Fastener Torque Values
| Description | Screw/Nut Size | Torque, Nm (Lbft) | Notes |
|---|---|---|---|
| Handlebar and Controls | |||
| Screw securing clutch control to handlebar | M6 | 10 (7.4) | |
| Throttle control screw | M6 | 4 (3.0) | |
| Ignition switch screw | M8 | 24 (17.7) | |
| Footrests | |||
| Footrest support bracket screw | M12 | 55 (40.6) | loctite 243 |
| Footrest support bracket screw | M8 | 25 (18.4) | loctite 243 |
| Chassis | |||
| Screw securing linkage to mudguard at front end | M6 | 12 (8.9) | |
| Screw securing linkage to mudguard at rear end | M6 | 12 (8.9) | |
| Screw securing mudguard to bottom yoke | M6 | 12 (8.9) | |
| Conveyors screw | M6 | 12 (8.9) | |
| Side body panels screw | M6 | 12 (8.9) | |
| Front screw securing tail end to subframe | M6 | 12 (8.9) | |
| Central nut securing tail end - mudguard - subframe | M6 | 12 (8.9) | |
| Rear screw securing tail end to subframe | M6 | 12 (8.9) | |
| Screw securing tail end to mudguard | M6 | 12 (8.9) | |
| Top screw securing under-tail end to number plate holder | M5 | 7 (5.2) | |
| Bottom screw securing under-tail end to number plate holder | M5 | 7 (5.2) | |
| Screw securing under-tail end - mudguard - starter contactor ext. | M6 | 12 (8.9) | |
| Shock absorber guard screw | M5 | 6 (4.4) | |
| Screw securing headlight fairing to instrument support | M5 | 6 (4.4) | |
| Instrument support screw | M5 | 6 (4.4) | |
| Under-tail end lower screw | M6 | 12 (8.9) | |
| Lights and Instrument Panel | |||
| Tail light screw | 3.9 | 2 (1.5) | |
| Turn indicators nut | M8 | 6 (4.4) | |
| Digital instrument nut | M5 | 6 (4.4) | |
| Headlight screw | M6 | 6 (4.4) | |
| Tanks | |||
| Screw securing plate to fuel tank | M6 | 12 (8.9) | |
| Screw securing fuel tank to frame | M6 | 12 (8.9) | |
| Screw securing pump body to fuel tank | M6 | 10 (7.4) | |
| Oil tank nut | M6 | 5 (3.7) | |
| Frame | |||
| Subframe screw | M10 | 49 (36.1) | |
| Upper chain roller screw | M8 | 22 (16.2) | |
| Lower slider rear screw | M5 | 4.4 (3.25) | |
| Lower slider front screw | M5 | 4.4 (3.25) | |
| Stand | |||
| Stand plate screw | M8 | 22 (16.2) | loctite 243 |
| Side stand nut | M10 | 34 (25.1) | loctite 243 |
| Exhaust System | |||
| Screw securing silencer to subframe | M8 | 22 (16.2) | |
| Exhaust pipes nut | M6 | 12 (8.9) | |
| Screw securing tubes to head | M6 | 12 (8.9) | |
| Screw securing brake to handlebar | M6 | 10 (7.4) | |
| Cooling System | |||
| Radiators upper screw | M6 | 5 (3.7) | |
| Radiators lower screw | M6 | 12 (8.9) | |
| Front Brake | |||
| Front brake caliper screw - RXV 450/550 | M8 | 25 (18.4) | |
| Front brake caliper screw - SXV 450/550 | M10 | 50 (36.9) | |
| Rear Brake | |||
| Rear brake master cylinder screw | M6 | 10 (7.4) | |
| Brake pedal screw | M8 | 25 (18.4) | loctite 243 |
| Front Wheel | |||
| Wheel shaft cap | M22 | 60 (44.3) | |
| Rear Wheel | |||
| Wheel shaft nut | M25 | 127 (93.7) | |
| Front Suspension | |||
| Steering head screw | M8 | 24 (17.7) | |
| Bottom yoke screw | M8 | 22 (16.2) | |
| Wheel shaft pinch bolt - RXV 450/550 | M6 | 10 (7.4) | |
| Wheel shaft pinch bolt - SXV 450/550 | M8 | 22 (16.2) | |
| Handlebar upper clamps screw | M8 | 24 (17.7) | |
| Steering shaft nut | M26 | 108 (79.7) | |
| Steering shaft ring nut | M30 | 7 (5.2) | |
| Handlebar lower clamp nut | M10 | 32 (23.6) | |
| Leg guard screw | M6 | 12 (8.9) | |
| Rear Suspension | |||
| Nut securing frame to linkage | M12 | 80 (59.0) | |
| Nut securing linkage to rocker | M12 | 80 (59.0) | |
| Nut securing rocker to swing arm | M12 | 80 (59.0) | |
| Shock absorber nut | M10 | 52 (38.3) | |
| Swing Arm | |||
| Chain guide nut | M6 | 12 (8.9) | |
| Nut securing swing arm shaft | M14 | 100 (73.8) | |
| Chain stretcher adjuster nut | M8 | 26 (19.2) | |
| Screw securing chain slider and tube guides to rear brake | 4.8 | 4.4 (3.25) | |
