Got these from a friend and since the owners manual is pretty thin on these, I thought I might as well share these.
*** CAUTION: there may be typos eventhough I have double checked. If a value seems way off, DO NOT follow through. I don’t want you to break anything by overtightening. Comment below if anything seems weird or off. DO NOT trust your life with any infromation you found on the internet ***
STANDARD TIGHTENING TORQUES | ||
FASTENER TYPE | TORQUE (Nm) | |
5 mm hex bolt and nut | 5.2 | |
6 mm hex bolt and nut | 10 | |
8 mm hex bolt and nut | 22 | |
10 mm hex bolt and nut | 34 | |
12 mm hex bolt and nut | 54 | |
5 mm screw | 4.2 | |
6 mm screw | 9 | |
6 mm flange bolt | 12 | |
8 mm flange bolt and nut | 27 | |
10 mm flange bolt and nut | 39 | |
FUEL PUMP UNIT | TORQUE (Nm) | |
Fuel pump setting plate nut | 12 | |
FUEL TANK | TORQUE (Nm) | |
Fuel filler cap bolt | 1.8 | Rally only |
AIR CLEANER | TORQUE (Nm) | |
Air cleaner cover screw | 1.2 | |
Air cleaner housing mounting bolt | 7 | |
Air cleaner connecting hose band screw | 1.5 | |
THROTTLE BODY | TORQUE (Nm) | |
Throttle cable A lock nut | 3 | |
Throttle cable B lock nut | 3 | |
Sensor unit torx screw | 3.4 | |
IACV seting plate torx screw | 2.1 | |
Throttle cable holder screw | 3.4 | |
Injector joint mounting bolt | 5.1 | |
SECONDARY AIR SUPPLY SYSTEM | TORQUE (Nm) | |
PAIR check valve cover bolt | 5.2 | |
LUBRICATION SYSTEM | TORQUE (Nm) | |
Oil drain bolt | 24 | |
COOLING SYSTEM | TORQUE (Nm) | |
Cooling fan nut | 1 | use thread lock |
Fan motor screw | 2.7 | |
Water pump impeller | 10 | |
CYLINDER HEAD | TORQUE (Nm) | |
Crankshaft hole cap | 8 | apply oil |
Timing hole cap | 6 | apply oil |
Cylinder head cover bolt | 10 | |
Cam chain tensioner lifter plug | 4.2 | |
Camshaft holder mounting bolt | 12 | apply oil |
Cylinder head mounting bolt | 45 | apply oil |
Cylinder head sealing bolt | 15 | |
CLUTCH / GEARSHIFT LINKAGE | TORQUE (Nm) | |
Clutch center lock nut | 108 | Lock nut > replace, apply oil |
Clutch lifter plate bolt | 12 | |
Primary drive gear lock nut | 108 | apply oil |
Shift drum stopper arm bolt | 10 | use thread lock |
Shift drum stopper plate bolt | 10 | use thread lock |
ALTERNATOR / STARTER CLUTCH | TORQUE (Nm) | |
Starter clutch socket bolt | 30 | use thread lock |
Flywheel bolt | 128 | apply oil |
CKP sensor mounting socket bolt | 10 | use thread lock |
Statormoiunting socket bolt | 10 | |
CRANKCASE / TRANSMISSION / BALANCER | TORQUE (Nm) | |
Cam chain tensioner pivot bolt | 10 | use thread lock |
Balancer shaft nut | 69 | apply oil |
ENGINE UNIT | TORQUE (Nm) | |
Engine hanger plate bolt | 27 | |
Engine hanger nut, front upper | 55 | |
Engine hanger nut, front lower | 55 | |
Engine hanger nut, rear upper | 45 | |
Engine hanger nut, rear lower | 45 | |
Drive sprocket fixing plate bolt | 10 | |
BODY PANELS | TORQUE (Nm) | |
Wind screen screw | 0.75 | Rally only |
Hook bolt | 21 | |
Brake lever pivot bolt | 1 | |
Brake lever pivot nut | 5.9 | |
Battery box bolt | 7 | |
Rearview mirror lock nut | 20 | |
Rear view mirror adaptor bolt | 20 | |
