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Torque Settings:

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Hey guys,

2005 TE510 here. I'm wondering what the torque settings are for changing out the tires. Can anyone tell me what the specs are for tightening the 2 screws for each fork and the nuts on the end? Thanks!!

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That's great--thanks for passing that on! My '09 owners manual has NO torque values. I just posted the same question earlier today on Cafe Husky. I'm not trying to doubt the facts, but 104.8 ft.lb. for the front and rear axle nut? The manual for my KTM recommends about 59 ft.lb. for the rear axle.

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That's great--thanks for passing that on! My '09 owners manual has NO torque values. I just posted the same question earlier today on Cafe Husky. I'm not trying to doubt the facts, but 104.8 ft.lb. for the front and rear axle nut? The manual for my KTM recommends about 59 ft.lb. for the rear axle.

Front axle bolt should be 38 lb/ft and the smaller retaining bolts 7.7 lb/ft. The rear axle nut is 104.8 lb/ft.

BTW what is the forum policy about posting service manuals for download? I purchased a manual from Hall's Cycles, and they charged me $20 shipped for a ****ing burned CD of the manual. 1) That is illegal 2) they are making a killing off selling a product that they do not own. **** them, I will put it up for everyone to download. :thumbsup:

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TIGHTENING TORQUES (+/- 5%)

ENGINE

Camshaft cap fastening screw M6x1 12 Nm 1,2 Kgm 8.7 ft/lb

Rocker arm axle plug M14x1,5 (+LOCTITE 243) 25 Nm 2,55 Kgm 18.4 ft/lb

Cylinder head cover fastening screw M6x1 8Nm 0,8 Kgm 5.8ft/lb

Cylinder head fastening nut M8x1,25 15 Nm 1,5 Kgm 10.8 ft/lb

Cylinder head and cylinder fastening nut M10x1,5 (+MOLIKOTE HSC) 37 Nm+90° 3.8 Kgm+90° 27.5 ft/lb+90°

Oil hose fastening screw (cylinder head-transmission cover) M10x1 15 Nm 1,5 Kgm 10.8 ft/lb

Cooling pipe connection on cylinder M14x1,5 (+LOCTITE 542) 25 Nm 2,55 Kgm 18.4 ft/lb

Water temperature sensor (TE-SMR) M10x1,25 5 Nm 0,5 Kgm 3.6 ft/lb

Plug for water temperature sensor hole (TC-TXC) M8x1,25 8 Nm 0,8 Kgm 5.8 ft/lb

Rear screw, left cylinder side (USA excluded) M5x0,8 (+LOCTITE 243) 5 Nm 0,5 Kgm 3.6 ft/lb

Gear selector stopping pin M10x1,25 (+LOCTITE 601) 15 Nm 1,5 Kgm 10.8 ft/lb

Oil hole plug on conrod pin M14x1 (+LOCTITE 243) 20 Nm 2 Kgm 14.5 ft/lb

Primary drive driving gear fastening nut M18x1,25 (+LOCTITE 243) 180 Nm 18 Kgm 130 ft/lb

Centrifugal disc on INTAKE CAMSHAFT fastening screw M6x1 (+LOCTITE 243) 8 Nm 0,8 Kgm 5.8 ft/lb

Timing chain slider fastening screw M8x1,25 12 Nm 1,23 Kgm 8.9 ft/lb

Crankcase bearings plates fastening screw M6x1 (+LOCTITE 272) 11 Nm 1,1 Kgm 7.9 ft/lb

Engine oil drain plug M16x1,5 25Nm 2,55 Kgm 18.4 ft/lb

Engine oil filter plug M14x1,5 25Nm 2,55 Kgm 18.4 ft/lb

Engine oil filter cartridge cover fastening screw M5x0,8 (+LOCTITE 243) 6 Nm 0,6 Kgm 4.3 ft/lb

Oil filling cap M18x1,5 3 Nm 0,3 Kgm 2.1 ft/lb

Carburetor union fastening screw (TC-TXC) M4x0,7 (+LOCTITE 272) 3 Nm 0,3 Kgm 2.2 ft/lb

