XJRider.com

US Model, XJ600 and Seca II, Torque Specs:
These are the factory torque specs for anything I could find a torque listed for. You can also download a text file with this information.

If you find an error, please post the correct torque and I'll get the list fixed.

Tune-Up Items:

• Oil Drain Plug: 31 ft-lbs
  Oil Filter: 100 in-lbs
  Spark Plugs: 108 in-lbs
  Exhaust pipe flange nuts: 132 in-lbs
  Steering head bearing ring nut: 37 ft-lbs to seat and then 156 in-lbs
  Valve cover bolts: 86 in-lbs
  Fork caps: 17 ft-lbs

Engine, Clutch and Gearbox:

• Cam chain tensioner cap bolt: 168 in-lbs
  Cam chain tensioner mounting bolts: 86 in-lbs
  
  Camshaft bearing cap bolts: 86 in-lbs
  Camshaft sprocket bolts: 17 ft-lbs
  
  Clutch boss nut: 50 ft-lbs
  Clutch cover mounting bolts: 86 in-lbs
  Clutch pressure plate bolts: 70 in-lbs
  
  Connecting rod cap nuts: 18 ft-lbs
  
  Crankcase bolts: 17 ft-lbs
  Crankcase plugs (M10): 105 in-lbs
  
  Cylinder block to crankcase nut: 168 in-lbs
  Cylinder block to cylinder head nuts: 86 in-lbs
  
  Cylinder head cap nuts: 16 ft-lbs
  
  Engine Mount bolts:
  • Front: 43 ft-lbs
    Rear: 64 ft-lbs
  Oil-Filter adapter bolt: 36 ft-lbs
  Oil pan mounting bolts - 86 in-lbs
  Oil pick-up mounting bolts: 86 in-lbs
  
  Oil pump assembly screws: 61 in-lbs
  Oil pump mounting screws: 61 in-lbs
  Oil pump screws: 61 in-lbs
  
  Primary drive gear nut: 36 ft-lbs
  
  Shift cam retaining plate screws: 61 in-lbs
  Shift cam stopper screw: 16 ft-lbs
  
  Shift lever pinch bolt: 86 in-lbs
  Shift pedal linkage locknuts: 86 in-lbs
  
  Starter chain guide bolts: 70 in-lbs
  Starter Chain tensioner bolts: 86 in-lbs
  Starter clutch Allen bolts: 18 ft-lbs
  
  Valve cover bolts: 86 in-lbs

Fuel & Exhaust Systems:

• Exhaust pipe flange nuts: 132 in-lbs
  Exhaust pipe nuts: 168 in-lbs
  
  Muffler bolts:
  • M8 in size: 168 in-lbs
    M10 in size: 18 ft-lbs
  Exhaust pipe joint bolts: 168 in-lbs
  
  Carburetor heater thermoswitch (if equipped): 124 in-lbs

Ignition System:

• Pick-up coil plate securing screws: 70 in-lbs
  Timing rotor bolt: 32 ft-lbs
  Signal generator cover screws: 86 in-lbs

Frame, Suspension & Final Drive:

• Front Forks:
  • Cap bolt to fork: 17 ft-lbs
    Damper rod bolt: 22 ft-bs
  Handlebars & Steering Stem:
  • Upper triple clamp bolts: 17 ft-lbs
    Lower triple calmp bolts: 27 ft-lbs
    Handlebar bracket bolts (mounting bolts): 17 ft-lbs
    Handlebar end-weights: 19 ft-lbs
    Steering stem nut: 80 ft-lbs
    Steering headset bearing ring nut: 37 ft-lbs to seat and then 156 in-lbs
  Rear shock absorber bolts and nuts: 46 ft-lbs
  Swingarm pivot shaft nut: 66 ft-lbs
  
  Drive chain front sprocket nut: 80 ft-lbs
  Drive chain rear sprocket nuts: 43 ft-lbs
  Engine sprocket cover bolts: 86 in-lbs

Brakes, Wheels & Tires:

• Caliper bracket mounting bolts: 25 ft-lbs
  Front caliper bracket Allen bolt: 17 ft-lbs
  Rear caliper pad retaining bolts: 86 in-lbs
  
  Front axle: 43 ft-lbs
  Front axle pinch bolts: 168 in-lbs
  
  Brake disc mounting bolts: 168 in-lbs
  Union bolts (banjo fittings on caliper & master): 22 ft-lbs
  
  Master cylinder mounting bolts:
  • Front: 78 in-lbs
    Rear: 17 ft-lbs
  Rear axle nut: 75 ft-lbs
  Torque link bolts and nuts ('92 to '96 model): 22 ft-lbs
  Torque link bolts and nuts (97+ model): 17 ft-lbs

Electrical System:

• Neutral switch screws: 35 in-lbs (use loctite on these threads)
  
  Alternator:
  • Rotor bolt: 58 ft-lbs
    Cover Allen bolts: 86 in-lbs
  Starter mounting bolts: 86 in-lbs
  Regulator/Rectifier Allen bolts: 61 in-lbs