General Specifications

 

Kaw ZX6R Torque Specs

 

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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