APPENDIX 121 TORQUE TABLE Tighten all bolts and nuts to the proper torque using an accurate torque wrench, A bolt or nut if insufficiently tightened may become damaged or fall out, possibly resulting in damage to the motor- cycle and injury to the rider. A bolt or nut which is over-tightened may become damaged, strip an internal screw, or break and then fal! out. The following table lists the tightening torque for the major bolts and nuts: Part Name Metric English See Pg. Clutch Spring Bolts 5° 0.4~0.5 kgm — 35~43 inlbs 30 Cylinder Head Nuts 8° 2.2 kgm 16 ft-lbs 24,39,68 Engine Drain Plug 0.7~1.0kgm — 61~87 in-lbs 119 Engine Mounting Nuts 109 (4) 26~3.5kgm 1925 ft-lbs 22 Engine Sprocket Bolt 6° 2.2~2.5 kgm 16~18 ft-lbs 32,38 Front Axle Nut 10° 3.4~4.6 kgm 25~33 ft-lbs 44 Front Fork Clamp Bolts 8° (Upper) 1.6~2.2 kgm 11.5~16.0 ft-lbs 56,59 Front Fork Clamp Bolts 10° (Lower) 2.6~3.5 kg-m 19~25 ft-lbs 14,56,59 Front Fork Top Bolts (2) 1.5~20kgm 1114.5 ft-lbs 56,97 Handlebar Clamp Bolts 8° 1.6~2.2 kgm 11.5~16 ft-lbs 50 Magneto Flywheel Nut 10% 5 kgm 36 ft-lbs 33,38 if Hose Banjo Bolts (3) 0.4~0.5 kgm —-36~43 in-Ibs 26 Primary Gear Nut 12° 7.0~7.5 kg-m 51~54 ft-lbs 31,39 Rear Axle Nut 10° 3.4~4.6 kg-m 25~33 ft-lbs 17,46 Rear Shock Absorber Nuts 12° (Upper) 2.6~3.5 kgm 19~25 ft-lbs 60 Rear Shock Absorber Bolts 10° (Bottom) 2.6~3.5 kgm 19~25 ft-tbs 60 Rear Sprocket Nuts 8° (4) 2.0~2.2 kam 14.5~16 ft-lbs 48 Spark Plug 25~30kgm —— 18~22 ftlbs 11,13 Spokes 0.2~0.4kgm ——17~36 in-tbs 49 Steering Stem Clamp Bolt 8° 1,6~2.2 kg-m 11.5~16 ftlbs 14 Steering Stem Head Bolt B.0~35kgm —— 22~25 ft-lbs 14,59 ‘Swing Arm Pivot Shaft Nut 10° 4.0~6.0kgm —— 29~43 ft-lbs 60 Torque Link Nut 10° 2.6~3.5 kgm 19~25 ft-lbs 17,46,60 Steering Stem Nut 1.8~2.2 kgm 13~16 ftlbs —122 APPENDIX The table below, relating tightening torque to thread diameter and pitch, lists the basic torque for the bolts and nuts used on Kawasaki Motorcycles. However, the actual torque that is necessary may vary among bolts and nuts with the same thread diameter and pitch. The bolts and nuts listed on Pg.121 vary to a greater or lesser extent from what is given in this table. Refer to this table for ‘only the bolts and nuts not included in the table on Pg. 121. All of these values are for use with dry solvent cleaned threads. Coarse threads dia 5 12 14 16 18 Fine threads dia 10 12 14 16 18 20 (mm) (mm) pitch (mm) 0.90 1.00 1.25 1.50 175 2.00 2.00 2.50 2.50 pitch (mm) 0.50 0.75 1,00 1.25 1.50 1.50 1.50 1.50 1.50 kgm 0.35~ 0.50 5.6~ 0.9 1.6~22 31~4.2 5.4~75 83~ 11.5 13~18 18~ 25 26~35 kg-m 0.35~ 0.50 0.6~ 0.8 14~ 1.9 26~35 45~6.2 7.4~10.2 11.5~ 16 17~ 23 23~ 33 ft-lbs 2.5~3.5 45~6.5 11.5~ 16.0 22~30 39~ 54 60~ 83 94~ 130 130~ 181 188 ~ 253 ftlbs 25~35 45~55 10.0~ 13.5 19.0~ 25 33~ 45 84~ 74 83~ 116 123 ~ 166 166 ~ 239