- 2T: Apply 2-stroke oil.
- L: Apply a non-permanent locking agent to the threads.
- Lh: Left-hand threads
- M: Apply molybdenum disulfide grease.
- MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
- S: Tighten the fasteners following the specified sequence.
- Si: Apply silicone grease (ex. PBC grease).
- SS: Apply silicone sealant.
| Fastener | Torque | Remarks | ||
| N-m | kgfm | ft·lb | ||
| Fuel System | ||||
| Water Temperature Sensor | 12 | 1.2 | 106 in·lb | |
| Speed Sensor Mounting Bolt | 9.8 | 1.0 | 87 in·lb | L |
| Fuel Pump Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Oxygen Sensor | 25 | 2.5 | 18 | |
| Fuel Level Sensor Mounting Bolts | 6.9 | 0.70 | 61 in·lb | L |
| Air Cleaner Housing Bolts | 9.8 | 1.0 | 87 in·lb | |
| Air Cleaner Cover Bolts | 4.9 | 0.50 | 43 in·lb | |
| Air Cleaner Element Screw | 4.9 | 0.50 | 43 in·lb | |
| Throttle Body Assy Holder Bolts | 9.8 | 1.0 | 87 in·lb | |
| Inlet Manifold Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Delivery Joint Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Delivery Joint Bracket Bolts | 9.8 | 1.0 | 87 in·lb | |
| Vehicle-down Sensor Bolts | 4.9 | 0.50 | 43 in·lb | |
| Inlet Air Pressure Sensor Bolt | 6.9 | 0.70 | 61 in·lb | |
| Inlet Air Temperature Sensor Screw | 1.2 | 0.12 | 11 in·lb | |
| Cooling System | ||||
| Radiator Hose Clamp Screws | 2.0 | 0.20 | 18 in·lb | |
| Water Pump Impeller Bolt | 9.8 | 1.0 | 87 in·lb | |
| Coolant Drain Bolt | 9.8 | 1.0 | 87 in·lb | |
| Thermostat Housing Cover Bracket Bolts | 6.9 | 0.70 | 61 in·lb | |
| Thermostat Housing Cover Bolts | 4.9 | 0.50 | 43 in·lb | L |
| Radiator Bolts | 6.9 | 0.70 | 61 in·lb | |
| Radiator Screen Screws | 6.9 | 0.70 | 61 in·lb | |
| Radiator Fan Bolts | 8.3 | 0.85 | 73 in·lb | |
| Water Hose Fitting Bolts | 9.8 | 1.0 | 87 in·lb | |
| Reserve Tank Bolts | 6.9 | 0.70 | 61 in·lb | |
| Engine Top End | ||||
| Cylinder Head nuts (M10) (First) | 20 | 2.0 | 15 | MO, S |
| Cylinder Head nuts (M10) (Final) | 49 | 5.0 | 36 | MO, S |
| Cylinder Head nuts (M8) | 25 | 2.5 | 18 | S |
| Camshaft Cap Bolts | 25 | 2.5 | 18 | |
| Cylinder Head Cover Bolts | 12 | 1.2 | 106 in·lb | |
| Cylinder Head Outer Cover Bolts | 9.8 | 1.0 | 87 in·lb | |
| Plug (PT1/4) | 15 | 1.5 | 11 | L |
| Plug (PT1/2) | 20 | 2.0 | 15 | L |
| Muffler Mounting Bolts | 25 | 2.5 | 18 | |
| Muffler Mounting Nut | 25 | 2.5 | 18 | |
| Muffler Joint Clamp Bolt | 17 | 1.7 | 12 | |
| Exhaust Pipe Cover Clamp Bolts | 6.9 | 0.70 | 61 in·lb | |
| Exhaust Pipe Cover Bolts | 6.9 | 0.70 | 61 in·lb | |
| Exhaust Pipe Holder Nuts | 17 | 1.7 | 12 | |
| Camshaft Sprocket Bolts | 49 | 5.0 | 36 | L |
| Camshaft Chain Tensioner Cap Bolts | 20 | 2.0 | 15 | |
| Camshaft Chain Guide Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Clutch | ||||
| Right Engine Cover Mounting Bolts | 9.8 | 1.0 | 87 in·lb | L (1) |
| Clutch Spring Bolts | 9.8 | 1.0 | 87 in·lb | |