| Rear chain guard screw | 4.8 | 4.4 (3.25) | |
| Chain guide screw | M6 | 12 (8.9) | |
| Engine (from the Engine Service Manual) | |||
| Nut securing engine to frame | M10 | 54 (39.82) | |
| Screw securing throttle body to head | M6 | 12 (8.85) | loctite 243 |
| Screw securing control unit to plate | M4 | 4.4 (3.24) | loctite 243 |
| Screw securing voltage regulator and control unit to frame | M6 | 12 (8.85) | |
| Coil screw | M6 | 12 (8.85) | |
| Screw securing sprocket cover and chain guide plate | M6 | 12 (8.85) | |
| Engine oil drain cap | M12x1.5 | 18 (13.28) | |
| Gearbox fluid drain cap | M10X1.5 | 18 (13.28) | |
| Oil filter cover | M56x1.5 | 25 (18.44) | |
| Piston mounting hole plug | M30x2 | 30 (22.13) | |
| Spark plug | M10X1.25 | 12 (8.85) | |
| Gearbox fluid check screw | M6x1 | 9.8 (7.23) | |
| Water pump impeller | M7x1 | 12 (8.85) | |
| Head cover screw | M6x1 | 9.8 (7.23) | |
| Water pump cover screw | M6x1 | 9.8 (7.23) | |
| Clutch cover screw | M6x1 | 9.8 (7.23) | |
| Right casing cover screw | M6x1 | 9.8 (7.23) | |
| Casing jointing bolt | M6x1 | 12 (8.85), 13 (9.6) | discrepancy; the Use+Maintenance Book indicates the italicized value |
| Casing jointing bolt | M7x1 | 15 (11.06) | |
| Ignition cover screw | M6x1 | 9.8 (7.23) | |
| Pick-up screw | M5x0.8 | 8 (5.90) | loctite 270 |
| Stator fixing screw | M5x0.8 | 8 (5.90) | loctite 270 |
| Chain tensioner sliding shoe screw | M6x1 | 9.8 (7.23) | loctite 270 |
| Timing chain tensioner screw | M6x1 | 10 (7.37) | |
| Cable guide ring screw | M6x1 | 10 (7.37) | |
| Oil lines mounting plate screw | M6x1 | 9.8 (7.23) | loctite 270 |
| Blow-by breather union | M12x1 | 18 (13.28) | use sealant |
| Flywheel nut | M14x1 | 98 (72.28) | |
| Starter motor screw | M6x1 | 9.8 (7.23) | |
| Chain guide plate screw | M6x1 | 12 (8.85) | |
| Screw securing primary shaft bearing | M6x1 | 12 (8.85) | loctite 270 |
| Screw securing lay shaft bearing | M6x1 | 12 (8.85) | loctite 270 |
| Desmo bearing screw | M5x0.8 | 8 (5.90) | loctite 270 |
| Gear indicator screw | M5x0.8 | 6 (4.43) | loctite 270 |
| Gear change pedal screw | M6x1 | 12 (8.85) | |
| Head bolt (pre-torque) | M10X1.25 | 30 (22.13) | smear screws and washers with oil |
| Head bolt | M10X1.25 | 50 (36.88) | |
| Head bolt | M6x1 | 12 (8.85) | |
| Timing gear nut | M12x1 | 50 (36.88) | |
| Timing cover screw | M5x0.8 | 6 (4.42) | loctite 243 |
| Primary sprocket nut | M18x1.25 | 160 (118.00) | |
| Gear selector stop plate screw | M6x1 | 12 (8.85) | loctite 270 |
| Oil collector plate screw | M6x1 | 12 (8.85) | loctite 270 |
| Gear selector shaft stop screw | M10X1.25 | 25 (18.44) | loctite 270 |
| Gear ratchet rotation screw | M6x1 | 12 (8.85) | loctite 243 |
| Selector shaft | M8x1.25 | 22 (16.23) | loctite 270 |
| Clutch hub nut | M18x1.25 | 75 (55.32) | |
| Clutch spring screw | M6x1 | 12 (8.85) | |
| Pressure reducing valve | M14x1.5 | 20 (14.75) | |
| Feed pump retaining screw | M6x1 | 9.8 (7.23) | |
| Scavenge pump retaining screw | M6x1 | 9.8 (7.23) | |
| Head lubricating nozzle | M7x1 | 2.5 (1.84) | |
| Valve lift block screw | M5x0.8 | 9 (6.64) | loctite 270 |
| Water union plate screw | M5x0.8 | 9 (6.64) | |
| Crankshaft stop screw | M8x1.25 | 22 (16.23) | loctite 270 |
| Freewheel outer ring screws | M6x1 | 13 (9.58) | loctite 270 |
| Throttle body screws | M6x1 | 13 (9.58) | loctite 243 |
| Camshaft gear retaining screw | M16x1 | 35 (25.82) | |
| Con-rod cap screw | M8x1 | ??? (???) | Molicote G-N Plus |
| Electrical Components | |||
| Screw securing solenoid starter and fuse holder | M5 | 7 (5.2) | loctite 243 |
| Frame ground retaining screw | M6 | 12 (8.9) | |
| Solenoid starter cables screw | M6 | 12 (8.9) | |
| Horn screw | M8 | 22 (16.2) | |
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page_revision: 9, last_edited: 1178672465|%e %b %Y, %H:%M %Z (%O ago)
