Everything is ft lbs unless noted with in.lb which is Inch pounds
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
L: Apply a non-permanent locking agent to the threads.
LH: Left-hand Threads
S: Tighten the fasteners following the specified sequence.
Basic Torque for General Fasteners
Threads Diameter - Torque
5mm - 43 in·lb
6mm -69 in·lb
8mm -13.5
10mm - 25
12mm - 45
14mm - 72
16mm - 115
18mm - 165
20mm - 240
Fuel System
Air Cleaner Element Wing Bolt – – – Hand Tighten
Throttle Pulley Cover Bolt 30 in·lb
Throttle Cable Locknut 61 in·lb
Hot Start Plunger Cap Bolt 10 in·lb
Air Cleaner Duct Bolt and Nuts 27 in·lb
Rear Frame Mounting Bolts 25
Air Cleaner Housing Bolts 87 in·lb
Air Cleaner Duct Clamp Screws 27 in·lb
Carburetor Holder Clamp Screws 17 in·lb
Fuel Tap Plate Mounting Screws 7 in·lb
Cooling System
Right Engine Cover Bolt 87 in·lb
Water Pipe Bolt 87 in·lb
Water Pump Cover Bolts 87 in·lb L (1)
Water Pump Cover Bolts (with washer) 87 in·lb L (1)
Water Pump Impeller Bolt 61 in·lb
Radiator Hose Clamp Screws 13 in·lb
Radiator Screen Bolts 87 in·lb
Coolant Drain Plug 61 in·lb
Radiator Mounting Bolts 87 in·lb
Radiator Shroud Bolts 87 in·lb
Engine Top End
Auto-Decompressor Bolt 104 in·lb
Decompressor Plug 87 in·lb
Cylinder Head Cover Bolts 87 in·lb
Cylinder Head Bolts:
M10 36 S
M6 104 in·lb S
Camshaft Cap Bolts 87 in·lb S
Carburetor Holder Clamp Screws 17 in·lb
Plug 14 L
Lower Camshaft Chain Guide Bolt 87 in·lb
Rear Camshaft Chain Guide Bolt 11
Exhaust Pipe Stud – – – L (Planted side)
Camshaft Chain Tensioner Mounting Bolts 87 in·lb
Camshaft Chain Tensioner Cap Bolt 14.5
Cylinder Bolt M6 104 in·lb S
Exhaust Pipe Cover Screws 104 in·lb
Exhaust Pipe Holder Nuts 15 S
Silencer Mounting Bolts 15 S
Silencer Cover Bolt 109 in·lb L
Engine Right Side
Primary Gear Nut 72 LH
Shift Drum Cam Bolt 17 L
Clutch Spring Bolts 87 in·lb
Clutch Hub Nut 72
Gear Set Lever Nut 78 in·lb
Gear Set Lever Pivot Stud – – – L (Planted
Side)
Ratchet Plate Mounting Bolt 87 in·lb L
Ratchet Plate Mounting Screw 56 in·lb L
Kick Ratchet Guide Bolt 78 in·lb L
Kick Pedal Mounting Bolt 18 L
Shift Pedal Bolt 87 in·lb
Clutch Cover Bolts 87 in·lb L (2)
Right Engine Cover Bolts 87 in·lb
Engine Lubrication System
Engine Oil Drain Bolt M10
(for transmission room oil sump) 11
Engine Oil Drain Bolt M6
(for crank room oil sump) 61 in·lb
Oil Filter Cap Bolts 87 in·lb
Oil Pump Mounting Bolts 61 in·lb L
Water Pump Cover Bolts 87 in·lb L (1)
Water Pump Cover Bolt (with washer) 87 in·lb L (1)
Right Engine Cover Bolts 87 in·lb
Breather Fitting 11 L
Oil Pump Idle Gear Shaft Screws 56 in·lb L
Engine Removal/Installation
Engine Mounting Nuts 33
Engine Bracket Nuts 22
Swingarm Pivot Shaft Nut 72
Crankshaft/Transmission
Breather Fitting 11 L
Reed Valve Screws 61 in·lb
Piston Oil Nozzle 26 in·lb
Crankcase Bolts 87 in·lb S
Engine Oil Drain Bolt
(for crank room oil sump) 61 in·lb
(for transmission room oil sump) 11
Output Shaft Bearing Retaining Screw 56 in·lb L
Drive Shaft Bearing Retaining Screw 56 in·lb L
Shift Drum Bearing Retaining Bolts 87 in·lb L
Gear Set Lever Nut 78 in·lb
Shift Drum Cam Bolt 17 L
Neutral Switch 104 in·lb
Wheels/Tires
Front Axle 58
Front Axle Clamp Bolts 14.5 AL
Rear Axle Nut 80