SIDESTAND | TORQUE (Nm) | |
Sidestand pivot bolt | 10 | |
Sidestand pivot nut | 30 | self lock nut |
Sidestand switch bolt | 10 | replace |
EXHAUST / MUFFLER | TORQUE (Nm) | |
Exhaust pipe joint nut | 18 | |
Muffler mounting bolt | 32 | |
Muffler band bolt | 23 | |
Exhaust pipe protector bolt | 12 | |
FRONT WHEEL | TORQUE (Nm) | |
Front axle bolt | 69 | |
Front axle holder bolt | 22 | |
Front axle disc bolt | 20 | replace |
Front spoke | 3.7 | |
FORK | TORQUE (Nm) | |
Top bridge pinch bolt | 29 | |
Bottom bridge pinch bolt | 29 | |
Fork center bolt | 20 | use thread lock |
Fork rod nut | 20 | |
Fork cap | 35 | |
Fork protector bolt | 7 | replace |
HANDLEBAR | TORQUE (Nm) | |
Left handlebar switch screw | 2.5 | |
Right handlebar switch screw | 2.5 | |
STEERING STEM | TORQUE (Nm) | |
Steering stem nut | 103 | |
Front brake hose quide bolt | 10 | |
Front brake hose clamp bolt | 10 | |
REAR WHEEL | TORQUE (Nm) | |
Rear axle nut | 88 | |
Drive sprocket nut | 32 | |
Drive chain adjuster lock nut | 27 | |
Rear brake disc bolt | 42 | replace |
Rear spoke | 3.7 | |
REAR SUSPENSION | TORQUE (Nm) | |
Shock absorber upper nut | 44 | |
Shock absorber lower nut | 44 | |
Shock link bolt, frame side | 44 | |
Shonk link nut, shock arm side | 44 | |
Shock arm to swingarm nut | 74 | apply oil |
Swingarm pivot nut | 88 | |
Drive chain slider bolt | 4.2 | replace |
Drive chain slider side bolt | 4.2 | replace |
Drive chain quide bolt | 10 | replace |
Drive chain slider quide nut | 2.5 | |
Rear brake hose quide mounting screw | 1.2 | |
FRONT BRAKE | TORQUE (Nm) | |
Front brake hose oil bolt | 34 | |
Front master cylinder holder bolt | 9.8 | |
Front master cylinder reservoir cover screw | 1.5 | |
Front brake light switch screw | 1.2 | |
Front brake caliper mounting bolt | 30 | replace |
Front brake caliper bleed valve | 5.4 | |
Front brake caliper torque nut | 22 | use thread lock |
Front brake caliper pin bolt | 17 | |
Front brake pad hanger pin | 17 | |
REAR BRAKE | TORQUE (Nm) | |
Rear brake hose oil bolt | 34 | |
Rear master cylinder bolt | 14 | replace |
Rear mastger cylinder reservoir cover screw | 1.5 | |
Rear master cylinder push rod nut | 17 | |
Rear brake caliper nut | 22 | use thread lock |
Rear brake pin bolt | 12 | use thread lock |
Rear brake pad hanger pin | 17 | |
Rear brake caliper bleed valve | 5.4 | |
PGM-FI SYSTEM | TORQUE (Nm) | |
ECT sensor | 25 | |
O2 sensor | 25 | |
Bank angle sensor nut | 9 | |
IGNITION SYSTEM | TORQUE (Nm) | |
Spark plug | 16 | |
ELECTRICAL STARTER | TORQUE (Nm) | |
Negative brush screw | 3.7 | |
Starter motor assembly bolt | 4.9 | |
Gear position switch | 10 |
There is one thing other manufacturers should learn from KTM. Documentation. Although not free, KTM at least sells their service manuals on their website for a reasonable price.
Thanks for this entry. When I had my 250rally I was really disappointed by the lack of available documentation on this bike.
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Thank you so much, this is gold.
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