Letters used in the "Remarks" column mean:
- AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
- EO: Apply engine oil.
- L: Apply a non-permanent locking agent to the threads.
- Lh: Left-hand Threads
- MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
- R: Replacement Parts
- S: Follow the specified tightening sequence.
- Si: Apply silicone grease (ex. PBC grease).
- SS: Apply silicone sealant.
| Fastener | Torque | Remarks | ||
| Nm | kgf·m | ft·lb | ||
| Fuel System (DFI) Fuel Pump Bolts | 9.8 | 1.0 | 87 in·lb | L, S |
| Right Switch Housing Screws | 3.5 | 0.36 | 31 in·lb | |
| Sidestand Switch Bolt | 3.9 | 0.40 | 35 in·lb | L |
| Crankshaft Sensor Bolts | 6.0 | 0.61 | 53 in·lb | |
| Oxygen Sensor (Europe Models) | 44.1 | 4.5 | 33 | |
| Spark Plugs | 15 | 1.5 | 11 | |
| Speed Sensor Bolt | 7.8 | 0.80 | 69 in·lb | |
| Timing Rotor Bolt | 40 | 4.1 | 30 | |
| Water Temperature Sensor | 12 | 1.2 | 106 in·lb | |
| Cooling System Baffle Plate Bolts | 5.9 | 0.60 | 52 in·lb | |
| Radiator Bolt | 15 | 1.5 | 11 | |
| Radiator Hose Clamp Screws | 2.0 | 0.20 | 18 in·lb | |
| Thermostat Housing Bolts | 9.8 | 1.0 | 87 in·lb | |
| Water Pump Cover Bolts | 9.8 | 1.0 | 87 in·lb | |
| Water Pump Drain Bolt | 9.8 | 1.0 | 87 in·lb | |
| Water Pump Impeller Bolt | 9.8 | 1.0 | 87 in·lb | |
| Water Temperature Sensor | 12 | 1.2 | 106 in·lb | |
| Engine Top End Air Suction Valve Cover Bolts | 9.8 | 1.0 | 87 in·lb | |
| Baffle Plate Bolts | 5.9 | 0.60 | 52 in·lb | |
| Camshaft Cap Bolts | 12 | 1.2 | 106 in·lb | S |
| Camshaft Chain Tensioner Cap Bolt | 20 | 2.0 | 15 | |
| Camshaft Chain Tensioner Mounting Bolts | 9.8 | 1.0 | 87 in·lb | |
| Camshaft Sprocket Bolts | 15 | 1.5 | 11 | L |
| Cylinder Head Bolts (M10) | 56 | 5.7 | 41 | MO, S |
| Cylinder Head Bolts (M6) | 12 | 1.2 | 106 in·lb | S |
| Cylinder Head Cover Bolts | 9.8 | 1.0 | 87 in·lb | |
| Rear Camshaft Chain Guide Bolts | 20 | 2.0 | 15 | L |
| Spark Plugs | 15 | 1.5 | 11 | |
| Throttle Body Assy Holder Bolts | 12 | 1.2 | 106 in·lb | |
| Cylinder Bolt (M8) | 27.5 | 2.8 | 20 | MO,S |
| Cylinder Nut (M10) | 49 | 5.0 | 36 | MO, S |
| Cylinder Bolts (M6) | 12 | 1.2 | 106 in·lb | |
| Exhaust Pipe Manifold Holder Nuts | 17 | 1.7 | 12 | |
| Muffler Body Mounting Bolt (Front) | 20 | 2.0 | 15 | |
| Muffler Body Mounting Bolt (Rear) | 20 | 2.0 | 15 | |
| Clutch | ||||
| Clutch Cable Clamp Bolt | 9.8 | 1.0 | 87 in·lb | |
| Clutch Cable Holder Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Clutch Cover Mounting Bolts | 9.8 | 1.0 | 87 in·lb | |
| Clutch Hub Nut | 130 | 13.3 | 96 | |
