Bolt torque specs

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Thanks to Jetblack The listed torque specifications are as accurate as the Kawasaki shop manual, and as I could type them. They are the general torques for all Kawasaki cycles; if any torque seems off or wrong; use the: Basic torques for general fasteners directly below; instead of the one listed...p.s. beware of the Lh or Left handed screws, it would be a good idea to memorize which ones are left handed.

Basic Torques For General Fasteners

5mm 30 ~ 43 in lb

6mm 52 ~ 69 in lb

8mm 10.0 ~ 13.5

10mm 19.0 ~ 25.0

12mm 33 ~ 45

14mm 54 ~ 72

16mm 83 ~ 115

18mm 125 ~ 165

20mm 165 ~ 240

Fuel System

Fuel Filter Nuts 87 in lb

Fuel Hose Clamp Screws 22 in lb

Vacuum Sensor Nut 87 in lb

Atmospheric Pressure Sensor Nut 87 in lb

High Pressure Fuel Hose Clamp Screws 13 in lb

Pressure Regulator Screws 43 in lb

Delivery Joint Screws 30 in lb

Throttle Body

Throttle Cable Holder Screw 30 in lb L

Throttle Body Flanged Bolts 43 in lb

Throttle Assy Holder Bolts 104 in lb Right Side

Inlet Manifold Bolts 104 in lb On Cylinder
Head

Exhaust Header Bolts 14 ft lb On
Cylinder Head

Full Throttle Stopper Screw - L, LH

Second Lead Holder Bolts 87 in lb Right
side

Air Cleaner Duct Holder Bolts 87 in lb Left side

Right & Left Air Cleaner Base Bolts 104 in lb

Right & Left Air Cleaner Base Screws 19 in lb L, Lower Duct

Left Air Cleaner Duct Tapping Screws 19 in lb

Left Air Cleaner Cover Allen Bolt 12

Right Air Cleaner Cover Allen Bolt 12

Right Air Cleaner Allen Bolts 95 in lb

Throttle Body

Choke Cable Plate Screw 26 in lb L, Throttle Body

Inlet Air Temperature Sensor Nut 69 in lb

Water Temperature Sensor 13 SS

Fuel Pump Bolts 61 in lb S, L

Return Fuel Check Valve 14

Cooling System

Radiator Hose Clamp Screws 22 in lb

Coolant Air Bleeder Bolt 69 in lb

Radiator Fan Switch 13

Water Temperature Switch 65 in lb SS

Water Pump Impeller Bolt 87 in lb Lh

Water Pump Cover Bolts 87 in lb

Water Pump Drain Bolt 87 in lb

Water Pipe Bolts 87 in lb

Radiator Drain Bolt 65 in lb

Clutch

Clutch Lever Pivot Bolt 8.7 in lb

Clutch Lever Pivot Bolt Locknut 52 in lb

Clutch Reservoir Cap Screws 13 in lb

Clutch Slave Cylinder Bleed Valve 69 in lb

Clutch Slave Cylinder Bolts - L

Clutch Hose Banjo Bolts 18

Clutch Master Cylinder Clamp Bolts 87 in lb
S

Starter Lockout Switch Screws 10 in lb

Push Rod Guide Bolts 87 in lb L

Clutch Cover Bolts 87 in lb

Clutch Cover Damper Bolts (outside) 87 in lb L

Clutch Cover Damper Bolts (inside) 87 in lb EO

Clutch Cover Damper Screws 43 in lb L

Clutch Hub Nut 108 EO

Engine Top End

Spark Plugs 13

Spark Plug Retainer 104 in lb

Air Suction Valve Cover Bolts 65 in lb

Chain Tensioner Mounting Bolts 87 in lb S

Chain Tensioner Lockbolt 43 in lb S

Chain Tensioner Cap 14 S

Timing Inspection Plug 13 in lb

Rotor Bolt Plug 13 in lb

Camshaft Sproket Bolts 11 L

Oil Hose Flange Bolts 87 in lb

Rocker Shafts 18

Rocker Case Nuts 12 mm 58 EO, S

Rocker Case Nuts 8 mm 18 S

Rocker Case Bolts 6 mm 78 in lb S

Cylinder Head Nuts 18 S

Cylinder Head Jacket Plug 14 L

Rocker Case Cover Bolts 78 in lb S

Camshaft Chain Guide Bolts 87 in lb L
Cylinder Nuts 18 S

Inlet Manifold Bolts 104 in lb

Exhaust Pipe Cover Clamp Bolts 61 in lb

Engine Lubrication System

Oil Filler Cap 13 in lb

Oil Screen Plug 15

Engine Oil Drain Plug 15

Oil Filter (cartridge) 13 EO, ft

Oil Filter Bolt 18 SS

Oil Pressure Relief Valve 11 L

Oil Pressure Switch Terminal Bolt 13 in lb

Oil Pressure Switch 11 SS

Oil Pump Cover Screws 69 in lb

Oil Pump Mounting Bolts 87 in lb

Oil Hose Banjo Bolts 87 in lb

Oil Hose Flange Bolt (outside) 87 in lb

Oil Pipe Holder Bolts (inside) 78 in lb L

Oil Pipe Clamp Bolts (inside) 87 in lb L

Right & Left Crankcase Oil Nozzles 30 in lb x3

Oil Reserve Tank Bolt 78 in lb

Crankcase Breather Hose Clamp Screw 13 in lb

Engine Removal/Installation

Downtube Bolts 32

Engine Mounting Bolts & Nuts 32

Engine Mounting Bracket Bolts 18

Engine Ground Terminal Bolt 69 in lb

Wheels & Tires

Front Axle Clamp Bolt 25 S

Front Axle Nut 79.6 S

Rear Axle Nut 79.6

Spoke Nipples 26 ~ 65 in lb

Final Drive

Oil Pipe Banjo Bolts (Front Gear) 104 in lb

Oil Nozzle (Front Gear) 26 in lb

Oil Nozzle (Front Gear) 13

Neutral Switch 11

Front Gear Case Bolts (6 mm) 104 in lb Mar 9

Front Gear Case Bolts (8 mm) 22

Speed Sensor Bolt 87 in lb L

Damper Cam Nut (Front Gear) 166 MO (threads)

