I have the service manual but it doesnt list the tools need for each bolt or screw. Is there a manual or a way to find out the screw and bolt sizes. Im tired of stripping screws helpppppppp.

 

The parts manual lists all that information. Or, you could take it to a hardware store and have them figure it out for them.

 

I usually just look at the head. Enough wrenching you will know what size something is just by glancing at it. For regular bolts, if all else fails use a tape measure or caliper to measure the head.

 

Hope this isn't a stupid question but is the parts manual a different manual than the service manual?

 

Yes. There is a parts manual, service manual, and a elec diagnostic manual.

 

Does anyone know what size torx is the screw that connects the fuel tank? It's the screw that is located under the rider seat.

 

Thanks for the info.

 

On a 2003 Softail model it's p/n 4763 which is a T40 torx screw...

 

Ok cool

 

Working out bolt sizes is simply a matter of matching the bolt thread diameter, and the threads per inch (TPI).
With Harleys, you have two thread forms, UNC (coarse) and UNF (Fine).
Here's a table that could help.

http://www.carbidedepot.com/formulas-tap-standard.htm

Then you have the A/F (across flats) diemsion on the spanner (sorry - wrench).

Eg, 7/16 A/F usually fits a 1/4 UNC (or UNF) bolt.

Easy!

Oh, and Torx fasteners have no place on a Harley. Replace them with allen bolts!

Andy
'95 XLH883
'13 Slim
Hampshire
England