| Clutch Hub Nut | 130 | 13.2 | 95.9 | |
| Clutch Lever Clamp Bolts | 7.8 | 0.80 | 69 in·lb | S |
| Engine Lubrication | ||||
| Engine Oil Drain Plug | 20 | 2.0 | 15 | |
| Oil Pump Cover Bolt | 9.8 | 1.0 | 87 in·lb | L |
| Oil Pump Drive Chain Guide Bolt | 9.8 | 1.0 | 87 in·lb | L |
| Oil Filter Plate Bolts | 7.8 | 0.80 | 69 in·lb | |
| Oil Pressure Switch | 15 | 1.5 | 11 | SS |
| Oil Pipe Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Oil Return Pipe Bolts | 9.8 | 1.0 | 87 in·lb | |
| Oil Pressure Switch Adapter | 20 | 2.0 | 15 | |
| Oil Filter | 18 | 1.8 | 13 | |
| Oil Screen Plug | 20 | 2.0 | 15 | |
| Oil Pressure Relief Valve | 15 | 1.5 | 11 | L |
| Engine Removal/Installation | ||||
| Engine Mounting Nuts | 44 | 4.5 | 32 | |
| Engine Mounting Bracket Bolts (M10) | 44 | 4.5 | 32 | |
| Engine Mounting Bracket Bolts (M8) | 25 | 2.5 | 18 | |
| Downtube Bolts | 44 | 4.5 | 32 | |
| Crankshaft/Transmission | ||||
| Balancer Gear Bolt | 69 | 7.0 | 51 | |
| Starter Motor Clutch Gear Bolt | 69 | 7.0 | 51 | |
| Primary Gear Bolt | 98 | 10 | 72 | MO |
| Connecting Rod Big End Bolts | 46 | 4.7 | 34 | MO |
| Shift Drum Bearing Stopper Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Shift Drum Cam Bolt | 12 | 1.2 | 106 in·lb | L |
| Neutral Switch | 15 | 1.5 | 11 | |
| Rear Shift Lever Clamp Bolt | 12 | 1.2 | 106 in·lb | |
| Shift Pedal Clamp Bolt | 12 | 1.2 | 106 in·lb | |
| Shift Rod Locknut (Front) | 9.8 | 1.0 | 87 in·lb | |
| Oil Nozzle | 3.9 | 0.40 | 34 in·lb | |
| Shift Rod Locknut (Rear) | 9.8 | 1.0 | 87 in·lb | Lh |
| Rear Shift Pedal Pad Screw | 6.9 | 0.70 | 61 in·lb | |
| Shift Drum Position Lever Bolt | 9.8 | 1.0 | 87 in·lb | |
| Shift Shaft Return Spring Pin | 29 | 3.0 | 21 | L |
| Bearing Retainer Bolts | 9.8 | 1.0 | 87 in·lb | L |
| Balancer Shaft Bearing Stopper Plate Bolts | 9.8 | 1.0 | 87 in·lb | |
| Crankcase Bolts (M10) | 39 | 4.0 | 29 | S |
| Crankcase Bolts (M6) | 9.8 | 1.0 | 87 in·lb | S |
| Engine Ground Lead Bolt | 9.8 | 1.0 | 87 in·lb | |
| Clamp Mounting Bolts | 9.8 | 1.0 | 87 in·lb | |
| External Shift Mechanism Cover Bolts | 9.8 | 1.0 | 87 in·lb | |
| Wheels/Tires | ||||
| Front Axle Nut | 108 | 11.0 | 79.7 | |
| Front Axle Clamp Bolt | 20 | 2.0 | 15 | |
| Rear Axle Nut | 108 | 11.0 | 79.7 | |
| Spoke Nipples | 5.2 | 0.53 | 46 in·lb | |
| Final Drive | ||||
| Rear Pulley Mounting Nuts | 59 | 6.0 | 44 | |
| Rear Pully Plate Bolts | 6.9 | 0.70 | 61 in·lb | L |
| Engine Pully Mounting Nut | 127 | 13.0 | 93.7 | M |
| Engine Pullly Plate Bolts | 9.8 | 1.0 | 87 in·lb | |
| Engine Pulley Cover Bolts | 9.8 | 1.0 | 87 in·lb | |
| Engine Pulley Cover Clamp Mounting Bolt | 9.8 | 1.0 | 87 in·lb | |
| Drive Belt Guide Bolts | 9.8 | 1.0 | 87 in·lb | |
| Brakes | ||||
| Bleed Valves | 7.8 | 0.80 | 69 in·lb | |
| Brake Hose Banjo Bolts | 25 | 2.5 | 18 | |
| Brake Lever Pivot Bolt | 1.0 | 0.10 | 88 in·lb | Si |