Alternator fastening nut M12x1 75Nm 7,65 Kgm 55.3 ft/lb

Stator plate fastening screw (TC-TXC) M6x1 (+LOCTITE 272) 8 Nm 0,8 Kgm 5.8 ft/lb

Stator plate fastening screw (TE-SMR) M5x0,8 (+LOCTITE 272) 6 Nm 0,6 Kgm 4.3 ft/lb

Starter lever fastening screw M6x1 (+LOCTITE 272) 8 Nm 0,8 Kgm 5.8 ft/lb

Spark plug M10x1 (*)

Pick-up fastening screw M5x0,8 (+LOCTITE 272) 6 Nm 0,6 Kgm 4.3 ft/lb

Clutch hub and disc housing fastening nut M18x1 75Nm 7,6 Kgm 55 ft/lb

Starting gears stop plate fastening screw M6x1 (+LOCTITE 243) 8 Nm 0,8 Kgm 5.8 ft/lb

Gearbox forks driving shaft fastening screw M8x1,25 (+LOCTITE 243) 20 Nm 2 Kgm 14.5 ft/lb

Gear control click and plate fastening screw M6x1 (+LOCTITE 243) 8 Nm 0,8 Kgm 5.8 ft/lb

Gear shift position sensor fastening screw M5x0,8 (+LOCTITE 243) 6Nm 0,6 Kgm 4.3 ft/lb

Water pump rotor fastening nut M5x0,8 (+LOCTITE 243) 3,9 Nm 0,4 Kgm 2.9 ft/lb

Water pump body fastening screw M6x1(+LOCTITE 542) 8 Nm 0,8 Kgm 5.8 ft/l

Drive sprocket seal ring plate fastening screw M5x0,8 (+LOCTITE 243) 6Nm 0,6 Kgm 4.3 ft/lb

Timing chain slider pin fastening screw M4x0,7 3 Nm 0,3 Kgm 2.2 ft/lb

(*): Apply a little graphite grease to the spark plug thread; fit and screw the spark plug by hand then tighten to the torque of 10÷12 Nm- 7.4÷8.9

ft/lb. Loosen the spark plug then tighten it again to the torque of 10÷12 Nm- 7.4÷8.9 ft/lb.

CHASSIS

Rear frame lower fastening screw M8x1,25 25,5 Nm 2,6 Kgm 18.8 ft/lb

Engine guard fastening screw M6x1 14,7 Nm 1,5 Kgm 10.8 ft/lb

Rear chain roller fastening screw M8x1,25 26,95 Nm 2,75 Kgm 19.9 ft/lb

Side stand fastening screw M8x1,25 (+LOCTITE 243) 11,75 Nm 1,2 Kgm 8.7 ft/lb

Rear frame upper fastening screw M8x1,25 25,5 Nm 2,6 Kgm 18.8 ft/lb

Frame to engine plate fastening screw M8x1,25 (+LOCTITE 270) 35,3 Nm 3,6 Kgm 26 ft/lb

Engine lower fastening screw M8x1,25 35,3 Nm 3,6 Kgm 26 ft/lb

Clutch and front brake controls clamp fastening screw M6x1 4,9 Nm 0,5 Kgm 3.6 ft/lb

Throttle control holders fastening screw M6x1 4,9 Nm 0,5 Kgm 3.6 ft/lb

Front brake hose upper fastening screw (TE, SMR) M10x1 19 Nm 1,95 Kgm 14 ft/lb

Front brake hose upper fastening screw (TC, TXC) M10x1 24,7 Nm 2,5 Kgm 18.2 ft/lb

Rear brake control pedal fastening screw M10x1,25 (+LOCTITE 243) 41,65 Nm 4,25 Kgm 30.7 ft/lb

Rear brake pump fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb

Front brake pump plate fastening screw (SMR) M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb

Rear brake fluid tank fastening screw M6x1 2,45 Nm 0,25 Kgm 1.8 ft/lb

Rear stop control switch (TE, SMR) M10x1 19 Nm 1,95 Kgm 14 ft/lb

Front control switch connector fastening screw (SMR) M2x0,4 0,8 Nm 0,1 Kgm 0,6 ft/lb

