ZX6.us

Torque & Capacity Specifications for ZX600-E (ZX600-E1 thru ZX600-E13)
Torque Specifications for 2009 ZX6-R can be found here

The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket.

Letters used in the Remarks column mean:
L:Apply a non-permanent locking agent to the threads.
LG:Apply liquid gasket to the threads.
Lh:Left-hand threads M : Apply molybdenum disulfide grease.
O:Apply an oil to the threads and seating surface.
S:Tighten the fasteners following the specified sequence.
SS:Apply silicone sealant.
St:Stake the fasteners to prevent loosening.

Basic Torque for general fasteners

Threads diameter (mm) Torque
N-m kg-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 ~ 33
30 ~ 43 in-lb
52 ~ 69 in-lb
10.0 ~ 13.5
19.0 ~ 25
33 ~ 45
54 ~ 72
83 ~ 115
125 ~ 165
165 ~ 240

Exact Torque for specific fasteners

Fastener Torque Remarks
N-m kg-m ft-lb
Fuel System:
   Carburetor Holder Bolts
   Fuel Tap Plate Screws
   Fuel Tap Knob Mounting Screw
   Fuel Pump Bolts

12
7.8
1.0
3.9

1.2
0.80
0.10
0.40

104 in-lb
69 in-lb
9 in-lb
35 in-lb


Fastener Torque Remarks
N-m kg-m ft-lb
Cooling System:
   Radiator Hose Clamp Bolts
   Coolant Air Bleeder Bolt (thermostat housing)
   Coolant Air Bleeder Boll (water pump)
   Coolant Drain Plugs
   Thermostatic Fan Switch
   Water Temperature Sensor

2.0
7.8
9.8
9.8
18
7.8

0.20
0.80
1.0
1.0
1.8
0.80

17 in-lb
69 in-lb
87 in-lb
87 in-lb
13.0
69 in-lb






SS
Fastener Torque Remarks
N-m kg-m ft-lb
Engine Top End:
   Spark Plug
   Cylinder Head Cover Bolts
   Cylinder Head Bolts New Parts
   Cylinder Head Bolts Used Parts
   Pickup Coil Cover Bolts
   Cylinder Head Jacket Plugs (PT 1/2, PT 3/8)
   Camshaft Bearing Cap Bolts
   Camshaft Chain Tensioner Mounting Bolts
   Camshaft Sprocket Bolts
   Camshaft Chain Guide Bolts (Rear)
   Oil Hose Banjo Bolts

14
9.8
47
43
12
20
12
12
15
12
25

1.4
1.0
4.8
4.4
1.2
2.0
1.2
1.2
1.5
1.2
2.5

10.0
87 in-lb
35
32
104 in-lb
14.5
104 in-lb
104 in-lb
11.0
104 in-lb
18.0

S, O (washer)
S, O (washer)


S

L
Fastener Torque Remarks
N-m kg-m ft-lb
Clutch:
   Clutch Cover Bolts
   Clutch Lever Holder Bolts
   Clutch Spring Bolts
   Clutch Hub Nut
   Clutch Cover Damper Bolts

12
7.8
8.8
130
5.9

1.2
0.80
0.90
13.5
0.60

104 in-lb
69 in-lb
78 in-lb
98
52 in-lb





L
Fastener Torque Remarks
N-m kg-m ft-lb
Engine Lubrication System:
   Engine Drain Plug
   Crankcase Main Oil Passage Plug
   Oil Pan Bolts
   Oil Filter
   Oil Filter Mounting Bolt
   Oil Pressure Relief Valve
   Oil Pressure Switch Terminal Bolt
   Oil Pressure Switch
   Oil Hose Banjo Bolts
   Oil Hose Clamp Bolts (Lower Crankcase)
   Oil Hose Flange Bolts
   Oil Separator Cover Bolts (Upper Crankcase)

20
15
12
9.8
29
15
1.5
15
25
8.8
12
9.8

2.0
1.5
1.2
1.0
3.0
1.5
0.15
1.5
2.5
0.90
1.2
1.0

14.5
11.0
104 in-lb
87 in-lb
22
11.0
13 in-lb
11.0
18.0
78 in-lb
104 in-lb
87 in-lb




or hand-tight

L

SS



L
Fastener Torque Remarks
N-m kg-m ft-lb
Engine Removal/Installation:
   Engine Mounting Bolts
   Engine Mounting Adjuster
   Engine Mounting Bracket Bolts

49
9.8
23

5.0
1.0
2.3

36
87 in-lb
16.5



Fastener Torque Remarks
N-m kg-m ft-lb
Crankshaft/Transmission:
   Oil Separator Cover Bolts
   Gear Positioning Lever Mounting Bolt
   Oil Pressure Switch
   Neutral Switch
   Shift Shaft Return Spring Pin
   Shift Drum Cam Bolts
   Shift Rod Plug (Left, M14)
   Connecting Rod Big End Cap Bolts
       (New)
       (In Assy)
   Crankcase Bolts Ø 8
   Crankcase Bolts Ø 6
   Timing Rotor Allen Bolt
   Crankcase Main Oil Passage Plug
       (Left, PT3/8)
       (Right M18)
   Oil Hose Banjo Bolts
   Oil Hose Bracket Bolts

9.8
8.8
15
15
20
12
15

24 + 120°
22 + 120°
27
12
25

20
15
25
8.8

1.0
0.90
1.5
1.5
2.0
1.2
1.5

2.4 + 120°
2.2 + 120°
2.8
1.2
2.5

2.0
1.5
2.5
0.90

87 in-lb
78 in-lb
11.0
11.0
14.5
104 in-lb
11.0

17.5 + 120°
16.0 + 120°
20
104 in-lb
18.0

14.5
11.0
18.0
78 in-lb

L

SS

L
L

R,O


S
S


L



Fastener Torque Remarks
N-m kg-m ft-lb
Wheels/Tires:
   Front Axle Clamp Bolts
   Front Axle Nut
   Rear Axle Nut

