ZX-6R.us

Torque and Locking Agent - 2009 Kawasaki ZX-6R

The following table lists the tightening torque and non-permanent locking agent or silicon sealant requirements for the major fasteners.

Letters used in the Remarks column mean:
AL:Tighten the two clamp bolts alternately two times to ensure even tightenting torque.
G:Apply grease.
L:Apply a non-permanent locking agent.
Lh:Left-hand threads
MO:Apply molybdenum disulfide oil solution.
R:Replacement parts
S:Follow the specified tightening sequence.
Si:Apply silicone grease (e.g. PBC grease).
SS:Apply silicone sealant.
(You can also hover over the letters in the Remarks column for tooltips with the meanings)
Fastener Torque Remarks
N·m kgf·m ft·lb
Fuel System (DFI)
   Air Cleaner Housing Assembly Screws
   Air Cleaner Housiing Clamp Bolts
   Air Cleaner Housing Mounting Bolt
   Air Inlet Duct Mounting Bolts
   Canister Bracket Screws
   Crankshaft Sensor Bolts
   Delivery Pipe Assy Mounting Screws (Nozzle Assy)
   Delivery Pipe Assy Mounting Screws (Throttle Body Assy)
   Exhaust Butterfly Valve Actuator Mounting Screws
   Exhaust Butterfly Valve Actuator Pulley Bolt
   Fuel Pump Bolts
   Gear Position Switch Screws
   Inlet Air Temperature Sensor Screw
   Nozzle Assy Mounting Screws
   Oxygen Sensor (Equipped Models)
   Separator Bracket Mounting Bolt
   Speed Sensor Bolt
   Throttle Body Assy Holder Bolts
   Throttle Body Assy Holder Clamp Bolts
   Throttle Cable Holder Plate Bolt
   Water Temperature Sensor
1.2
2.0
6.9
9.8
1.2
5.9
3.43
3.43
4.3
4.9
9.8
2.9
0.80
1.2
25
6.9
6.9
12
2.9
3.9
25
0.12
0.20
0.70
1.0
0.12
0.60
0.35
0.35
0.44
0.50
1.0
0.30
0.081
0.12
2.5
0.70
0.70
1.2
0.30
0.40
2.5
11 in·lb
18 in·lb
61 in·lb
87 in·lb
11 in·lb
52 in·lb
30 in·lb
30 in·lb
38 in·lb
43 in·lb
87 in·lb
26 in·lb
7.1 in·lb
11 in·lb
18
61 in·lb
61 in·lb
106 in·lb
26 in·lb
35 in·lb
18
 
 
 
L
 
 
 
 
 
 
L, S
L
 
S
 
 
L
L
 
L
 
Fastener Torque Remarks
N·m kgf·m ft·lb
Cooling System
   Coolant By-pass Fitting Bolt
   Coolant Drain Bolt (Cylinder)
   Coolant Drain Bolt (Water Pump)
   Coolant Reserve Tank Mounting Bolts
   Heat Insulation Plate Bolt
   Impeller Bolt
   Oil Cooler Mounting Bolts
   Radiator Bracket Mounting Bolt
   Radiator Lower Bolt
   Radiator Upper Bolt
   Thermostat Housing Cover Bolts
   Water Hose Clamp Screws
   Water Hose Fitting Bolts
   Water Pump Cover Bolts
   Water Temperature Sensor
8.8
9.8
8.8
6.9
3.9
9.8
20
9.8
6.9
9.8
5.9
2.0
9.8
12
25
0.90
1.0
0.90
0.70
0.40
1.0
2.0
1.0
0.70
1.0
0.60
0.20
1.0
1.2
2.5
78 in·lb
87 in·lb
78 in·lb
61 in·lb
35 in·lb
87 in·lb
15
87 in·lb
61 in·lb
87 in·lb
52 in·lb
18 in·lb
87 in·lb
106 in·lb
18
L
 
