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Kx250F: Torque Spec

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Everything is ftlbs unless noted with in.lb which is Inchpounds

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

L: Apply a non-permanent locking agent to the threads.

Lh: Left-hand Threads

S: Tighten the fasteners following the specified sequence.

Basic Torque for General Fasteners

Threads dia. Torque

(mm) ft·lb

5mm 43 in·lb

6mm 69 in·lb

8mm 13.5

10mm 25

12mm 45

14mm 72

16mm 115

18mm 165

20mm 240

Fuel System

Air Cleaner Element Wing Bolt – – – Hand Tighten

Throttle Pulley Cover Bolt 30 in·lb

Throttle Cable Locknut 61 in·lb

Hot Start Plunger Cap Bolt 10 in·lb

Air Cleaner Duct Bolt and Nuts 27 in·lb

Rear Frame Mounting Bolts 25

Air Cleaner Housing Bolts 87 in·lb

Air Cleaner Duct Clamp Screws 27 in·lb

Carburetor Holder Clamp Screws 17 in·lb

Fuel Tap Plate Mounting Screws 7 in·lb

Cooling System

Right Engine Cover Bolt 87 in·lb

Water Pipe Bolt 87 in·lb

Water Pump Cover Bolts 87 in·lb L (1)

Water Pump Cover Bolts (with washer) 87 in·lb L (1)

Water Pump Impeller Bolt 61 in·lb

Radiator Hose Clamp Screws 13 in·lb

Radiator Screen Bolts 87 in·lb

Coolant Drain Plug 61 in·lb

Radiator Mounting Bolts 87 in·lb

Radiator Shroud Bolts 87 in·lb

Engine Top End

Auto-Decompressor Bolt 104 in·lb

Decompressor Plug 87 in·lb

Cylinder Head Cover Bolts 87 in·lb

Cylinder Head Bolts:

M10 36 S

M6 104 in·lb S

Camshaft Cap Bolts 87 in·lb S

Carburetor Holder Clamp Screws 17 in·lb

Plug 14 L

Lower Camshaft Chain Guide Bolt 87 in·lb

Rear Camshaft Chain Guide Bolt 11

Exhaust Pipe Stud – – – L (Planted

side)

Camshaft Chain Tensioner Mounting Bolts 87 in·lb

Camshaft Chain Tensioner Cap Bolt 14.5

Cylinder Bolt M6 104 in·lb S

Exhaust Pipe Cover Screws 104 in·lb

Exhaust Pipe Holder Nuts 15 S

Silencer Mounting Bolts 15 S

Silencer Cover Bolt 109 in·lb L

Engine Right Side

Primary Gear Nut 72 Lh

Shift Drum Cam Bolt 17 L

Clutch Spring Bolts 87 in·lb

Clutch Hub Nut 72

Gear Set Lever Nut 78 in·lb

Gear Set Lever Pivot Stud – – – L (Planted

Side)

Ratchet Plate Mounting Bolt 87 in·lb L

Ratchet Plate Mounting Screw 56 in·lb L

Kick Ratchet Guide Bolt 78 in·lb L

Kick Pedal Mounting Bolt 18 L

Shift Pedal Bolt 87 in·lb

Clutch Cover Bolts 87 in·lb L (2)

Right Engine Cover Bolts 87 in·lb

Engine Lubrication System

Engine Oil Drain Bolt M10

(for transmission room oil sump) 11

Engine Oil Drain Bolt M6

(for crank room oil sump) 61 in·lb

Oil Filter Cap Bolts 87 in·lb

Oil Pump Mounting Bolts 61 in·lb L

Water Pump Cover Bolts 87 in·lb L (1)

Water Pump Cover Bolt (with washer) 87 in·lb L (1)

Right Engine Cover Bolts 87 in·lb

Breather Fitting 11 L

Oil Pump Idle Gear Shaft Screws 56 in·lb L

Engine Removal/Installation

Engine Mounting Nuts 33

Engine Bracket Nuts 22

Swingarm Pivot Shaft Nut 72

Crankshaft/Transmission

Breather Fitting 11 L

Reed Valve Screws 61 in·lb

Piston Oil Nozzle 26 in·lb

Crankcase Bolts 87 in·lb S

Engine Oil Drain Bolt

(for crank room oil sump) 61 in·lb

(for transmission room oil sump) 11

Output Shaft Bearing Retaining Screw 56 in·lb L

Drive Shaft Bearing Retaining Screw 56 in·lb L

Shift Drum Bearing Retaining Bolts 87 in·lb L

Gear Set Lever Nut 78 in·lb

Shift Drum Cam Bolt 17 L

Neutral Switch 104 in·lb

Wheels/Tires

Front Axle 58

Front Axle Clamp Bolts 14.5 AL

Rear Axle Nut 80

Spoke Nipple

Not less

than 19 in·lb

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Final Drive

Rear Sprocket Nuts 25

Engine Sprocket Cover Bolts 87 in·lb

Brakes

Brake Lever Pivot Locknut 52 in·lb

Brake Reservoir Cap Screws 13 in·lb

Brake Lever Pivot Bolt 52 in·lb

Caliper Mounting Bolts (Front) 18

Brake Hose Banjo Bolts 25

Front Master Cylinder Clamp Bolts 78 in·lb S

Rear Master Cylinder Mounting Bolts 88 in·lb

Rear Master Cylinder Push Rod Locknut 12.5

Brake Reservoir Cap Bolts 13 in·lb

Brake Disc Mounting Bolts:

