XR600R Torque Specs

XR600R 1985 to 2000

General Service Torques

Oil drain plug in frame
XR600R
1985 through 1987 35 to 45 Nm (25 to 33 ft-lbs)
1988 and later 40 Nm (29 ft-lbs)
Oil drain plug in crankcase
1983 through 1987 models 30 to 40 Nm (22 to 29 ft-lbs)
1988 and later 25 Nm (18 ft-lbs)
Oil filter cover bolts
1983 through 1987 models 8 to 10 Nm (60 to 84 in-lbs)
1988 and later 12 Nm (108 in-lbs)
Oil strainer screen to frame 55 Nm (40 ft-lbs)
Hose fitting to oil strainer screen 40 Nm (29 ft-lbs)
Crankcase oil strainer screen bolt 40 Nm (29 ft-lbs)
Spark plug 18 Nm (156 in-lbs)
Valve adjusting screw locknut 25 Nm (18 ft-lbs)
Valve adjusting hole cover
Through 1997 Not specified
1998 and later XR600R 15 Nm (132 in-lbs)
Crankshaft hole cap (exc XR650R)
Through 1997 Not specified
1998 and later 15 Nm (132 in-lbs)
Timing hole cap
Through 1997 Not specified
1998 and later 10 Nm (84 in-lbs)

Wheels Torques

Front axle
1983 through 1987 models 50 to 80 Nm (36 to 58 ft-lbs)
1988 through 1992 models 65 Nm (47 ft-lbs)
1993 and later models 85 Nm (61 ft-lbs)
Front axle holder nuts
1983 through 1987 models 10 to 14 Nm (84 to 120 in-lbs)
1988 and later models 12 Nm (108 in -lbs)
Rear axle nut
1983 through 1987 models 80 to 110 Nm (58 to 72 ft-lbs)
1988 and later models 95 Nm (69 ft-lbs)
Wheel spokes 4.0 Nm (36 in-lbs)
Rim lock locknut 13 Nm (108 in-lbs)

Steering Torques

Steering stem adjusting nut
Initial torque (to seat bearings) 20 to 30 Nm (14 to 22 ft-lbs)
Final torque
1983 through 1987 1 to 2 Nm (9 to 16 in-lbs)
1988 through 1990 3 Nm (24 in-lbs)
1991 and 1992 1 Nm (9 in-lbs)
1993 and later 1.5 Nm (13 in-lbs)
Steering stem nut
1985 to 1987 95 to 140 Nm (69 to 101 ft-lbs)
1988 and later 118 Nm (85 ft-lbs)
Handlebar bracket bolts
1985 through 1987 22 to 30 Nm (16 to 22 ft-lbs)
1988 on 27 Nm (20 ft-lbs)
Upper triple clamp bolts
1985 through 1987 25 to 30 Nm (18 to 22 ft-lbs}
1988 through 1990 33 Nm (24 ft-lbs)
1991 on 28 Nm (20 ft-lbs)
Lower triple clamp bolts
1985 through 1987 30 to 35 Nm (22 to 25 ft-lbs)
1988 on 35 Nm (25 ft-lbs)

Suspension Torques

Front forks
Damper rod Allen bolt 15 to 25 Nm (11 to 18 ft-lbs)
Fork bottom bolt (1988 and later) 35 Nm (25 ft-lbs)
Fork cap-to-fork tube
1985 through 1987 15 to 30 Nm (11 to 22 ft-lbs)
1988 and later 23 Nm (17 ft-lbs)
Fork cap locknut (1991 and later) 60 Nm (43 ft-lbs)
Fork piston retainer (1991 on) 35 Nm (25 ft-lbs)
Rear shock absorber upper mounting bolt
1985 through 1987 40 to 50 Nm (29 to 36 ft-lbs)
1988 on 45 Nm (33 ft-lbs)
Rear shock absorber lower mounting bolt
1985 through 1987 25 to 35 Nm (14 to 25 ft-lbs)
1988 through 1990 30 Nm (22 ft-lbs)
1991 on 35 Nm (25 ft-lbs)
Shock arm-to-swingarm
1985 through 1987 60 to 80 Nm (43 to 57 ft-lbs)
1988 on 70 Nm (51 ft-lbs)
Shock arm-to-shock link
1985 through 1987 40 to 50 Nm (29 to 36 ft-lbs)
1988 on 45 Nm (33 ft-lbs)
Shock link-to-frame
1985 through 1987 40 to 50 Nm (29 to 36 ft-lbs)
1988 on 45 Nm (33 ft-lbs)
Swingarm pivot bolt nut
1985 through 1987 80 to 100 Nm (58 to 72 ft-lbs)
1988 and later 90 Nm (65 ft-lbs)

Final Drive (Sprockets) Torques

Engine sprocket bolts  Not specified
Rear sprocket bolts/nuts
1985 through 1987 34 to 40 Nm (24 to 29 ft-lbs)
1988 on 44 Nm (32 ft-lbs)