Spoke Nipple
Not less
than 19 in·lb[/QUOTE]
Final Drive
Rear Sprocket Nuts 25
Engine Sprocket Cover Bolts 87 in·lb
Brakes
Brake Lever Pivot Locknut 52 in·lb
Brake Reservoir Cap Screws 13 in·lb
Brake Lever Pivot Bolt 52 in·lb
Caliper Mounting Bolts (Front) 18
Brake Hose Banjo Bolts 25
Front Master Cylinder Clamp Bolts 78 in·lb S
Rear Master Cylinder Mounting Bolts 88 in·lb
Rear Master Cylinder Push Rod Locknut 12.5
Brake Reservoir Cap Bolts 13 in·lb
Brake Disc Mounting Bolts:
(Front) 87 in·lb L
(Rear) 16.6 L
Caliper Bleed Valves (Front, Rear) 69 in·lb
Front Caliper Holder Shaft 16 L
Rear Caliper Holder Shaft 20
Caliper Pin Bolts 104 in·lb L
Brake Pad Bolts 12.5
Rear Brake Pad Bolt Plug 22 in·lb
Brake Pedal Mounting Bolt 18 L
Suspension
Front Fork Cylinder Unit 25
Front Fork Clamp Bolts
(Upper) 14.5 L, AL
(Lower) 14.5 AL
Front Fork Adjuster Assembly 51 L
Front Fork Base Valve Assembly 21.8
Adjuster Assemble Locknut 16
Swingarm Pivot Shaft Nut 72
Rear Shock Absorber Mounting Nuts:
(Upper) 29
(Lower) 25
Spring Locknut 33
Piston Rod Locknut 27
Gas Reservoir Damping Adjuster
Assembly
21
Tie-Rod Mounting Nut (Front, Rear) 61
Rocker Arm Pivot Nut 61
Steering
Steering Stem Head Nut 72
Steering Stem Locknut 43 in·lb
Handlebar Clamp Bolts 18 S
Frame
Footpeg Bracket Bolts (Upper) 40 L
Rear Frame Mounting Bolts 25
Electrical System
Neutral Switch 104 in·lb
Neutral Switch Lead Terminal Screw 12 in·lb
Flywheel Nut 36
Flywheel Nut Cap 44 in·lb
Timing Inspection Cap 35 in·lb
Stator Bolts 61 in·lb
Crankshaft Sensor Bolts 61 in·lb
Spark Plug 115 in·lb
C.D.I. Unit Bolts 87 in·lb
Magneto Cover Bolts
L: 30 87 in·lb
L: 35 87 in·lb L
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
L: Apply a non-permanent locking agent to the threads.
LH: Left-hand Threads
S: Tighten the fasteners following the specified sequence.
Basic Torque for General Fasteners
Threads Diameter - Torque
5mm - 43 in·lb
6mm -69 in·lb
8mm -13.5
10mm - 25
12mm - 45
14mm - 72
16mm - 115
18mm - 165
20mm - 240
Fuel System
Air Cleaner Element Wing Bolt – – – Hand Tighten
Throttle Pulley Cover Bolt 30 in·lb
Throttle Cable Locknut 61 in·lb
Hot Start Plunger Cap Bolt 10 in·lb
Air Cleaner Duct Bolt and Nuts 27 in·lb
Rear Frame Mounting Bolts 25
Air Cleaner Housing Bolts 87 in·lb
Air Cleaner Duct Clamp Screws 27 in·lb
Carburetor Holder Clamp Screws 17 in·lb
Fuel Tap Plate Mounting Screws 7 in·lb
Cooling System
Right Engine Cover Bolt 87 in·lb
Water Pipe Bolt 87 in·lb
Water Pump Cover Bolts 87 in·lb L (1)
Water Pump Cover Bolts (with washer) 87 in·lb L (1)
Water Pump Impeller Bolt 61 in·lb
Radiator Hose Clamp Screws 13 in·lb
Radiator Screen Bolts 87 in·lb
Coolant Drain Plug 61 in·lb
Radiator Mounting Bolts 87 in·lb
Radiator Shroud Bolts 87 in·lb
Engine Top End
Auto-Decompressor Bolt 104 in·lb
Decompressor Plug 87 in·lb
Cylinder Head Cover Bolts 87 in·lb
Cylinder Head Bolts:
M10 36 S
M6 104 in·lb S
Camshaft Cap Bolts 87 in·lb S
Carburetor Holder Clamp Screws 17 in·lb
Plug 14 L
Lower Camshaft Chain Guide Bolt 87 in·lb
Rear Camshaft Chain Guide Bolt 11
Exhaust Pipe Stud – – – L (Planted side)
Camshaft Chain Tensioner Mounting Bolts 87 in·lb
Camshaft Chain Tensioner Cap Bolt 14.5
Cylinder Bolt M6 104 in·lb S