| Brake Lever Pivot Locknut | 5.9 | 0.60 | 52 in·lb | |
| Brake Pedal Clamp Bolt | 25 | 2.5 | 18 | |
| Front Brake Disc Mounting Bolts | 27 | 2.8 | 20 | L |
| Front Brake Light Switch Screw | 1.2 | 0.12 | 11 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 | S |
| Rear Brake Disc Mounting Bolts | 27 | 2.8 | 20 | L |
| Rear Caliper Mounting Bolts | 34 | 3.5 | 25 | |
| Rear Master Cylinder Mounting Bolts | 25 | 2.5 | 18 | |
| Rear Master Cylinder Push Rod Locknut | 17 | 1.7 | 12 | |
| Suspension | ||||
| Swingarm Pivot Shaft Nut | 98 | 10 | 72 | |
| Rear Shock Absorber Nuts | 59 | 6.0 | 44 | |
| Lower Tie-Rod Nut | 59 | 6.0 | 44 | |
| Upper Tie-Rod Nut | 108 | 11.0 | 80 | |
| Rocker Arm Pivot Shaft Nut | 59 | 6.0 | 44 | |
| Upper Front Fork Clamp Bolts | 20 | 2.0 | 15 | |
| Lower Front Fork Clamp Bolts | 34 | 3.5 | 25 | |
| Front Fork Bottom Allen Bolts | 20 | 2.0 | 15 | L |
| Front Fork Upper Cover Stopper Bolts | 4.2 | 0.43 | 37 in·lb | |
| Steering | ||||
| Handlebar Holder Nuts | 34 | 3.5 | 25 | |
| Handlebar Clamp Bolts | 34 | 3.5 | 25 | S, 2T |
| Steering Stem Head Bolt | 49 | 5.0 | 36 | |
| Steering Stem Nut | 4.9 | 0.50 | 43 in·lb | |
| Frame | ||||
| Sidestand Mounting Nut | 44 | 4.5 | 32 | |
| Sidestand Mounting Bolt | 44 | 4.5 | 32 | |
| Footboard Bracket Bolts | 34 | 3.5 | 25 | |
| Left Footpeg Bracket Bolts | 25 | 2.5 | 18 | |
| Right Footpeg Bracket Bolts | 25 | 2.5 | 18 | |
| Lower Muffler Bracket Bolts | 34 | 3.5 | 25 | |
| Upper Muffler Bracket Bolts | 34 | 3.5 | 25 | |
| Electrical System | ||||
| Alternator Outer Cover Bolts | 9.8 | 1.0 | 87 in·lb | |
| Tail/Brake Light Unit Mounting Nuts | 5.9 | 0.60 | 52 in·lb | |
| Alternator Cover Bolts | 9.8 | 1.0 | 87 in·lb | |
| Timing Inspection Plate Bolts | 9.8 | 1.0 | 87 in·lb | |
| Alternator Lead Holder Plate Bolts | 5.9 | 0.60 | 52 in·lb | |
| Stator Coil Bolts | 12 | 1.2 | 106 in·lb | L |
| Alternator Rotor Bolt (First) | 69 | 7.0 | 51 | S |
| Alternator Rotor Bolt (Final) | 160 | 16.3 | 118 | S, MO |
| Regulator/Rectifier Bolts | 6.9 | 0.70 | 61 in·lb | |
| Starter Motor Mounting Bolts | 9.8 | 1.0 | 87 in·lb | |
| Starer Relay Terminal Screws | 3.9 | 0.40 | 34 in·lb | |
| Starter Motor Cable Terminal Nut | 5.9 | 0.60 | 52 in·lb | |
| Starter Motor Terminal Locknut | 11 | 1.1 | 97 in·lb | |
| Starter Motor Through Bolts | 4.9 | 0.50 | 43 in·lb | |
| Headlight Rim Screws | 2.9 | 0.30 | 26 in·lb | L |
| Crankshaft Sensor Bolts | 5.9 | 0.60 | 52 in·lb | |
| Ignition Coil Bracket Bolt | 9.8 | 1.0 | 87 in·lb | |
| Ignition Coil Mounting Nuts | 6.9 | 0.70 | 61 in·lb | |
| Fuel Level Sensor Mounting Bolts | 6.9 | 0.70 | 61 in·lb | |
| Spark Plugs | 18 | 1.8 | 13 in·lb | |
| Sidestand Switch Mounting Bolts | 8.8 | 0.90 | 78 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 | ||
| N-m | 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 |