Post by Jon "bustanut" on Nov 1, 2011 16:53:57 GMT -5
2009 Kawasaki zx-6r
Tightening Torque The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in "Remarks" column mean AL Tighten the two clamp bolts alternately two times to insure even tightening torque G Apply grease to the threads L Apply a non-permanent locking agent to the threads LH Left- hand threads MO Apply molybdenum disulfide grease oil solution R Replacement parts S Follow the specific tightening sequence Si Apply silicone grease SS Apply silicone sealant
Fuel System Fastener Torque ft-lb Remarks Air Cleaner Housing Screws 11 in-lb Air Cleaner Housing Clamp Bolts 18 in-lb Air Cleaner Housing Mounting Bolts 61 in-lb Air Inlet Duct Mounting Bolts 87 in-lb L Canister Bracket Screws 11 in-lb Crankshaft Sensor Bolts 52 in-lb Delivery Pipe Mounting Screws (Nozzle Assy) 30 in-lb
Delivery Pipe Mounting Screws (Throttle Assy) 30 in-lb
Exhaust Butterfly Valve Actuator Mounting Screws 38 in-lb
Exhaust Butterfly Valve Actuator Pulley Bolt 43 in-lb
Fuel Pump Bolts 87 in-lb L, S Gear Position Switch Screws 26 in-lb L Inlet Air Temperature Sensor Screw 7.1 in-lb Nozzle Assy Mounting Screws 11 in-lb S Oxygen Sensor (equipped models) 18 Separator Bracket Mounting Bolt 61 in-lb Speed Sensor Bolt 61 in-lb Throttle Body Assembly Holder Clamp Bolts 26 in-lb
Throttle Body Holder Bolts 106 in-lb L Throttle Cable Holder Plate Bolt 35 in-lb L Vehicle-down Sensor Bolts 52 in-lb Water Temperature Sensor 18 SS
Cooling System Fastener Torque ft-lb Remarks Coolant-bypass Fitting Bolt 78 in-lb L Coolant Drain Bolt (Cylinder) 87 in-lb Coolant Drain Bolt (Water Pump) 78 in-lb Coolant Reserve Tank Mounting Bolts 61 in-lb
Heat Insulation Plate Bolt 35 in-lb L Impeller Bolt 87 in-lb Oil Cooler Mounting Bolts 15 Radiator Bracket Mounting Bolt 87 in-lb Radiator Lower Bolt 61 in-lb Radiator Upper Bolts 87 in-lb Thermostat Housing Cover Bolts 52 in-lb Water Hose Clamp Screws 18 in-lb Water Hose Fitting Bolts 87 in-lb Water Pump Cover Bolts 106 in-lb L Water Temperature Sensor 18
Engine Top End Fastener Torque ft-lb Remarks Air Suction Valve Cover Bolts 87 in-lb L Breather Hose Fitting 11 L Camshaft Cap Bolts 106 in-lb S Camshaft Chain Tensioner Cap Bolt 15 Camshaft Chain Tensioner Mounting Bolts 97 in-lb
Camshaft Sprocket Bolts 11 L Coolant Drain Bolt (Cylinder) 87 in-lb Cylinder Head Bolts (M9) 29 MO, S Cylinder Head Bolts (M6) 106 in-lb S Cylinder Head Cover Bolts 87 in-lb S Exhaust Butterfly Valve Cable Adjuster Locknuts 61 in-lb
Exhaust Butterfly Valve Cable Locknuts 61 in-lb
Exhaust Pipe Clamp Bolt 13 Exhaust Pipe Guard Bolts 61 in-lb Exhaust Pipe Holder Nuts 13 Front Camshaft Chain Guide Bolt (Lower) 106 in-lb
Front Camshaft Chain Guide Bolt (Upper) 18