 
 
L
 
 
 
 
 
 
 
 
L
 
Fastener Torque Remarks
N·m kgf·m ft·lb
Engine Top End
   Air Suction Valve Cover Bolts
   Breather Hose Fitting
   Camshaft Cap Bolts
   Camshaft Chain Tensioner Cap Bolt
   Camshaft Chain Tensioner Mounting Bolts
   Camshaft Sprocket Bolts
   Coolant Drain Bolt (Cylinder)
   Cylinder Head Bolts (M9)
   Cylinder Head Bolts (M6)
   Cylinder Head Cover Bolts
   Exhaust Butterfly Valve Cable Adjuster Locknuts
   Exhaust Butterfly Valve Cable Locknuts
   Exhaust Pipe Clamp Bolt
   Exhaust Pipe Guard Bolts
   Exhaust Pipe Holder Nuts
   Front Camshaft Chain Guide Bolt (Lower)
   Front Camshaft Chain Guide Bolt (Upper)
   Muffler Body Clamp Bolt
   Muffler Body Cover Bolts
   Muffler Body Mounting Bolt
   Muffler Body Rear Cover Bolts
   Premuffler Chamber Bracket Bolt
   Premuffler Chamber Guard Bolts
   Premuffler Chamber Mounting Bolt
   Spark Plugs
   Starter Clutch Bolt Cap
   Throttle Body Assy Holder Bolts
   Throttle Body Assy Holder Clamp Bolts
   Timing Inspection Cap
   Upper Camshaft Chain Guide Bolts
   Water Passage Plugs
9.8
15
12
20
11
15
9.8
39
12
9.8
6.9
7.0
17
6.9
17
12
25
17
7.0
25
7.0
35
6.9
35
12
-
12
2.9
-
12
19.6
1.0
1.5
1.2
2.0
1.1
1.5
1.0
4.0
1.2
1.0
0.70
0.71
1.7
0.70
1.7
1.2
2.5
1.7
0.71
2.5
0.71
3.6
0.70
3.6
1.3
-
1.2
0.30
-
1.2
2.0
87 in·lb
11
106 in·lb
15
97 in·lb
11
87 in·lb
29
106 in·lb
87 in·lb
61 in·lb
62 in·lb
13
61 in·lb
13
106 in·lb
18
13
62 in·lb
18
62 in·lb
26
61 in·lb
26
115 in·lb
-
106 in·lb
26 in·lb
-
106 in·lb
14
L
L
S
 
 
L
 
MO, S
S
S
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Hand-Tighten
L
 
Hand-Tighten
S
L
Fastener Torque Remarks
N·m kgf·m ft·lb
Clutch
   Clutch Cover Bolts (M6, L = 40 mm)
   Clutch Cover Bolts (M6, L = 25 mm)
   Clutch Cover Plate Bolts
   Clutch Hub Nut
   Clutch Lever Clamp Bolts
   Clutch Spring Bolts
   Oil Filler Plug
   Sub Clutch Hub Bolts
9.8
9.8
9.8
135
7.8
8.8
-
25
1.0
1.0
1.0
13.8
0.80
0.90
-
2.5
87 in·lb
87 in·lb
87 in·lb
99.6
69 in·lb
78 in·lb
-
18
 