| Clutch Lever Clamp Bolts | 7.8 | 0.80 | 69 in·lb | S |
| Clutch Spring Bolts | 9.8 | 1.0 | 87 in·lb | |
| Timing Rotor Bolt Cap | 4.9 | 0.50 | 43 in·lb | |
| Oil Filler Plug | — | — | — | Hand-tighten |
| Oil Pump Chain Guide Bolts | 12 | 1.2 | 106 in·lb | L (1) |
| Oil Pump Sprocket Bolt | 12 | 1.2 | 106 in·lb | L, Lh |
| Timing Inspection Cap | 3.9 | 0.40 | 35 in·lb | |
| Engine Lubrication System | ||||
| Engine Oil Drain Bolt | 30 | 3.1 | 22 | |
| Filter Plate Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Holder Mounting Bolt | 25 | 2.5 | 18 | L |
| Lower Fairing Bracket Bolts | 12 | 1.2 | 106 in·lb | L |
| Oil Filter | 17.5 | 1.8 | 13 | EO, R |
| Oil Pan Bolts | 12 | 1.2 | 106 in·lb | |
| Oil Passage Plug | 20 | 2.0 | 15 | L |
| Oil Pipe Plate Bolt | 9.8 | 1.0 | 87 in·lb | L |
| Oil Plate Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Oil Pressure Relief Valve | 15 | 1.5 | 11 | L |
| Oil Pressure Switch | 15 | 1.5 | 11 | SS |
| Oil Pump Chain Guide Bolts | 12 | 1.2 | 106 in·lb | L (1) |
| Oil Pump Cover Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Oil Pump Sprocket Bolt | 12 | 1.2 | 106 in·lb | L, Lh |
| Engine Removal/Installation | ||||
| Engine Mounting Bracket Bolts | 25 | 2.5 | 18 | S |
| Front Engine Mounting Bolts | 44 | 4.5 | 32 | S |
| Rear Engine Mounting Nuts | 44 | 4.5 | 32 | S |
| Crankshaft/Transmission | ||||
| Breather Plate Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Race Holder Screw | 4.9 | 0.50 | 43 in·lb | L |
| Connecting Rod Big End Nuts | see Text | ← | ← | |
| Crankcase Bolt (M8, L = 110 mm) | 27.5 | 2.8 | 20 | S |
| Crankcase Bolt (M6, L = 32 mm) | 19.6 | 2.0 | 14 | S |
| Crankcase Bolts (M6, L = 38 mm) | 19.6 | 2.0 | 14 | S |
| Crankcase Bolts (M6, L = 45 mm) | 19.6 | 2.0 | 14 | S |
| Crankcase Bolts (M8, L = 50 mm) | 27.5 | 2.8 | 20 | S |
| Crankcase Bolts (M8, L = 60 mm) | 35 | 3.6 | 26 | MO, S |
| Crankcase Bolts (M8, L = 73 mm) | 35 | 3.6 | 26 | MO, S |
| Crankcase Bolts (M9, L = 113 mm) | 44 | 4.5 | 32 | MO, S |
| Crankcase Bolts (M9, L = 83 mm) | 44 | 4.5 | 32 | MO, S |
| Upper Crankcase Bolt (M8, L = 120 mm) | 27.5 | 2.8 | 20 | S |
| Upper Crankcase Bolts (M8, L = 110 mm) | 27.5 | 2.8 | 20 | S |
| Oil Pipe Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Oil Plate Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Shift Shaft Return Spring Pin | 29 | 3.0 | 21 | L |
| Timing Rotor Bolt | 40 | 4.1 | 30 | |
| Drive Shaft Bearing Holder Screw | 4.9 | 0.50 | 43 in·lb | L |
| Gear Positioning Lever Bolt | 12 | 1.2 | 106 in·lb | L |