(Front) 87 in·lb L

(Rear) 16.6 L

Caliper Bleed Valves (Front, Rear) 69 in·lb

Front Caliper Holder Shaft 16 L

Rear Caliper Holder Shaft 20

Caliper Pin Bolts 104 in·lb L

Brake Pad Bolts 12.5

Rear Brake Pad Bolt Plug 22 in·lb

Brake Pedal Mounting Bolt 18 L

Suspension

Front Fork Cylinder Unit 25

Front Fork Clamp Bolts

(Upper) 14.5 L, AL

(Lower) 14.5 AL

Front Fork Adjuster Assembly 51 L

Front Fork Base Valve Assembly 21.8

Adjuster Assemble Locknut 16

Swingarm Pivot Shaft Nut 72

Rear Shock Absorber Mounting Nuts:

(Upper) 29

(Lower) 25

Spring Locknut 33

Piston Rod Locknut 27

Gas Reservoir Damping Adjuster

Assembly

21

Tie-Rod Mounting Nut (Front, Rear) 61

Rocker Arm Pivot Nut 61

Steering

Steering Stem Head Nut 72

Steering Stem Locknut 43 in·lb

Handlebar Clamp Bolts 18 S

Frame

Footpeg Bracket Bolts (Upper) 40 L

Rear Frame Mounting Bolts 25

Electrical System

Neutral Switch 104 in·lb

Neutral Switch Lead Terminal Screw 12 in·lb

Flywheel Nut 36

Flywheel Nut Cap 44 in·lb

Timing Inspection Cap 35 in·lb

Stator Bolts 61 in·lb

Crankshaft Sensor Bolts 61 in·lb

Spark Plug 115 in·lb

C.D.I. Unit Bolts 87 in·lb

Magneto Cover Bolts

L: 30 87 in·lb

L: 35 87 in·lb L

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Yeah, well I guess I am.. just people ask 30 million times even when the awnser is in a post on the first page of the group.. Look at all the darn team green posts weather or not it will work for me or for you for what ever.

Thanks Bryan.

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Just wondering has this been helpfull for anyone yet???

anything anyone wants? I can post the tightening sequences if need be? for like the head bolts, cam camps ect???

How about I add the electrical specs voltages ohms ect???

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Been helpful for me, Im gonna print it, laminate it and shove it in my track box today actually! Thanks

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woulda helped me out when i made all those phone calls to you

im ditchin the bike for $2,600 for a new 09 kx450f

=D

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I can't find the torque spec for the nuts on the underside of the top triple clamp. The ones that hold the rubber bar mounts. I've looked and looked. Anybody know? I'm afraid if I go to tight it might smash the rubbers or something....

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guess i'll just go with 25' lbs since there 10mm locknuts. i was just concerned with the rubber dampers....

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guess i'll just go with 25' lbs since there 10mm locknuts. i was just concerned with the rubber dampers....

Steering

Steering Stem Head Nut 72

Steering Stem Locknut 43 in·lb

Handlebar Clamp Bolts 18 S

Allthough now that I look at it. Maybe that may not be it.. Sorry never thought about that. I just torqued them tight. the rubber is designed to squash out anyways.

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Awesome post, I'm constantly looking up one or two torque specs at a time, with the manual or past posts on here... Now I've got 'em all in one place!

Thanks a bunch Primal :crazy:

Peace.

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I am currentlly looking to purchase a torque wrench or set of torque wrenches that will cover the entire range of torque specs for 2009 KX250F. It looks like the lowest is 7 inch pounds and highest is 80 foot pounds. Am I correct in this assumption? Also will one wrench cover this range or will I need to buy more than one? Also what would be a good quality brand that won't send me to the poor house?

Thanks

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Sorry for the late reply. If you want a single wrench that can service all torque ranges your gonna spend a good amount of money. You need a snap on digital one. I can get you one for the same price that your local snap on truck buys it from snap on. I.e. Wholesale through my national acount with my company if you want I can get a price you pay me through paypal I'll order it then you pay me for sniping when it comes in

It's still gonna be a couple hundred bucks

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Pr1malR8gw,

I really appreciate the offer. I think I am going to get a few with different ranges from MCS Industrial. I work for a large machine shop and we will use them for various jobs, but will also be allowed to use them to work on our bikes because we keep all the bikes at the machine shop.

Thanks again

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the nuts on the bottom of the triple clamps for the bar mounts is preference, but I found factory to be at 8ftlbs. u can go to like 10 or 12 but then you risk twisting your bars more easily then if you were to tighten them to 8lbs. at 8 the rubber absorbs flex, any higher and they wont flex and then they take it out on the bar clamp. Dont just bottom them out, there is a proper torque. Also the tighter you get them the more feel you will have and the looser they are the more flex you will get when you turn hard. also you can run your clamps at 20 or 21 if you loosen your lower mount nuts. Should prob add that in there...

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