 
L
R
S
 
Hand-Tighten
L
Fastener Torque Remarks
N·m kgf·m ft·lb
Engine Lubrication System
   Air Bleed Bolt
   Engine Oil Drain Bolt
   Impeller Bolt
   Oil Cooler Mounting Bolts
   Oil Cooler/Oil Filter Case Mounting Bolts
   Oil Filter
   Oil Filter Guard Bolts
   Oil Filter Holder Bolt
   Oil Jet Nozzles
   Oil Pan Bolts
   Oil Passage Plug
   Oil Passage Plugs (Taper)
   Oil Pressure Relief Valve
   Oil Pressure Switch
   Oil Pressure Switch Terminal Bolt
   Oil Pump Drive Gear Bolt
   Water Pump Cover Bolts
98
29
9.8
20
20
17
4.0
25
2.9
9.8
17
20
15
15
1.5
9.8
12
1.0
3.0
1.0
2.0
2.0
1.7
0.41
2.5
0.30
1.0
1.7
2.0
1.5
1.5
0.15
1.0
1.2
87 in·lb
21
87 in·lb
15
15
13
35 in·lb
18
26 in·lb
87 in·lb
13
15
11
11
13 in·lb
87 in·lb
106 in·lb
 
 
 
 
L
G, R
L
L
 
S
 
L
L
SS
G
L
L
Fastener Torque Remarks
N·m kgf·m ft·lb
Engine Removal/Installation
   Adjusting Collar Locknuts
   Adjusting Collars
   Left Front Engine Mounting Bolt
   Lower Engine Mounting Nut
   Middle Engine Mounting Nut
   Right Front Engine Mounting Bolt
49
9.8
44
44
44
44
5.0
1.0
4.5
4.5
4.5
4.5
36
87 in·lb
32
32
32
32
S
S
S
S
S
S
Fastener Torque Remarks
N·m kgf·m ft·lb
Crankshaft/Transmission
   Bearing Holder Screws
   Breather Hose Fitting
   Breather Plate Bolts
   Connecting Rod Big End Nuts
   Crankcase Bolt (M8, L = 90 mm)
   Crankcase Bolts (M8, L = 95 mm)
   Crankcase Bolts (M8, L = 75 mm)
   Crankcase Bolts (M6, L = 65 mm)
   Crankcase Bolts (M6, L = 50 mm)
   Gear Position Switch Screws
   Gear Positioning Lever Bolt
   Idle Gear Cover Bolts
   Oil Jet Nozzles
   Oil Passage Nozzle
   Oil Passage Plug
   Oil Passage Plugs
   Race Holder Screws
   Shift Drum Cam Holder Bolt
   Shift Lever Bolt
   Shift Pedal Mounting Bolt
   Shift Shaft Return Spring Pin
   Starter Clutch Bolt
   Starter Clutch Cover Bolt (L = 40 mm)
   Starter Clutch Cover Bolt (L = 20 mm)
   Starter Clutch Cover Bolts (L = 30 mm)
   Tie-Rod Locknut (Front)
   Tie-Rod Locknut (Rear)
   Transmission Case Bolt (M6)
   Transmission Case Bolts (M8)
4.9
15
9.8
See the text
27
31
27
12
12
2.9
12
9.8
2.9
4.9
17
20
4.9
12
6.9
25
28
49
9.8
9.8
9.8
6.9
6.9
9.8
20
0.50
1.5
1.0
<--
2.8
3.2
2.8
1.2
1.2
0.30
1.2
1.0
0.30
0.50
1.7
2.0
0.50
1.2
0.70
2.5
2.9
5.0
1.0
1.0
1.0
0.70
0.70
1.0
2.0
43 in·lb
11
87 in·lb
<--
20
23
20
106 in·lb
106 in·lb
26 in·lb
106 in·lb
87 in·lb
26 in·lb
43 in·lb
13
15
43 in·lb
106 in·lb
61 in·lb
18
21
36
87 in·lb
87 in·lb
87 in·lb
61 in·lb
61 in·lb
87 in·lb
15
L
L
L
MO
S
MO, S
S
S
 
L
 
 
 
 
 
L
L
L
 
L
L
 
 
 
 
Lh
 
 
 
Fastener Torque Remarks
N·m kgf·m ft·lb
Wheels/Tires
   Front Axle Clamp Bolts
   Front Axle Nut
   Rear Axle Nut
20
127
127
2.0
13.0
13.0
15
93.7
93.7
AL
 