Exhaust Pipe Cover Screws 104 in·lb
Exhaust Pipe Holder Nuts 15 S
Silencer Mounting Bolts 15 S
Silencer Cover Bolt 109 in·lb L
Engine Right Side
Primary Gear Nut 72 LH
Shift Drum Cam Bolt 17 L
Clutch Spring Bolts 87 in·lb
Clutch Hub Nut 72
Gear Set Lever Nut 78 in·lb
Gear Set Lever Pivot Stud – – – L (Planted
Side)
Ratchet Plate Mounting Bolt 87 in·lb L
Ratchet Plate Mounting Screw 56 in·lb L
Kick Ratchet Guide Bolt 78 in·lb L
Kick Pedal Mounting Bolt 18 L
Shift Pedal Bolt 87 in·lb
Clutch Cover Bolts 87 in·lb L (2)
Right Engine Cover Bolts 87 in·lb
Engine Lubrication System
Engine Oil Drain Bolt M10
(for transmission room oil sump) 11
Engine Oil Drain Bolt M6
(for crank room oil sump) 61 in·lb
Oil Filter Cap Bolts 87 in·lb
Oil Pump Mounting Bolts 61 in·lb L
Water Pump Cover Bolts 87 in·lb L (1)
Water Pump Cover Bolt (with washer) 87 in·lb L (1)
Right Engine Cover Bolts 87 in·lb
Breather Fitting 11 L
Oil Pump Idle Gear Shaft Screws 56 in·lb L
Engine Removal/Installation
Engine Mounting Nuts 33
Engine Bracket Nuts 22
Swingarm Pivot Shaft Nut 72
Crankshaft/Transmission
Breather Fitting 11 L
Reed Valve Screws 61 in·lb
Piston Oil Nozzle 26 in·lb
Crankcase Bolts 87 in·lb S
Engine Oil Drain Bolt
(for crank room oil sump) 61 in·lb
(for transmission room oil sump) 11
Output Shaft Bearing Retaining Screw 56 in·lb L
Drive Shaft Bearing Retaining Screw 56 in·lb L
Shift Drum Bearing Retaining Bolts 87 in·lb L
Gear Set Lever Nut 78 in·lb
Shift Drum Cam Bolt 17 L
Neutral Switch 104 in·lb
Wheels/Tires
Front Axle 58
Front Axle Clamp Bolts 14.5 AL
Rear Axle Nut 80
Spoke Nipple
Not less
than 19 in·lb[/QUOTE]
Final Drive
Rear Sprocket Nuts 25
Engine Sprocket Cover Bolts 87 in·lb
Brakes
Brake Lever Pivot Locknut 52 in·lb
Brake Reservoir Cap Screws 13 in·lb
Brake Lever Pivot Bolt 52 in·lb
Caliper Mounting Bolts (Front) 18
Brake Hose Banjo Bolts 25
Front Master Cylinder Clamp Bolts 78 in·lb S
Rear Master Cylinder Mounting Bolts 88 in·lb
Rear Master Cylinder Push Rod Locknut 12.5
Brake Reservoir Cap Bolts 13 in·lb
Brake Disc Mounting Bolts:
(Front) 87 in·lb L
(Rear) 16.6 L
Caliper Bleed Valves (Front, Rear) 69 in·lb
Front Caliper Holder Shaft 16 L
Rear Caliper Holder Shaft 20
Caliper Pin Bolts 104 in·lb L
Brake Pad Bolts 12.5
Rear Brake Pad Bolt Plug 22 in·lb
Brake Pedal Mounting Bolt 18 L
Suspension
Front Fork Cylinder Unit 25
Front Fork Clamp Bolts
(Upper) 14.5 L, AL
(Lower) 14.5 AL
Front Fork Adjuster Assembly 51 L
Front Fork Base Valve Assembly 21.8
Adjuster Assemble Locknut 16
Swingarm Pivot Shaft Nut 72
Rear Shock Absorber Mounting Nuts:
(Upper) 29
(Lower) 25
Spring Locknut 33
Piston Rod Locknut 27
Gas Reservoir Damping Adjuster
Assembly
21
Tie-Rod Mounting Nut (Front, Rear) 61
Rocker Arm Pivot Nut 61
Steering
Steering Stem Head Nut 72
Steering Stem Locknut 43 in·lb
Handlebar Clamp Bolts 18 S
Frame
Footpeg Bracket Bolts (Upper) 40 L
Rear Frame Mounting Bolts 25
Electrical System
Neutral Switch 104 in·lb
Neutral Switch Lead Terminal Screw 12 in·lb
Flywheel Nut 36
Flywheel Nut Cap 44 in·lb
Timing Inspection Cap 35 in·lb
Stator Bolts 61 in·lb
Crankshaft Sensor Bolts 61 in·lb
Spark Plug 115 in·lb
C.D.I. Unit Bolts 87 in·lb
Magneto Cover Bolts
L: 30 87 in·lb
L: 35 87 in·lb L