kpage
New Member
Posts: 12
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Post by kpage on Jun 7, 2012 15:58:41 GMT -6
I've looked all over the internet, 2 different online manuals, but cannot find bolt torque specs. I usually like to have them for all major systems, but especially the engine. The online ver of the Haynes manual refers to a page of specs at end of Chapter 1, but my copy doesn't have them. Can someone who have them please post for everyone in a prominent place on the forum? Thanks.
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Post by Jet⚡Black on Jun 8, 2012 18:42:45 GMT -6
Probably more torques than you'd ever want but here they are...it's a long list; so to find exactly the screw or bolt you want to tighten fast: Hold down Ctrl on your keyboard then press F (Ctrl+F) that brings up the search function for the page you are on, type in the key word then click: Next, or click the down arrow(depends on your browser) to find what you are looking for.(this works everywhere on the web)
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 Lock nut 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 (chrome) 65
Steering Stem Nut (serrated) 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 Lock nut 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 threads 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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Post by zekkfett on Jun 9, 2012 1:52:39 GMT -6
Hmm....you sure you got all of em?? ;D
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kpage
New Member
Posts: 12
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Post by kpage on Jun 9, 2012 12:43:21 GMT -6
Hey, Jet! Great job! Thanks for this! I did find the Engine torque specs at the beginning of Chapter 2 of the Haynes Manual for those seeking engine specs. I hope I don't have to need them, if you know what I mean!
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Post by Jet⚡Black on Jun 9, 2012 14:09:23 GMT -6
No worries; it did look a lot prettier until the auto formatting from the paste got a hold of it. It took away the bold and jumped things around a bit. I could have fixed it better; but the tiny window provided and how long the list was kinda tossed a wrench in there, I haven't gotten familiar with the text editor on here yet either so...yeah. I am glad you got the specs you needed, Cheers! Zekk I am pretty sure a few are duplicates; it was late and I was tired, my cat got some separation anxiety from me going on vacation, so she's either using me as a catwalk to strut her stuff while I'm trying to sleep or meowing outside the door when I've had enough of the struts.
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Post by eaglerider on Jun 9, 2012 15:24:05 GMT -6
;D The torque specs are now posted permanantly at the top, where they can easily be found.
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Post by Jet⚡Black on Jun 9, 2012 17:24:42 GMT -6
I feel like I should have put more effort in cleaning up the post now that it's all sticky
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Post by Bearded Biker on Jun 9, 2012 22:36:05 GMT -6
jetblack, i think you covered it pretty good. i also hate my haynes manaul also. thanks for putting the time in to help us out. gayland
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Post by Bearded Biker on Jun 9, 2012 22:42:16 GMT -6
sorry eagleride, and thank you for making it available up above. gayland
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Post by hounddog22642 on Jul 4, 2019 10:00:37 GMT -6
And 7 years later, this post is still very useful Thank you JetBlack
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Post by ben103 on Apr 25, 2024 8:13:52 GMT -6
I've looked all over the internet, 2 different online manuals, but cannot find bolt torque specs. I usually like to have them for all major systems, but especially the engine. The online ver of the Haynes manual refers to a page of specs at end of Chapter 1, but my copy doesn't have them. Can someone who have them please post for everyone in a prominent place on the forum? Thanks.
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Post by ben103 on Apr 25, 2024 8:16:51 GMT -6
Hi anyone got the en 454 cylinder head torque settings bolts specs 14mm head bolts in newton metres .thanks
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