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Naval aviation mechanics do a simple float test for used bolts.
Through it overboard, if it floats it's reusable.
They learned that by following the manual.
The call out for new bolts is for convenience to the mechanic at the dealership.
They come clean and usually with the correct dry coat encapsulated epoxy locking compound.
Clean threads with a die nut designed to around a GH5 size for cleaning and straighting a damaged thread. Not cutting. It's 0.0025 over basic.
I would definitely replace that.
I would like said replace fastner parts steel to steel on the engine.
As long as you clean properly and use correct locking compound as called out, fastners is aluminum can be reused. Don't use locking compound on maintenance covers with gaskets.
The gasket squeeze keeps them tight. And they will tend to stay tight. You can than also tighten them slightly if gasket gets old and seeps.
I assume that was supposed to say, "fasteners IN aluminum can be reused." and I've got BS flag on that statement also. The last time I pulled my inner primary the dealer was closed, and I didn't want to wait, so I reused the 5 bolts that attach it to the cases. I got about a 1/3 of the required torque on the 3rd bolt and it snapped, fortunately it didn't completely break in 2 and I was able to back it out. Those bolts are a Torque-to-Yield (and they are used in aluminum) but there are many, many forum geniuses here who swear up and down they reuse them and never had an issue, and that may be true, but these are also the "calibrated wrist" guys, and to be honest, I wouldn't get on their bikes if you paid me.
I think it's been said at least twice on this thread so far, it's simple, if the manual says to replace the bolt after removal, then replace it. Dang.
I assume that was supposed to say, "fasteners IN aluminum can be reused." and I've got BS flag on that statement also. The last time I pulled my inner primary the dealer was closed, and I didn't want to wait, so I reused the 5 bolts that attach it to the cases. I got about a 1/3 of the required torque on the 3rd bolt and it snapped, fortunately it didn't completely break in 2 and I was able to back it out. Those bolts are a Torque-to-Yield (and they are used in aluminum) but there are many, many forum geniuses here who swear up and down they reuse them and never had an issue, and that may be true, but these are also the "calibrated wrist" guys, and to be honest, I wouldn't get on their bikes if you paid me.
I think it's been said at least twice on this thread so far, it's simple, if the manual says to replace the bolt after removal, then replace it. Dang.
I was referring to non critical maintenance cover bolts in aluminum.
And all my post here have said replace that said bolt.
Nothing was taken from AI.
Just from 46 years from starting off as a Apprentice Toolmaker and then the remaining as management in and around the Machine Shop.
My Apprentice Ship included the normal machine and tool grinding but also 3 months in the related departments at that time to the toolmakers. Gear cutting, Heat treating, Plating, Foundry and Tool Design.
After finishing I moved over as Apprentice Instructor since Union trouble with pay spread caused the renaming of those to machinist.
And all my maintenance comes from the oem service manuals
User didn't mention year.
A Dyna was not an M8. Not sure why it needs all the M8 info.
Thread has gone sideways now. My info I posted was as a brief understanding.
Sorry it went over your head.
Last edited by Jackie Paper; May 13, 2026 at 10:10 AM.
I was referring to non critical maintenance cover bolts in aluminum.
And all my post here have said replace that said bolt.
Nothing was taken from AI.
Just from 46 years from starting off as a Apprentice Toolmaker and then the remaining as management in and around the Machine Shop.
My Apprentice Ship included the normal machine and tool grinding but also 3 months in the related departments at that time to the toolmakers. Gear cutting, Heat treating, Plating, Foundry and Tool Design.
After finishing I moved over as Apprentice Instructor since Union trouble with pay spread caused the renaming of those to machinist.
And all my maintenance comes from the oem service manuals
User didn't mention year.
A Dyna was not an M8. Not sure why it needs all the M8 info.
Thread has gone sideways now. My info I posted was as a brief understanding.
Sorry it went over your head.
"fasteners IN aluminum can be reused." is a blanket statement and your clarification comes only after being questioned. "The call out for new bolts is for convenience to the mechanic at the dealership." is also a blanket statement that is misinformed and gives new guys a bad opinion of the MoCo. It's funny how you're implying that any of this is over my head, @Dan89FLSTC is 100% on this, too much rambling BS from you.
I have reused both and, yes, I do have and have read the service manual. I used to have an '02 FLHT running an all bore 107" motor (118TQ/104HP) and one year, I changed cams three times and reused those bolts each time and never lost one. Just one man's experience, not suggesting the OP or others do the same.
I ordered new S&S bolts and the cam bolt is a little longer, and there are less threads - is this an ok replacement? This is a 2004 TC88
If it's the prescribed replacement for your bike, then you're fine. If it were me, I'd get a depth on the counter bore just to be absolutely certain that bolt won't bottom out.
I assume that was supposed to say, "fasteners IN aluminum can be reused." and I've got BS flag on that statement also. The last time I pulled my inner primary the dealer was closed, and I didn't want to wait, so I reused the 5 bolts that attach it to the cases. I got about a 1/3 of the required torque on the 3rd bolt and it snapped, fortunately it didn't completely break in 2 and I was able to back it out. Those bolts are a Torque-to-Yield (and they are used in aluminum) but there are many, many forum geniuses here who swear up and down they reuse them and never had an issue, and that may be true, but these are also the "calibrated wrist" guys, and to be honest, I wouldn't get on their bikes if you paid me.
I think it's been said at least twice on this thread so far, it's simple, if the manual says to replace the bolt after removal, then replace it. Dang.
Those bolts aren't tprque to yield. They are torqued to stretch. The torque value is too high if you reuse.. The reason for the extra torque is the loctite patch. They need to make sure the loctite smooshes out on the tension side threads. If not heat cycles will let it smoosh out and the bolt will loosen. HD wants something like 150 in lbs on some 1/4-20 screws. It's OK for them as they use patched bolts and it's the first assembly. Reused stuff can should be TQed less.
When you reused the inner primary bolts, was it the first time reuse. I've reused them a few times without issue. I've also reused the cam / crank bolts a number of times but I'll let the experts do the waying in....
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