Brake Calipers, Disks and Drums Torques

Front Caliper
1983 through 1987
Caliper bracket bolts 20 to 30 Nm (14 to 22 ft-lbs)
Upper slider pin-to-bracket 20 to 25 Nm (1 4 to 18 ft-lbs)
Lower slider pin-to-bracket 15 to 20 Nm (84 to 168 in -lbs)
Pad pins 15 to 20 Nm (84 to 168 in-lbs)
1988 on
Caliper bracket bolts
1988 to 1992 27 Nm (20 ft-lbs)
1992 and later 30 Nm (22 ft-lbs)
Slider pin-to-caliper 23 Nm (17 ft-lbs)
Slider pin-to-caliper bracket 13 Nm (120 in-lbs)
Pad pins 18 Nm (156 in-lbs)
Pad pin plugs 3 Nm (26 in -lbs)
Rear caliper
Allen head slider pin-to-caliper 28 Nm (20 ft-lbs)
Slider pin-to-bracket 13 Nm (1 20 in -lbs)
Pad pins 18 Nm (1 56 in -lbs)
Pad pin plugs 3 Nm (26 inch-lbs)
Brake line union bolts
1983 through 1987 Not specified
1988 on 35 Nm (25 ft-lbs)
Brake disc-to-wheel bolts
1985 through 1987 models 14 to 16 Nm (1 20 to 144 in -lbs)
1988 through 1990 models 15 Nm (1 32 in-lbs)*
1991 and later models 20 Nm (1 68 in-lbs)*
Front master cylinder Mounting bolts
1983 through 1987 Not specified
1988 on 27 Nm (20 ft-lbs)
Pivot bolt locknut
1983 through 1987 Not specified
1988 on 10 Nm (84 inch-lbs)
Rear master cylinder mounting bolts Not specified
*Replace the bolts with new ones whenever they’re removed

Engine Torques

External oil hose and pipe nuts 40 Nm (29 ft-lbs)
Cylinder head cover bolts
6 mm small head bolt 10 Nm (84 in-lbs)
6 mm regular head bolts 12 Nm (108 in-lbs)
8 mm bolt 23 Nm (17 ft-lbs) (1)
Cam sprocket bolts 20 Nm (14 ft-lbs)
Main rocker shafts 27 Nm (20 ft-lbs)
Sub-rocker shafts (2)
Intake 27 Nm (20 ft-lbs)
Exhaust 23 Nm (17 ft-lbs)
Cam chain tensioner bolt
Through 1997 Not specified
1998 and later 12 Nm (108 inch-lbs) (2)
Cylinder head main bolts
1983 through 1987 models 27 to 32 Nm (20 to 23 ft-lbs)
1988 and later 36 Nm (26 ft-lbs)
Cylinder head small nuts/bolts
Through 1997 Not specified
1998 and later 12 Nm (1 08 inch-lbs)
Cylinder main bolts 50 Nm (36 ft-lbs)
Cylinder small bolts Not specified
Intake manifold (carburetor insulator) bolts Not specified
Right and left engine cover bolts 12 Nm (108 in-lbs)
Clutch spring bolts
Through 1997 Not specified
1998 and later 12 Nm (1 08 in-lbs)
Primary drive gear locknut
1985 through 1987 70 to 80 Nm (50 to 58 ft-lbs)
1988 and later 110 Nm (80 ft-lbs)
Clutch locknut
1985 through 1987 70 to 80 Nm (50 to 58 ft-lbs)
1988 and later 110 Nm (80 ft-lbs)
Shift cam plate to shift drum bolt 12 Nm (108 in-lbs)
Shift drum stopper arm bolt 25 Nm (18 ft-lbs)
Shift pedal pinch bolt Not specified
Crankcase bolts 12 Nm (1 08 in-lbs)
Crankshaft bearing retainer bolt
Through 1997 Not specified
1998 and later 25 Nm (18 ft-lbs)
Center shift fork-to-shaft bolt 15 Nm (132 in-lbs)

Exhaust Pipes and Mufflers Torques

Exhaust pipe-to-cylinder head nuts
1985 through 1987 8 to 12 Nm (72 to 108 in-lbs)
1988 through 1990 27 Nm (20 ft-lbs)
1991 and later 17 Nm (144 in-lbs)
Muffler clamp bolts 27 Nm (20 ft-lbs)
Muffler mounting bolts
1983 through 1987 20 to 30 Nm (15 to 22 ft-lbs)
1988 through 1990 70 Nm (51 ft-lbs)
1991 and later 35 Nm (25 ft-lbs)

Ignition and Electrical System Torques

Alternator rotor bolt
1983 through 1987 100 to 120 Nm (72 to 87 ft-lbs)
1988 and later 125 Nm (90 ft-lbs)*
Timing hole cover 84 in-lbs
*Apply oil to the bolt threads and head

 Frame and Bodywork Torques

Seat mounting bolts  Not available
Footpeg bolt/nut
1985 to 1987 models 50 to 60 Nm (36 to 43 ft-lbs)
1988 and later models 65 Nm (47 ft-lbs)
Skid plate/bar Not available
Sidestand 35 to 45 Nm (25 to 33 ft- lbs)