2009 Torque

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