 
Fastener Torque Remarks
N·m kgf·m ft·lb
Final Drive
   Chain Guide Bolts
   Engine Sprocket Cover Bolts
   Engine Sprocket Cover Plate Mounting Bolts
   Engine Sprocket Nut
   Rear Axle Nut
   Rear Sprocket Nuts
   Speed Sensor Bolt
9.8
9.8
9.8
125
127
59
6.9
1.0
1.0
1.0
13.0
13.0
6.0
0.70
87 in·lb
87 in·lb
87 in·lb
92.2
93.7
44
61 in·lb
L
 
L
MO
 
 
L
Fastener Torque Remarks
N·m kgf·m ft·lb
Brakes
   Bleed Valves
   Brake Hose Banjo Bolts
   Brake Lever Pivot Bolt
   Brake Lever Pivot Bolt Locknut
   Brake Pedal Mounting Bolt
   Front Brake Disc Mounting Bolts
   Front Brake Light Switch Screw
   Front Brake Pad Pins
   Front Brake Reservoir Cap Stopper Screw
   Front Caliper Assembly Bolts
   Front Caliper Mounting Bolts
   Front Master Cylinder Bleed Valve
   Front Master Cylinder Clamp Bolts
   Rear Brake Disc Mounting Bolts
   Rear Caliper Mounting Bolts
   Rear Master Cylinder Mounting Bolts
   Rear Master Cylinder Push Rod Locknut
7.8
25
1.0
5.9
34
27
1.2
17
1.2
27
34
5.4
11
27
25
25
17
0.80
2.5
0.10
0.60
3.5
2.8
0.12
1.7
0.12
2.8
3.5
0.55
1.1
2.8
2.5
2.5
1.7
69 in·lb
18
8.9 in·lb
52 in·lb
25
20
11 in·lb
13
11 in·lb
20
25
48 in·lb
97 in·lb
20
18
18
13
 
 
Si
 
L
L
 
 
 
L
 
 
S
L
 
 
 
Fastener Torque Remarks
N-m kgf-m ft-lb
Suspension
   Front Axle Clamp Bolts
   Front Fork Top Plugs
   Lower Front Fork Clamp Bolts
   Lower Rear Shock Absorber Nut
   Piston Rod Guide Case
   Rear Shock Absorber Bracket Nut
   Swingarm Pivot Adjusting Collar Locknut
   Swingarm Pivot Shaft
   Swingarm Pivot Shaft Nut
   Tie-Rod Nuts
   Uni-Trak Rocker Arm Bolt
   Upper Front Fork Clamp Bolts
   Upper Rear Shock Absorber Nut
20
35
23
34
90
59
98
20
108
59
34
20
34
2.0
3.6
2.3
3.5
9.2
6.0
10.0
2.0
11.0
6.0
3.5
2.0
3.5
15
26
17
25
66
44
72.3
15
79.7
44
25
15
25
AL
 
AL
 
 
 
 
 
 
 
 
 
 
Fastener Torque Remarks
N-m kgf-m ft-lb
Steering
   Handlebar Clamp Bolts
   Handlebar Positioning Bolts
   Left Switch Housing Screws
   Lower Front Fork Clamp Bolts
   Right Switch Housing Screws
   Steering Damper Mounting Bolts
   Steering Stem Head Nut
   Steering Stem Nut
   Throttle Case Screws
   Upper Front Fork Clamp Bolts
25
9.8
3.5
23
3.5
11
78
20
3.5
20
2.5
1.0
0.36
2.3
0.36
1.1
8.0
2.0
0.36
2.0
18
87 in·lb
31 in·lb
17
31 in·lb
97 in·lb
58
15
31 in·lb
15
 
L
 
AL
 
L
 
 
 