Drive Gear Nut (Front Gear) 195 MO, ST

Driven Gear Assy Mounting Bolts 18

Driven Gear Bolt (Front Gear) 101 MO, ST

Bearing Retainer Bolts (Front Gear) 78 in lb L

Final Gear Case Drain Plug 78 in lb

Final Gear Case Mounting Nuts 25

Final Gear Case Studs - L

Final Gear Case Cover Bolts (8 mm) 17

Final Gear Case Cover Bolts (10 mm) 25

Pinion Gear Nut (Final Gear) 86.8 St, MO

Pinion Bearing Retainer (Final Gear) 181 Lh

Retainer Stop Screw 12 L

Brakes

Caliper Bleed Valves 69 in lb

Brake Hose Banjo Bolts 18

Brake Lever Pivot Bolt 8.7 in lb

Brake Lever Pivot Bolt Locknut 52 in lb

Front Brake Reservoir Cap Screws 13 in lb

Front Brake Light Switch Screw 10 in lb

Front Master Cylinder Clamp Bolts 78 in lb S

Front Caliper Mounting Bolts 25

Rear Caliper Mounting Bolts 25

Rear Caliper Holder Bolt 47

Brake Disc Bolts 20 L

Rear Master Cylinder Mounting Bolts 18

Rear Master Cylinder Push Rod Locknut 13

Brake Pedal Clamp Bolt 18

Suspension

Piston Rod Nut 14

Front Fork Top Plug 16

Upper Front Fork Clamp Bolts 14

Lower Front Fork Clamp Bolts 25

Lower Front Fork Cover Bolts 65 in lb

Front Fork Cover Screws 39 in lb

Front Fork Bottom Allen Bolts 14 L

Front Axle Clamp Bolt 25 S

Spacer Bolt 35 in lb

Rear Shock Absorber Nuts 25

Shock Absorber Air Valves 47 in lb

Swingarm Pivot Shaft 94 G

Steering

Steering Stem Head Nut (the chrome one) 65

Steering Stem Nut (the serrated one) 14 ft lbs for 1500's, 43 in lbs for 1600

Handlebar Clamp Bolts 25 S

Handlebar Holder Nuts 25

Handlebar End Caps - Lh, L

Handlebar Switch Housing Screws 30 in lb

Upper Front Fork Clamp Bolts 14

Lower Front Fork Clamp Bolts 25

Headlight Cover Bolts 65 in lb

Upper Fork Cover Bolts 39 in lb

Brake Joint Bolts 65 in lb

Turn Signal Light Holder Bolts 65 in lb

Frame

Front Fender Bolts 61 in lb

Downtube Bolts 32

Front Footboard Bracket Bolts 25

Rear Footpeg Bracket Bolts 14

Sidestand Nut 32

Electrical

Spark Plugs 13

Pickup Coil Screws 26 in lb

Stator Lead Holder Screw 87 in lb L

Pickup Coil Lead Holder Bolt 87 in lb L

Alternator Outer Cover Bolts 104 in lb

Alternator Cover Joint Bolts 104 in lb

Alternator Outer Cover Damper Bolts 87 in lb EO (tip)

Alternator Cover Bolts 87 in lb

Alternator Inner Cover Bolts 87 in lb

Alternator Rotor Bolt 57 EO

Alternator Outer Stator Bolts 113 in lb L

Alternator Inner Stator Bolts 113 in lb L

Timing Inspection Plug 13 in lb

Starter Motor Terminal Locknut 95 in lb

Starter Motor Terminal Nut 43 in lb

Starter Motor Assembly Bolts 43 in lb

Starter Motor Mounting Bolts 87 in lb

Headlight Body Mounting Screws (inside) 26 in lb L

Headlight Rim Screws 8.7 in lb

Handlebar Switch Housing Screws 30 in lb

Starter Lockout Switch Screw 10 in lb

Front Brake Light Switch Screw 10 in lb

Sidestand Switch Bolt 78 in lb L

Radiator Fan Switch 13

Water Temperature Switch 65 in lb SS

Oil Pressure Switch Terminal Bolt 13 in lb

Oil Pressure Switch 11 SS

Neutral Switch 11

Turn Signal Light Lens Screws 8.7 in lb

Turn Signal Light Mounting Nuts 52 in lb

Notes:

G: Apply grease to the threads

EO: Apply engine oil to the threads and the seating surface

L: Apply a non-permanentlockng agent to the threads

LH: Left-hand threads

MO: Apply molybdenum disulfide oil to the treads and seating surfaces

S: Tighten the fasteners following the specified sequence

SS: Apply silicone sealant

ST: Stake the fasteners to prevent loosening

R: Replacement parts

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