than welcome. I don't know how different it will be than your bike, but it should be close enough. I had to use a power driver to get the handle bar bolts up, they were on so tight I thought they got welded on. Air box comes off no problem. Watch out, the screws for the lower air box are also lock tighted to the point they are pretty much welded on. The velocity stack ring is a bitch to get back on the base plate till you get the hang of it. I tend to pull it all the way through so that its above the plate, then push it back down feeding the rubber ring around the air box plate. It goes like this, pop off seat, remove 4 screws holding outer cover, disconnect the connector from servo on top of the inner air box, pop off the tabs for inner cover, remove it, remove the air filter, undo the 4 screws holding the base plate (watch for lock tight!), pull it up, the sensor disconnects, then you’re done  | ||
| Tipsymcstagger |
Thanks very much for the info! Froggy, I'll check to see if the Lighting manual will be an adequate stop-gap and let you know. Tipsy |