Muffler Body Clamp Bolt 13 Muffler Rear Cover Bolts 62 in-lb Muffler Body Mounting Bolts 18 Muffler Body Rear Cover Bolt 62 in-lb Premuffler Chamber Bracket Bolts 26 Premuffler Chamber Guard Bolts 61 in-lb Premuffler Chamber Mounting Bolts 26 Spark Plugs 113 in-lb Starter Clutch Bolt Cap -Hand Tighten Throttle Body Assembly Holder Bolts 106 in-lb L
Throttle Body Assembly Holder Clamp Bolts 26 in-lb
Timing Inspection Cap Hand Tighten Upper Camshaft Guide Bolts 106 in-lb S Water Passage Plugs 14 L
Clutch Fastener Torque ft-lb Remarks Clutch Cover Bolts (M6, L = 40mm) 87 in-lb Clutch Cover Bolts (M6, L = 25mm) 87 in-lb Clutch Cover Plate Bolts 87 in-lb L Clutch Hub Nut 99.6 R Clutch Lever Clamp Bolts 69 in-lb S Clutch Spring Bolts 78 in-lb Oil Filler Plug -Hand Tighten Sub Clutch Hub Bolts 18 L
Engine Lubrication System Fastener Torque ft-lb Remarks Air Bleed Bolt 87 in-lb Engine Oil Drain Bolt 21 Impeller Bolt 87 in-lb Oil Cooler Mounting Bolt 15 Oil Cooler/Oil Filter Case Mounting Bolts 15 L
Oil Filter 13 G, R Oil Filter Guard Bolts 35 in-lb L Oil Filter Holder Bolt 18 L Oil Jet Nozzles 26 in-lb Oil Pan Bolts 87 in-lb S Oil Passage Plug 13 Oil Passage Plugs (Taper) 15 L Oil Pressure Relief Valve 11 L Oil Pressure Switch 11 SS Oil Pressure Switch Terminal Bolt 13 in-lb G Oil Pump Drive Gear Bolt 87 in-lb L Water Pump Cover Bolts 104 in-lb L
Engine Removal/Installation Fastener Torque ft-lb Remarks Adjusting Collar Locknut 36 S Adjusting Collar 87 in-lb S Left Front Engine Mounting Bolt 32 S Lower Engine Mounting Nut 32 S Middle Engine Mounting Nut 32 S Right Front Engine Mounting Bolt 32 S
Crankshaft/Transmission Fastener Torque ft-lb Remarks Breather holder Screws 43 in-lb L Breather Hose Fitting 11 L Breather Plate Bolts 87 in-lb L Connecting Rod Big End Bolts SEE TEXT MO Crankcase Bolt (M8, L = 90mm) 20 S Crankcase Bolts (M8, L = 95mm) 23 MO, S Crankcase Bolts (M8, L = 75mm) 20 S Crankcase Bolts (M6, L = 65mm) 106 in-lb S Crankcase Bolts (M6, L = 50mm) 106 in-lb Gear Position Switch Screws 26 in-lb L Gear Positioning Lever Bolt 106 in-lb Idle Gear Cover Bolts 87 in-lb Oil Jet Nozzle 26 in-lb Oil Passage Nozzle 43 in-lb Oil Passage Plug 13 Oil Passage Plugs (Taper) 15 L Race Holder Screw 43 in-lb L Shift Drum Cam Holder Bolt 106 in-lb L Shift Lever Bolt 61 in-lb Shift Pedal Mounting Bolt 18 L Shift Shaft Return Spring Pin 21 L Starter Clutch Bolt 36 Starter Clutch Cover Bolt (L= 40mm) 87 in-lb Starter Clutch Cover Bolt (L= 20mm) 87 in-lb Starter Clutch Cover Bolts (L= 30mm) 87 in-lb
Tie-Rod Locknut (Front) 61 in-lb Lh Tie-Rod Locknut (Rear) 61 in-lb Transmission Case Bolts (M6) 87 in-lb Transmission Case Bolts (M8) 15
Wheels/Tires Fastener Torque ft-lb Remarks Front Axle Clamp Bolts 15 AL Front Axle Nut 93.7 Rear Axle Nut 93.7
Final Drive Fastener Torque ft-lb Remarks Chain Guide Bolts 87 in-lb L Engine Sprocket Cover Bolts 87 in-lb Engine Sprocket Cover Plate Mounting Bolts 87 in-lb L
Engine Sprocket Nut 92.2 MO Rear Axle Nut 93.7 Rear Sprocket Nuts 44 Speed Sensor Bolt 61 in-lb L
