Replace any damaged or missing fasteners.
1. Attempt to turn the fastener using a torque wrench set to the minimum torque specification for that fastener. Refer to Table 1-20.
- a. If the fastener does not rotate, the fastener torque has been maintained. No further attention is necessary.
- b. If the fastener rotates, remove it to determine if it has a locking agent.
- c. Ifit has a locking agent, clean all locking material from the threaded hole. Replace the fastener with a new one or clean the original fastener threads and apply the appropriate locking agent (see appropriate procedure).
- d. Install fastener. Tighten to specification.
2. If the fastener does not have a locking agent, install fastener. Tighten to specification.
Table 1-20. Critical fasteners
SYSTEM | FASTENER | TORQUE | |
Hand controls | Switch housing screws, upper and lower | 35-45 in·lbs | 4.0-5.1 Nm |
Clutch lever handlebar clamp screws | 108-132 in·lbs | 12.2-14.9 Nm | |
Master cylinder handlebar clamp screws | 108-132 in·lbs | 12.2-14.9 Nm | |
Engine | Stabilizer link screws | 25-35 ft·lbs | 33.9-47.5 Nm |
Stabilizer link frame bracket mounting screws, upper front | 25-35 ft·lbs | 33.9-47.5 Nm | |
Stabilizer link engine bracket mounting screws, upper front | 55-65 ft·lbs | 74.6-88.2 Nm | |
Stabilizer link frame bracket mounting screws, lower front | 25-35 ft·lbs | 33.9-47.5 Nm | |
Isolator mounting bolt, front | 95-105 ft·lbs | 129-142 Nm | |
Fork pivot/engine mount bolts | 60-70 ft·lbs | 81.4-95.0 Nm | |
Isolator mounting bracket screws, front (left side) | 25-35 ft·lbs | 33.9-47.5 Nm | |
Isolator mounting bracket screws, rear (left side) | 25-35 ft·lbs | 33.9-47.5 Nm | |
Brakes | Brake line banjo bolts | 20-25 ft·lbs | 27.1-33.9 Nm |
Brake disc mounting screws, front | 16-24 ft·lbs | 21.7-32.6 Nm | |
Brake disc mounting screws, rear | 30-45 ft·lbs | 40.7-61.1 Nm | |
Reservoir cover screws, front | 9-17 in·lbs | 1.0-2.0 Nm | |
Master cylinder mounting screws, rear: XL | 17-22 ft·lbs | 23.1-29.9 Nm | |
Master cylinder mounting screws, rear: XR | 72-96 in·lbs | 8.1-10.9 Nm | |
Master cylinder bracket-to-frame mounting screws, rear: XL | 17-22 ft·lbs | 23.1-29.9 Nm | |
Master cylinder/footrest bracket-to-frame mounting screws, rear: XR | 45-50 ft·lbs | 61-67.8 Nm | |
Brake caliper mounting bolts, front | 28-38 ft·lbs | 38.0-51.6 Nm | |
Axle nuts | Front | 60-65 ft·lbs | 81-88 Nm |
Rear | 95-105 ft·lbs | 129-142 Nm | |
Front fork/handlebar | Lower bracket pinch screws | 30-35 ft·lbs | 40.7-47.5 Nm |
Fork upper bracket pinch screws | 30-35 ft·lbs | 40.7-47.5 Nm | |
Fork stem bolt | 23-27 ft·lbs, loosen, 72-96 in·lbs | 31.2-36.6 Nm, loosen, 8.1-10.9 Nm | |
Fork stem pinch screw | 30-35 ft·lbs | 40.7-47.5 Nm | |
Axle pinch screw, front: XL | 21-27 ft·lbs | 28.5-36.6 Nm | |
Axle pinch screw, front: XR | 41-48 ft·lbs | 55.6-65.1 Nm | |
Handlebar clamp mounting screw | 12-18 ft·lbs | 16.3-24.4 Nm | |
Riser mounting bolts | 30-40 ft·lbs | 40.7-54.3 Nm | |
Final drive | Sprocket mounting bolts, rear | 60 ft·lbs, loosen 180 degrees, 80 ft·lbs | 81.3 Nm, loosen 180 degrees, 108 Nm |