XR650L Torque Specs

XR650L 1993 to 2008

General Service Torque

Oil drain plug in frame 25 Nm (18 ft-lbs)
Oil drain plug in crankcase 25 Nm (18 ft-lbs)
Oil filter cover bolts 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 17 Nm (144 in-lbs)
Valve adjusting screw locknut 25 Nm (18 ft-lbs)
Valve adjusting hole cover Not specified
Crankshaft hole cap Not specified

Wheels Torque

Front axle 87 Nm (63 ft-lbs)
Front axle holder nuts 12 Nm (108 in-lbs)
Rear axle nut 90 Nm (65 ft-lbs)
Wheel spokes 4.0 Nm (36 in-lbs)
Rim lock locknut 13 Nm (108 in-lbs)

Steering Torque

Steering stem adjusting nut
Initial torque (seat bearings) 20 to 30 Nm (14 to 22 ft-lbs)
Steering stem adjusting nut 1 Nm (9 in-lbs)
Steering stem nut 118 Nm (85 ft-lbs)
Handlebar bracket bolts 27 Nm (20 ft-lbs)
Upper triple clamp bolts 28 Nm (20 ft-lbs)
Lower triple clamp bolts 33 Nm (24 ft-lbs)

Suspension Torque

Rear shock absorber upper mounting bolt 45 Nm (33 ft-lbs)
Rear shock absorber lower mounting bolt 35 Nm (25 ft-lbs)
Shock arm-to-swingarm 70 Nm (51 ft-lbs)
Shock arm-to-shock link 45 Nm (33 ft-lbs}
Shock link-to-frame 55 Nm (40 ft-lbs)
Swingarm pivot bolt nut 90 Nm (65 ft-lbs)

Final Drive (Sprockets) Torque

Engine sprocket bolts Not specified
Rear sprocket bolts/nuts 64 Nm (46 ft-lbs)

Brake Calipers, Disks and Drums Torque

Front Caliper
Caliper bracket bolts 30 Nm (22 ft-lbs)
Slider pin-to-caliper 23 Nm (17 ft-lbs)
Slider pin-to-caliper bracket 13 Nm (1 20 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 35 Nm (25 ft-lbs)
Brake disc-to-wheel bolts
Front (replace if removed) 37 Nm (27 ft-lbs)
Rear (replace if removed) 42 Nm (30 ft-lbs)
Front master cylinder Mounting bolts 12 Nm (108 in -lbs)
Rear master cylinder mounting bolts 15 Nm (132 in -lbs)
Pedal pivot bolt (drum brake models) 30 Nm (22 ft-lbs)

Engine Torque

Engine mounting bolts
8 mm bolts 27 Nm (20 ft-lbs)
10 mm bolts 50 Nm (30 ft-lbs)
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 Not specified
Cylinder head small nuts/bolts 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 Not specified
Primary drive gear locknut 110 Nm (80 ft-lbs)
Clutch locknut 120 Nm (87 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 12 Nm (108 in-lbs)
Crankcase bolts 12 Nm (1 08 in-lbs)
Crankshaft bearing retainer bolt Not specified
Center shift fork-to-shaft bolt 15 Nm (132 in-lbs)

Exhaust Pipes and Mufflers Torque

Exhaust pipe-to-cylinder head nuts 17 Nm (144 in-lbs)
Muffler clamp bolts 20 Nm (168 in-lbs)
Muffler mounting bolts 32 Nm (24 ft-lbs)

Ignition and Electrical System Torque

Alternator rotor bolt (apply oil to threads and head) 125 Nm (90 ft-lbs)
Starter gear cover bolts 12 Nm (108 in-lbs)
Starter motor mounting bolts Not specified
Starter clutch housing-to-alternator rotor bolts 30 Nm (22 ft-lbs)
Timing hole cover 84 in-lbs

 Frame and Bodywork Torque

Seat mounting bolts Not specified
Footpeg bolt/nut 65 Nm (47 ft-lbs)
Skid plate/bar Not specified
Sidestand
Step 1 Tighten bolt to 10 Nm (84 in-lbs)
Step 2 Loosen bolt 1/8-turn
Step 3 Tighten nut to 40 Nm (29 ft-lbs)