Brakes Fastener Torque ft-lb Remarks Bleed Valves 69 in-lb Brake Hose Banjo Bolts 18 Brake Lever Pivot Bolt 8.9 in-lb Si Brake Lever Mounting Bolt 25 Front Brake Disk Mounting Bolts 20 L Front Brake Light Switch Screw 11 in-lb Front Brake Pad Pins 13 front Brake Reservoir Cap Stopper Screw 11 in-lb
Front Caliper Assembly Bolts 20 L Front Caliper Mounting Bolts 25 Front Master Cylinder Bleed Valve 48 in-lb Front Master Cylinder Clamp Bolts 97 in-lb S Rear Brake Disk Mounting Bolts 20 L Rear Caliper Mounting Bolts 18 Rear Master Cylinder Mounting Bolts 18
Rear Master Cylinder Push Rod Locknut 13
Suspension Fastener Torque ft-lb Remarks Front Axle Clamp Bolts 15 AL Front Fork Top Plugs 26 Lower Front Fork Clamp Bolts 17 AL Lower Rear Shock Absorber Nut 25 Piston Rod Guide Case 66 Rear Shock Absorber Bracket Nut 44 Swingarm Pivot Adjusting Collar Locknut 72.3
Swingarm Pivot Shaft 15 Swingarm Pivot Shaft Nut 79.7 Tie-Rod Nuts 44 Uni-trak Rocker Arm Nut 25 Upper Front Fork Clamp Bolts 15 Upper Rear Shock Absorber Nut 25
Steering Fastener Torque ft-lb Remarks Handlebar Clamp Bolts 18 Handlebar Positioning Bolts 87 in-lb L Left Switch Housing Screws 31 in-lb Lower Front Fork Clamp Bolts 17 AL Right Switch Housing Screws 31 in-lb Steering Damper Mounting Bolts 97 in-lb L Steering Stem Head Nut 58 Steering Stem Nut 15 Throttle Case Bolts 31 in-lb Upper Front Fork Clamp Bolts 15
Frame Fastener Torque ft-lb Remarks Front Fender Mounting Bolts 35 in-lb Front Footpeg Bracket Bolts 18 Rear Footpeg Bracket Bolts 18 Rear Frame Bolts (M10) 32 L Rear Frame Bolts (M8) 18 L Sidestand Bolt 32 G Sidestand Bracket Bolts 36 L Sidestand Switch Bolt 78 in-lb L Windshield Mounting Bolts 3.7 in-lb
Electical System Fastener Torque ft-lb Remarks Alternator Cover Bolts 87 in-lb Alternator Lead Holding Plate Bolt 87 in-lb L Alternator Rotor Bolt 114 S Crankshaft Sensor Bolts 52 in-lb Engine Ground Cable Terminal Bolt 87 in-lb Front Break Light Switch Screw 11 in-lb Front Turn Signal Light Mounting Screws 11 in-lb
Fuel Pump Bolts 87 in-lb L, S Gear Position Switch Screws 26 in-lb L Left Switch Housing Screws 31 in-lb License Plate Light Cover Screws 8.9 in-lb License Light Mounting Nuts 31 in-lb Meter Unit Mounting Screws 11 in-lb Oil Pressure Switch 11 SS Oil Pressure Switch Terminal Bolt 13 in-lbs G Oxygen Sensor (Equipped Models) 18 Rear Turn Signal Light Lens Screws 8.9 in-lb Regulator/Rectifier Bracket Screws 11 in-lb Right Switch Housing Screws 31 in-lb Side Stand Switch Bolt 78 in-lb L Spark Plugs 115 in-lb Speed Sensor Bolt 61 in-lb L Starter Clutch Bolt Cap 36 Hand Tighten Starter Clutch Cover Bolt (L= 40mm) 87 in-lb Starter Clutch Cover Bolt (L= 20mm) 87 in-lb Starter Clutch Cover Bolt (L= 30mm) 87 in-lb Starter Motor Cable Terminal Bolt 26 in-lb Starter Motor Mounting Bolts 87 in-lb Stater Coil Bolts 106 in-lb L Water Temperature Sensor 18