20
110
110

2.0
11.0
11.0

14.5
80
80



Fastener Torque Remarks
N-m kg-m ft-lb
Final Drive:
   Engine Sprocket Nut
   Torque Link Nuts
   Rear Sprocket Nuts
   Rear Sprocket Nuts (04-05)
   Rear Sprocket Studs

125
34
75
59
-

13.0
3.5
7.5
6.0
-

94
25
54
43
-





L
Fastener Torque Remarks
N-m kg-m ft-lb
Brakes:
   Bleed Valves
   Brake Hose Banjo Bolts
   Master Cylinder Reservoir Cap
   Torque Link Nut
   Caliper Mounting Bolts (Front)
   Caliper Mounting Bolts (Rear)
   Caliper Bolts (Front)
   Front Caliper Pad Spring Screws
   Disc Mounting Bolts (Front)
   Disc Mounting Bolts (Rear)
   Brake Lever Pivot Bolt
   Brake Lever Pivot Bolt Locknut
   Front Brake Switch Mounting Screws
   Front Brake Reservoir Cap Screws
   Front Master Cylinder Clamp Bolts
   Rear Master Cylinder Mounting Bolts
   Rear Master Cylinder Pushrod Locknut
   Brake Pedal Shaft Bolts (Right Footpeg Bolt)
   Rear Master Cylinder Bracket Locknut
   Brake Pedal Mounting Bolt

7.8
25
1.5
34
34
25
21
2.9
23
23
1.0
5.9
1.0
1.5
9.8
23
18
8.8
18
8.8

0.80
2.5
0.15
3.5
3.5
2.5
2.1
0.30
2.3
2.3
0.10
0.60
0.10
0.15
1.0
2.3
1.8
0.90
1.8
0.90

69 in-lb
18.0
13 in-lb
25
25
18.0
15.0
26 in-lb
16.5
16.5
9 in-lb
52 in-lb
9 in-lb
13 in-lb
87 in-lb
16.5
13
78 in-lb
13.0
78 in-lb


















Fastener Torque Remarks
N-m kg-m ft-lb
Suspension:
   Front Fork Clamp Bolts (Upper, Lower)
   Front Fork Bottom Allen Bolts
   Front Axle Clamp Bolts
   Rear Shock Absorber Mounting Nuts
   Rear Shock Absorber Preload Adjuster Nut
   Tie-Rod Nuts
   Rocker Arm Pivot Shaft Nut
   Swing Arm Pivot Shaft Nut
   Swing Arm Pivot Shaft Nut (03-04)

20
20
20
59
88
59
59
88
108

2.0
2.0
2.0
6.0
9.0
6.0
6.0
9.0
11.0

14.5
14.5
14.5
43
65
43
43
65
80


L






Fastener Torque Remarks
N-m kg-m ft-lb
Steering:
   Steering Stem Head Nut
   Steering Stem Nut

   Handlebar Holder Mounting Bolts

49
Hand-Tight
or 4.9
23

5.0
Hand-Tight
or 0.50
2.3

36
Hand-Tight
or 43 in-lb
16.5

Fastener Torque Remarks
N-m kg-m ft-lb
Frame:
   Side Stand Bolt
   Side Stand Bracket Bolts Mounting Bolt
   Front Footpeg Stay Bolts
   Rear Footpeg Stay Bolts
   Tail Grip Bracket Mounting Bolts
   Center Stand Bolt

44
49
25
25
25
44

4.5
5.0
2.5
2.5
2.5
4.5

32
36
18.0
18.0
18.0
32


L




Fastener Torque Remarks
N-m kg-m ft-lb
Electrical System:
   Fuel Gauge Bolt
   Pickup Coil Cover Bolts
   Timing Rotor Allen Bolts
   Alternator Cover Bolts
   Alternator Rotor Bolt
   Alternator Starter Bolts
   Starter Relay Terminal Nut
   Starter Motor Terminal Nut
   Starter Clutch Bolt
   Spark Plug
   Handlebar Switch Housing Clamp Screws
   Thermostatic Fan Switch
   Water Temperature Sensor
   Oil Pressure Switch
   Neutral Switch
   Speedometer & Trip Meter Mounting Screws
   Tail Light Mounting Nut
   Side Stand Switch

3.9
12
25
12
78
12
4.9
4.9
34
14
3.4
18
7.8
15
15
-
5.9
3.9

0.4
1.2
2.5
1.2
8.0
1.2
0.50
0.50
3.5
1.4
0.35
1.8
0.80
1.5
1.5
-
0.6
0.4

35 in-lb
8.5
18.0
8.5
58
104 in-lb
43 in-lb
43 in-lb
25
10
30 in-lb
13.0
69 in-lb
11.0
11.0
-
52 in-lb
35 in-lb









L



SS
SS

L




Capacity Information

Fuild Capacity
Metric Standard
Unlead Gasoline
Engine Oil** when filter is not removed
Engine Oil** when filter is removed
Engine Oil** when engine is completely dry
Fork oil capacity when completely dry
Fork oil capacity when changing oil
Antifreeze (Green 50/50 mix)
18.0 Liters
2.8 Liters
3.2 Liters
3.7 Liters
452 ml (+/- 4mL)
384 ml
2.5 Liters
4.75 Gallons
0.74 Gallons
0.85 Gallons
0.98 Gallons
15.3 oz (+/- 0.13oz)
13 oz
2.65 quarts
** Oil Viscosity: SAE10W-40, 10W-50, 20W-40, or 20W-50

Chain slack should be between 1.4" and 1.6".

Copyright
2014