| Neutral Switch | 15 | 1.5 | 11 | |
| Neutral Switch Holder Screw | 4.9 | 0.50 | 43 in·lb | L |
| Oil Jet Nozzle | 2.9 | 0.30 | 26 in·lb | L |
| Shift Drum Bearing Holder Screws | 4.9 | 0.50 | 43 in·lb | L |
| Shift Drum Cam Bolt | 12 | 1.2 | 106 in·lb | L |
| Shift Lever Bolt | 12 | 1.2 | 106 in·lb | L |
| Shift Rod Plate Bolt | 9.8 | 1.0 | 87 in·lb | L |
| Shift Shaft Cover Bolts | 9.8 | 1.0 | 87 in·lb | L (3) |
| Shift Shaft Cover Screw | 4.9 | 0.50 | 43 in·lb | L |
| Transmission Case Bolts | 20 | 2.0 | 15 | |
| Wheels/Tires | ||||
| Front Axle | 108 | 11.0 | 80 | |
| Front Axle Clamp Bolt | 20 | 2.0 | 15 | |
| Rear Axle Nut | 108 | 11.0 | 80 | |
| Final Drive | ||||
| Engine Sprocket Nut | 125 | 12.7 | 92 | MO |
| Rear Axle Nut | 108 | 11.0 | 80 | |
| Rear Sprocket Nuts | 59 | 6.0 | 44 | |
| Speed Sensor Bolt | 7.8 | 0.80 | 69 in·lb | L |
| Speed Sensor Bracket Bolts | 9.8 | 1.0 | 87 in·lb | |
| Brakes | ||||
| Bleed Valve | 7.8 | 0.80 | 69 in·lb | |
| Brake Hose Banjo Bolts | 25 | 2.5 | 18 | |
| Brake Lever Pivot Bolt | 1.0 | 0.10 | 9 in4b | Si |
| Brake Lever Pivot Bolt Locknut | 5.9 | 0.60 | 52 in·lb | |
| Front Brake Disc Mounting Bolts | 27 | 2.8 | 20 | L |
| Front Brake Light Switch Screw | 1.0 | 0.10 | 9 in·lb | |
| Front Brake Reservoir Cap Screws | 1.5 | 0.15 | 13 in·lb | |
| Front Caliper Mounting Bolts | 34 | 3.5 | 25 | |
| Front Master Cylinder Clamp Bolts | 8.8 | 0.90 | 78 in·lb | |
| Bleed Valve | 7.8 | 0.80 | 69 in·lb | |
| Brake Hose Banjo Bolts | 25 | 2.5 | 18 | |
| Brake Pedal Bolt | 8.8 | 0.90 | 78 in·lb | |
| Rear Brake Disc Mounting Bolts | 27 | 2.8 | 20 | L |
| Rear Caliper Mounting Bolts | 25 | 2.5 | 18 | |
| Rear Master Cylinder Mounting Bolts | 25 | 2.5 | 18 | |
| Rear Master Cylinder Push Rod Locknut | 18 | 1.8 | 13 | |
| Brake Pipe Joint Nuts (KLE650B Models) | 18 | 1.8 | 13 | |
| Suspension Front Axle Clamp Bolt | 20 | 2.0 | 15 | |
| Front Fork Bottom Allen Bolts | 20 | 2.0 | 15 | |
| Front Fork Clamp Bolts (Lower) | 29 | 3.0 | 21 | AL |
| Front Fork Clamp Bolts (Upper) | 20 | 2.0 | 15 | |
| Front Fork Top Plugs | 35 | 3.6 | 26 | |
| Piston Rod Nuts | 20 | 2.0 | 15 | |
| Rear Shock Absorber Bolt (Upper) | 59 | 6.0 | 44 | |
| Rear Shock Absorber Nut (Lower) | 59 | 6.0 | 44 | |
| Swingarm Pivot Shaft Nut | 108 | 11.0 | 80 | |
| Steering Front Fork Clamp Bolts (Lower) | 29 | 3.0 | 21 | AL |
| Front Fork Clamp Bolts (Upper) | 20 | 2.0 | 15 | |
| Upper Handlebar Holder Bolts | 25 | 2.5 | 18 | S |
| Lower Handlebar Holder Bolts | 25 | 2.5 | 18 | |