Tightening Torque The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in "Remarks" column mean AL Tighten the two clamp bolts alternately two times to insure even tightening torque G Apply grease to the threads L Apply a non-permanent locking agent to the threads LH Left- hand threads MO Apply molybdenum disulfide grease oil solution R Replacement parts S Follow the specific tightening sequence Si Apply silicone grease SS Apply silicone sealant
Fuel System Fastener Torque ft-lb Remarks Air Cleaner Housing Screws 11 in-lb Air Cleaner Housing Clamp Bolts 18 in-lb Air Cleaner Housing Mounting Bolts 61 in-lb Air Inlet Duct Mounting Bolts 87 in-lb L Canister Bracket Screws 11 in-lb Crankshaft Sensor Bolts 52 in-lb Delivery Pipe Mounting Screws (Nozzle Assy) 30 in-lb
Delivery Pipe Mounting Screws (Throttle Assy) 30 in-lb
Exhaust Butterfly Valve Actuator Mounting Screws 38 in-lb
Exhaust Butterfly Valve Actuator Pulley Bolt 43 in-lb
Fuel Pump Bolts 87 in-lb L, S Gear Position Switch Screws 26 in-lb L Inlet Air Temperature Sensor Screw 7.1 in-lb Nozzle Assy Mounting Screws 11 in-lb S Oxygen Sensor (equipped models) 18 Separator Bracket Mounting Bolt 61 in-lb Speed Sensor Bolt 61 in-lb Throttle Body Assembly Holder Clamp Bolts 26 in-lb
Throttle Body Holder Bolts 106 in-lb L Throttle Cable Holder Plate Bolt 35 in-lb L Vehicle-down Sensor Bolts 52 in-lb Water Temperature Sensor 18 SS
Cooling System Fastener Torque ft-lb Remarks Coolant-bypass Fitting Bolt 78 in-lb L Coolant Drain Bolt (Cylinder) 87 in-lb Coolant Drain Bolt (Water Pump) 78 in-lb Coolant Reserve Tank Mounting Bolts 61 in-lb
Heat Insulation Plate Bolt 35 in-lb L Impeller Bolt 87 in-lb Oil Cooler Mounting Bolts 15 Radiator Bracket Mounting Bolt 87 in-lb Radiator Lower Bolt 61 in-lb Radiator Upper Bolts 87 in-lb Thermostat Housing Cover Bolts 52 in-lb Water Hose Clamp Screws 18 in-lb Water Hose Fitting Bolts 87 in-lb Water Pump Cover Bolts 106 in-lb L Water Temperature Sensor 18
Engine Top End Fastener Torque ft-lb Remarks Air Suction Valve Cover Bolts 87 in-lb L Breather Hose Fitting 11 L Camshaft Cap Bolts 106 in-lb S Camshaft Chain Tensioner Cap Bolt 15 Camshaft Chain Tensioner Mounting Bolts 97 in-lb
Camshaft Sprocket Bolts 11 L Coolant Drain Bolt (Cylinder) 87 in-lb Cylinder Head Bolts (M9) 29 MO, S Cylinder Head Bolts (M6) 106 in-lb S Cylinder Head Cover Bolts 87 in-lb S Exhaust Butterfly Valve Cable Adjuster Locknuts 61 in-lb
Exhaust Butterfly Valve Cable Locknuts 61 in-lb
Exhaust Pipe Clamp Bolt 13 Exhaust Pipe Guard Bolts 61 in-lb Exhaust Pipe Holder Nuts 13 Front Camshaft Chain Guide Bolt (Lower) 106 in-lb
Front Camshaft Chain Guide Bolt (Upper) 18
Muffler Body Clamp Bolt 13 Muffler Rear Cover Bolts 62 in-lb Muffler Body Mounting Bolts 18 Muffler Body Rear Cover Bolt 62 in-lb Premuffler Chamber Bracket Bolts 26 Premuffler Chamber Guard Bolts 61 in-lb Premuffler Chamber Mounting Bolts 26 Spark Plugs 113 in-lb Starter Clutch Bolt Cap -Hand Tighten Throttle Body Assembly Holder Bolts 106 in-lb L
