The rocker arm cover bolts keep breaking. I had two original bolts that broke. I replaced them with new grade 8 bolts thinking it was a defect in the old bolts but again they are breaking. I am using the torque specs from the manual that say from 1991 and on 1/4 inch hex head torque to 10-13 ft lbs. The bolts have broken at around 8-10 ft lbs. Any suggestions. My bike is a 2003 sportster 883.

 

I don't have any suggestions for you,but I also broke one of those bolts. But mine was one of the black bolts. It snapped way too easy I thought.

 

Would it be possible my torque wrench is foot pounds is off? Possibly saying its 10 ft lbs but it could be like 15-20 or something?

 

That's possible and should be easy enough to check if you can borrow one from someone to compare.
Also, are you sure the manual says FOOT pounds not INCH pounds?

 

HOTLAP- ya we checked the foot lbs/ inch lbs first thing. Its all good now. Had one more bolt snap but then got another new set of bolts and it finished up in about 15 mins. So bad set of bolts? Who knows. It all done!

 

If you have one of those clicking or electronic wrenches then yes, it is probably off. I was aware of the problem when I was shopping for mine and I did extensive online search, ended up buying a beam-type Craftsman for $30, accuracy better than 10%. Online review I read claimed the first clicking/electronic one that exceeds it's accuracy is Snap-On for $500.

 

I stopped Using my Torque wrench,,

I had a real wrench take me thru the paces with several bolts and
different length open ends n ratchets
He Has been all through Sporster engines for decades.
He don't pull out a torque wrench unless he's headed north of 30 ft Lbs,,

 

What's the chance that you are using a 1991 manual for a 2003 bike have something to do with it???

 

+1 here. I'd never bother using a torque wrench on minor bolts like rocker cover bolts. In fact, on car engines I use it only for heads, connecting rods, main bearings and flywheel bolts.