XR650R Torque Specs

XR650R 2000 to 2007

General Service Torques

Coolant drain bolt 12 Nm (108 in-lbs)
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 37 Nm (27 ft-lbs)
Spark plug 18 Nm (156 in-lbs)
Valve adjusting screw locknut 25 Nm (18 ft-lbs)
Valve adjusting hole cover 12 Nm (1 08 in-lbs)
Timing hole cap 10 Nm (84 in-lbs)

Wheels Torques

Front axle 88 Nm (65 ft-lbs)
Front axle holder nuts 12 Nm (108 in-lbs)
Rear axle nut 93 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 (seat bearings) 20 to 30 Nm (14 to 22 ft-lbs)
Final torque 8 Nm (69.5 in-lbs)
Steering stem nut 98 Nm (72 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 Torques

Fork cap-to-fork tube  ?
Fork bottom bolt 54 Nm (40 ft-lbs)
Fork cap-to-damper rod 15 Nm (132 in-lbs)
Fork cap-to-fork tube 30 Nm (22 ft-lbs)
Rear shock absorber upper mounting bolt 45 Nm (33 ft-lbs)
Rear shock absorber lower mounting bolt 45 Nm (33 ft-lbs)
Shock arm-to-swingarm 78 Nm (58 ft-lbs)
Shock arm-to-shock link 69 Nm (51 ft-lbs)
Shock link-to-frame 69 Nm (51 ft-lbs)
Swingarm pivot bolt nut 108 Nm (80 ft-lbs)
Swingarm pivot adjusting nut
Stage 1 12 Nm (108 in-lbs)
Stage 2 Loosen until under no torque
Stage 3 7 Nm (5.1 in-lbs)
Adjusting nut lock nut 64 Nm (47 ft-lbs)

Final Drive (Sprockets) Torques

Engine sprocket bolts 12 Nm (108 in-lbs)
Rear sprocket bolts/nuts 42 Nm (31 ft-lbs)

Brake Calipers, Disks and Drums Torques

Front Caliper
Caliper bracket bolts 30 Nm (22 ft-lbs)
Slider pin-to-caliper 23 Nm (1 7 ft-lbs)
Slider pin-to-caliper bracket 23 Nm (17 ft-lbs)
Pad pins 18 Nm (1 56 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 (do not reuse) 20 Nm (168 in-lbs)*
Front master cylinder Mounting bolts 10 Nm (84 in-lbs)
Rear master cylinder mounting bolts 13 Nm (108 in -lbs)

Engine Torques

Engine mounting fasteners
Hanger plate nuts
8mm 26 Nm (20 ft-lbs)
10mm 54 Nm (40 ft-lbs)
Hanger plate bolt (at rear of transmission) 26 Nm (20 ft-lbs)
External oil hose and pipe bolt
Upper (at steering head) Tighten securely
Lower (at bottom of frame downtube) 37 Nm (27 ft-lbs)
At engine Tighten securely
Cylinder head cover bolts
6 mm bolts 12 Nm (108 in -lbs)
8 mm bolts 23 Nm (17 ft-lbs)
Cam sprocket bolts 20 Nm (14 ft-lbs) (2)
Decompressor lifter lever bolt 12 Nm (108 in -lbs) (2)
Cam chain tensioner lifter bolts (on back of cylinder) 12 Nm (108 inch-lbs)
Cam chain tensioner bolt (behind right crankcase cover) 12 Nm (108 inch-lbs) (2)
Cylinder head nuts (10 mm) 67 Nm (49 ft-lbs) (1)
Cylinder-to-crankcase bolts 12 Nm (108 in -lbs)
Crankcase cover bolts (right and left) 12 Nm (108 in-lbs)
Clutch lever perch bolts 10 Nm (84 in-lbs)
Clutch spring bolts 12 Nm (108 in -lbs)
Clutch locknut 118 Nm (87 ft-lbs) (1)
Flywheel (alternator rotor) bolt 125 Nm (90 ft-lbs) (1)
Primary drive gear locknut 118 Nm (87 ft-lbs) (1)
Engine sprocket bolts 12 Nm (108 in-lbs)
Mainshaft bearing set plate bolt 12 Nm (108 in-lbs)
Oil pump stopper plate screw Tighten securely
Oil pump plate bolts 12 Nm (108 in -lbs)
Shift cam-to-shift drum bolt 12 Nm (108 in -lbs) (2)
Shift cam stopper arm bolt 12 Nm (108 in -lbs)
Shift pedal pinch bolt Not specified
Kickstarter bolt 26 Nm (20 ft-lbs)
Crankcase bolts 12 Nm (108 in-lbs)
Mainshaft bearing retainer bolt 12 Nm (108 in -lbs) (2)
(1) Apply clean engine oil to the threads and head
(2) Apply non-permanent thread lock to bolt threads

Exhaust Pipes and Mufflers Torques

Exhaust pipe-to-cylinder head nuts 18 Nm (156 in-lbs)
Muffler clamp bolts 20 Nm (168 in-lbs)
Muffler mounting bolts 32 Nm (24 ft-lbs)

Ignition and Electrical System Torques

Alternator rotor bolt 125 Nm (90 ft-lbs)*
Timing hole cover 84 in-lbs
*Apply clean engine oil to bolt threads and head

Frame and Bodywork Torques

Footpeg bolt/nut 54 Nm (40 ft-lbs)
Skid plate/bar Not available
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)
Sidestand bracket-to-frame bolts
8 mm bolt 26 Nm (20 ft-lbs)
10 mm bolt 36 Nm (29 ft-lbs)
Subframe
Upper bolt 26 Nm (20 ft-lbs)
Lower bolts 42 Nm (31 ft-lbs)