Throttle Body Assembly Holder Clamp Bolts 26 in-lb
Timing Inspection Cap Hand Tighten Upper Camshaft Guide Bolts 106 in-lb S Water Passage Plugs 14 L
Clutch Fastener Torque ft-lb Remarks Clutch Cover Bolts (M6, L = 40mm) 87 in-lb Clutch Cover Bolts (M6, L = 25mm) 87 in-lb Clutch Cover Plate Bolts 87 in-lb L Clutch Hub Nut 99.6 R Clutch Lever Clamp Bolts 69 in-lb S Clutch Spring Bolts 78 in-lb Oil Filler Plug -Hand Tighten Sub Clutch Hub Bolts 18 L
Engine Lubrication System Fastener Torque ft-lb Remarks Air Bleed Bolt 87 in-lb Engine Oil Drain Bolt 21 Impeller Bolt 87 in-lb Oil Cooler Mounting Bolt 15 Oil Cooler/Oil Filter Case Mounting Bolts 15 L
Oil Filter 13 G, R Oil Filter Guard Bolts 35 in-lb L Oil Filter Holder Bolt 18 L Oil Jet Nozzles 26 in-lb Oil Pan Bolts 87 in-lb S Oil Passage Plug 13 Oil Passage Plugs (Taper) 15 L Oil Pressure Relief Valve 11 L Oil Pressure Switch 11 SS Oil Pressure Switch Terminal Bolt 13 in-lb G Oil Pump Drive Gear Bolt 87 in-lb L Water Pump Cover Bolts 104 in-lb L
Engine Removal/Installation Fastener Torque ft-lb Remarks Adjusting Collar Locknut 36 S Adjusting Collar 87 in-lb S Left Front Engine Mounting Bolt 32 S Lower Engine Mounting Nut 32 S Middle Engine Mounting Nut 32 S Right Front Engine Mounting Bolt 32 S
Crankshaft/Transmission Fastener Torque ft-lb Remarks Breather holder Screws 43 in-lb L Breather Hose Fitting 11 L Breather Plate Bolts 87 in-lb L Connecting Rod Big End Bolts SEE TEXT MO Crankcase Bolt (M8, L = 90mm) 20 S Crankcase Bolts (M8, L = 95mm) 23 MO, S Crankcase Bolts (M8, L = 75mm) 20 S Crankcase Bolts (M6, L = 65mm) 106 in-lb S Crankcase Bolts (M6, L = 50mm) 106 in-lb Gear Position Switch Screws 26 in-lb L Gear Positioning Lever Bolt 106 in-lb Idle Gear Cover Bolts 87 in-lb Oil Jet Nozzle 26 in-lb Oil Passage Nozzle 43 in-lb Oil Passage Plug 13 Oil Passage Plugs (Taper) 15 L Race Holder Screw 43 in-lb L Shift Drum Cam Holder Bolt 106 in-lb L Shift Lever Bolt 61 in-lb Shift Pedal Mounting Bolt 18 L Shift Shaft Return Spring Pin 21 L Starter Clutch Bolt 36 Starter Clutch Cover Bolt (L= 40mm) 87 in-lb Starter Clutch Cover Bolt (L= 20mm) 87 in-lb Starter Clutch Cover Bolts (L= 30mm) 87 in-lb
Tie-Rod Locknut (Front) 61 in-lb Lh Tie-Rod Locknut (Rear) 61 in-lb Transmission Case Bolts (M6) 87 in-lb Transmission Case Bolts (M8) 15
Wheels/Tires Fastener Torque ft-lb Remarks Front Axle Clamp Bolts 15 AL Front Axle Nut 93.7 Rear Axle Nut 93.7
Final Drive Fastener Torque ft-lb Remarks Chain Guide Bolts 87 in-lb L Engine Sprocket Cover Bolts 87 in-lb Engine Sprocket Cover Plate Mounting Bolts 87 in-lb L
Engine Sprocket Nut 92.2 MO Rear Axle Nut 93.7 Rear Sprocket Nuts 44 Speed Sensor Bolt 61 in-lb L