 
Fastener Torque Remarks
N-m kgf-m ft-lb
Frame
   Front Fender Mounting Bolts
   Front Footpeg Bracket Bolts
   Rear Footpeg Bracket Bolts
   Rear Frame Bolts (M10)
   Rear Frame Bolts (M8)
   Sidestand Bolt
   Sidestand Bracket Bolts
   Sidestand Switch Bolt
   Windshield Mounting Bolts
3.9
25
25
44
25
44
49
8.8
0.42
0.40
2.5
2.5
4.5
2.5
4.5
5.0
0.90
0.043
35 in·lb
18
18
32
18
32
36
78 in·lb
3.7 in·lb
 
 
 
L
L
G
L
L
 
Fastener Torque Remarks
N-m kgf-m ft-lb
Electrical System
   Alternator Cover Bo/td>
   Alternator Lead Holding Plate Bolt
   Alternator Rotor Bolt
   Crankshaft Sensor Bolts
   Engine Ground Cable Terminal Bolt
   Front Brake Light Switch Screw
   Front Turn Signal Light Mounting Screw
   Fuel Pump Bolts
   Gear Position Switch Screws
   Left Switch Housing Screws
   License Plate Light Cover Screws
   License Plate Light Mounting Nuts
   Meter Unit Mounting Screws
   Oil Pressure Switch
   Oil Pressure Switch Terminal Bolt
   Oxygen Sensor (Equipped Models)
   Rear Turn Signal Light Lens Screws
   Regulator/Rectifier Bracket Screws
   Right Switch Housing Screws
   Sidestand Switch Bolt
   Spark Plugs
   Speed Sensor Bolt
   Starter Clutch Bolt Cap
   Starter Clutch Cover Bolt (L = 40 mm)
   Starter Clutch Cover Bolt (L = 20 mm)
   Starter Clutch Cover Bolts (L = 30 mm)
   Starter Motor Cable Terminal Bolt
   Starter Motor Mounting Bolts
   Stator Coil Bolts
   Water Temperature Sensor
9.8
9.8
155
5.9
9.8
1.2
1.2
9.8
2.9
3.5
1.0
3.5
1.2
15
1.5
25
1.0
1.2
3.5
8.8
13
6.9
-
9.8
9.8
9.8
2.9
9.8
12
25
1.0
1.0
15.8
0.60
1.0
0.12
0.12
1.0
0.30
0.36
0.10
0.36
0.12
1.5
0.15
2.5
0.10
0.12
0.36
0.90
1.3
0.70
-
1.0
1.0
1.0
0.30
1.0
1.2
2.5
87 in·lb
87 in·lb
114
52 in·lb
87 in·lb
11 in·lb
11 in·lb
87 in·lb
26 in·lb
31 in·lb
8.9 in·lb
31 in·lb
11 in·lb
11
13 in·lb
18
8.9 in·lb
11 in·lb
31 in·lb
78 in·lb
115 in·lb
61 in·lb
-
87 in·lb
87 in·lb
87 in·lb
26 in·lb
87 in·lb
106 in·lb
18
 
L
S
 
 
 
 
L, S
L
 
 
 
 
SS
G
 
 
 
 
L
 
L
Hand-Tighten
 
 
 
 
 
L
 


Basic Torque for General Fasteners

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.
Threads Diameter
(mm)		 Torque
N·m kgf·m ft·lb
5
6
8
10
12
14
16
18
20		 3.4 ~ 4.9
5.9 ~ 7.8
14 ~ 19
25 ~ 34
44 ~ 61
73 ~ 98
115 ~ 155
165 ~ 225
225 ~ 325		 0.35 ~ 0.50
0.60 ~ 0.80
1.4 ~ 1.9
2.6 ~ 3.5
4.5 ~ 6.2
7.4 ~ 10.0
11.5 ~ 16.0
17.0 ~ 23.0
23.0 ~ 33.0		 30 ~ 43
52 ~ 69
10 ~ 13.5
19 ~ 25
33 ~ 45
54 ~ 72
83 ~ 115
125 ~ 165
165 ~ 240