| Left Switch Housing Screws | 3.5 | 0.36 | 31 in·lb | |
| Right Switch Housing Screws | 3.5 | 0.36 | 31 in·lb | |
| Steering Stem Head Bolt | 108 | 11.0 | 80 | |
| Steering Stem Nut | 20 | 2.0 | 15 | |
| Frame Footpeg Holder Bolts | 34 | 3.5 | 25 | L |
| Front Footpeg Stay Bolts | 25 | 2.5 | 18 | |
| Rear Footpeg Stay Bolts | 25 | 2.5 | 18 | |
| Sidestand Bolt | 44 | 4.5 | 32 | |
| Sidestand Switch Bolt | 3.9 | 0.40 | 35 in·lb | L |
| Lower Fairing Mounting Bolts | 8.8 | 0.90 | 78 in·lb | |
| Windshield Mounting Bolts | 0.40 | 0.041 | 3.5 in·lb | |
| Tandem Grip Mounting Bolts | 25 | 2.5 | 18 | |
| Electrical System Tail/Brake Light Mounting Bolts | 1.2 | 0.12 | 11 in·lb | |
| License Plate Light Cover Screws | 0.90 | 0.090 | 8 in·lb | |
| License Plate Light Mounting Screws | 1.2 | 0.12 | 11 in·lb | |
| Turn Signal Light Lens Screws | 1.0 | 0.10 | 9 in·lb | |
| Alternator Cover Bolts | 9.8 | 1.0 | 87 in·lb | |
| Alternator Lead Holding Plate Bolt | 9.8 | 1.0 | 87 in·lb | L |
| Alternator Rotor Bolt | 155 | 15.8 | 114 | MO |
| Engine Ground Cable Terminal Bolt | 9.8 | 1.0 | 87 in·lb | |
| Front Brake Light Switch Screw | 1.2 | 0.12 | 11 in·lb | |
| Left Switch Housing Screws | 3.5 | 0.36 | 31 in·lb | |
| Right Switch Housing Screws | 3.5 | 0.36 | 31 in·lb | |
| Sidestand Switch Bolt | 3.9 | 0.40 | 35 in·lb | L |
| Starter Motor Cable Terminal Nut | 6.0 | 0.61 | 53 in·lb | |
| Starter Motor Clutch Bolts | 34 | 3.5 | 25 | L |
| Starter Motor Mounting Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Starter Motor Terminal Locknut | 11 | 1.1 | 97 in·lb | |
| Starter Motor Through Bolts | 4.9 | 0.50 | 43 in·lb | |
| Stator Coil Bolts | 12 | 1.2 | 106 in·lb | L |
| Crankshaft Sensor Bolts | 6.0 | 0.61 | 53 in·lb | |
| Neutral Switch | 15 | 1.5 | 11 | |
| Oil Pressure Switch | 15 | 1.5 | 11 | SS |
| Oxygen Sensor (Europe Models) | 44.1 | 4.50 | 32.5 | |
| Spark Plugs | 15 | 1.5 | 11 | |
| Speed Sensor Bolt | 7.8 | 0.80 | 69 in·lb | L |
| Timing Rotor Bolt | 40 | 4.1 | 30 | |
| Water Temperature Sensor | 12 | 1.2 | 106 in·lb | |
| Fuel Level Sensor Bolts | 6.9 | 0.70 | 61 in·lb | L |
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
| Threads Diameter (mm) | Torque | ||
| Nm | kgf·m | ft·lb | |
| 5 | 3.4-4.9 | 0.35-0.50 | 30-43 in·lb |
| 6 | 5.9-7.8 | 0.60-0.80 | 52-69 in·lb |
| 8 | 14-19 | 1.4-1.9 | 10.0-13.5 |
| 10 | 25-34 | 2.6-3.5 | 19.0-25 |
| 12 | 44-61 | 4.5-6.2 | 33-45 |
| 14 | 73-98 | 7.4-10.0 | 54-72 |
| 16 | 115-155 | 11.5-16.0 | 83-115 |
| 18 | 165-225 | 17.0-23.0 | 125-165 |
| 20 | 225-325 | 23.0-33.0 | 165-240 |