Brakes Fastener Torque ft-lb Remarks Bleed Valves 69 in-lb Brake Hose Banjo Bolts 18 Brake Lever Pivot Bolt 8.9 in-lb Si Brake Lever Mounting Bolt 25 Front Brake Disk Mounting Bolts 20 L Front Brake Light Switch Screw 11 in-lb Front Brake Pad Pins 13 front Brake Reservoir Cap Stopper Screw 11 in-lb
Front Caliper Assembly Bolts 20 L Front Caliper Mounting Bolts 25 Front Master Cylinder Bleed Valve 48 in-lb Front Master Cylinder Clamp Bolts 97 in-lb S Rear Brake Disk Mounting Bolts 20 L Rear Caliper Mounting Bolts 18 Rear Master Cylinder Mounting Bolts 18
Rear Master Cylinder Push Rod Locknut 13
Suspension Fastener Torque ft-lb Remarks Front Axle Clamp Bolts 15 AL Front Fork Top Plugs 26 Lower Front Fork Clamp Bolts 17 AL Lower Rear Shock Absorber Nut 25 Piston Rod Guide Case 66 Rear Shock Absorber Bracket Nut 44 Swingarm Pivot Adjusting Collar Locknut 72.3
Swingarm Pivot Shaft 15 Swingarm Pivot Shaft Nut 79.7 Tie-Rod Nuts 44 Uni-trak Rocker Arm Nut 25 Upper Front Fork Clamp Bolts 15 Upper Rear Shock Absorber Nut 25
Steering Fastener Torque ft-lb Remarks Handlebar Clamp Bolts 18 Handlebar Positioning Bolts 87 in-lb L Left Switch Housing Screws 31 in-lb Lower Front Fork Clamp Bolts 17 AL Right Switch Housing Screws 31 in-lb Steering Damper Mounting Bolts 97 in-lb L Steering Stem Head Nut 58 Steering Stem Nut 15 Throttle Case Bolts 31 in-lb Upper Front Fork Clamp Bolts 15
Frame Fastener Torque ft-lb Remarks Front Fender Mounting Bolts 35 in-lb Front Footpeg Bracket Bolts 18 Rear Footpeg Bracket Bolts 18 Rear Frame Bolts (M10) 32 L Rear Frame Bolts (M8) 18 L Sidestand Bolt 32 G Sidestand Bracket Bolts 36 L Sidestand Switch Bolt 78 in-lb L Windshield Mounting Bolts 3.7 in-lb
Electical System Fastener Torque ft-lb Remarks Alternator Cover Bolts 87 in-lb Alternator Lead Holding Plate Bolt 87 in-lb L Alternator Rotor Bolt 114 S Crankshaft Sensor Bolts 52 in-lb Engine Ground Cable Terminal Bolt 87 in-lb Front Break Light Switch Screw 11 in-lb Front Turn Signal Light Mounting Screws 11 in-lb
Fuel Pump Bolts 87 in-lb L, S Gear Position Switch Screws 26 in-lb L Left Switch Housing Screws 31 in-lb License Plate Light Cover Screws 8.9 in-lb License Light Mounting Nuts 31 in-lb Meter Unit Mounting Screws 11 in-lb Oil Pressure Switch 11 SS Oil Pressure Switch Terminal Bolt 13 in-lbs G Oxygen Sensor (Equipped Models) 18 Rear Turn Signal Light Lens Screws 8.9 in-lb Regulator/Rectifier Bracket Screws 11 in-lb Right Switch Housing Screws 31 in-lb Side Stand Switch Bolt 78 in-lb L Spark Plugs 115 in-lb Speed Sensor Bolt 61 in-lb L Starter Clutch Bolt Cap 36 Hand Tighten Starter Clutch Cover Bolt (L= 40mm) 87 in-lb Starter Clutch Cover Bolt (L= 20mm) 87 in-lb Starter Clutch Cover Bolt (L= 30mm) 87 in-lb Starter Motor Cable Terminal Bolt 26 in-lb Starter Motor Mounting Bolts 87 in-lb Stater Coil Bolts 106 in-lb L Water Temperature Sensor 18
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