Rear brake pedal adjusting cam fastening screw M6x1 14,7 Nm 1,4 Kgm 10.8 ft/lb

Front brake hose guide plate fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb

Front brake tank cap fastening screw (SMR) M6x1 4,9 Nm 0,5 Kgm 3.6 ft/lb

Front fork legs fastening screw M8x1,25 25 Nm 2,5 Kgm 18.4 ft/lb

Front wheel axle fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb

Steering bearings adjusting ring nut M25x1 3,45 Nm 0,35 Kgm 2.5 ft/lb

Steering pivot fastening nut M24x1 83,3 Nm 8,5 Kgm 61.4 ft/lb

Handlebar upper clamp M8x1,25 28,4 Nm 2,9 Kgm 20.9 ft/lb

Handlebar holder fastening screw M10x1,5 21,1 Nm 2,15 Kgm 15.6 ft/lb

Front fork legs guard fastening screw M5x0,8 7,85 Nm 0,8 Kgm 5.8 ft/lb

Front fork legs ring guard fastening screw M5x0,8 2,45 Nm 0,25 Kgm 1.8 ft/lb

Rear swing arm axle fastening nut M16x1,5 (+LOCTITE 243) 122,5 Nm 12,5 Kgm 90.3 ft/lb

Rear swing arm to rocker arm fastening nut M12x1,25 80 Nm 8,2 Kgm 59 ft/lb

Tie rod to rocker arm fastening nut M12x1,25 80 Nm 8,2 Kgm 59 ft/lb

NOTE: If not otherwise specified, standard tightening torques for the following thread M5x0,8 5,6÷6,2 Nm 0,57÷0,63 Kgm 4.1÷4.5 ft/lb

M6x1 7,6÷8,4 Nm 0,80÷0,85 Kgm 5.8÷6.1 ft/lb

M8x1,25 24÷26 Nm 2,4÷2,6 Kgm 17.3÷18.8 ft/lb

Frame to tie rod fastening nut M12x1,25 80 Nm 8,2 Kgm 59 ft/lb

Rocker arm to tie rod lubricator M6x1 2,95 Nm 0,3 Kgm 2,2 ft/lb

Rear shock absorber to frame fastening pivot M10x1,25 52,4 Nm 5,35 Kgm 38,6 ft/lb

Rocker arm to frame fastening pivot M10x1,25 52,4 Nm 5,35 Kgm 38,6 ft/lb

Chain guide to rear swing arm fastening screw (TE-SMR) M8x1,25 25 Nm 2,5 Kgm 18.4 ft/lb

Chain guide to rear swing arm front fastening screw (TC) M8x1,25 (+LOCTITE 243)\ 10,4 Nm 1,05 Kgm 7.7 ft/lb

Chain guide to rear swing arm rear fastening screw (TC) M6x1 (+LOCTITE 243) 10,4 Nm 1,05 Kgm 7.7 ft/lb

Bracket to chain guide fastening screw (TE-SMR) M6x1 (+LOCTITE 243) 2 Nm 0,2 Kgm 1.5 ft/lb

Chain slider and rear brake hose clamp lower fastening screw M5x0,8 4,4 Nm 0,45 Kgm 3.2 ft/lb

Chain slider and rear brake hose clamp reear fastening screw (TC-TXC) M5x0,8 4,4 Nm 0,45 Kgm 3.2 ft/lb

Chain guard fastening screw (TE-SMR) M5x0,8 4,4 Nm 0,45 Kgm 3.2 ft/lb

Chain adjuster fastening nut M8x1,25 4,4 Nm 0,45 Kgm 3.2 ft/lb

Spoiler to fuel tank fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb

Front number holder upper fastening screw (TC-TXC) M6x1 6 Nm 0,6 Kgm 4.4 ft/lb

Front number holder lower fastening screw (TC-TXC) M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb

Rear shock absorber guard fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb

Rear fender front fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb

Rear fender rear fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb

Front fender fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb

Radiator guard fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb

Side panel fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb

License plate fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb

Rear reflector fastening nut M4x0,7 1,9 Nm 0,2 Kgm 1.4 ft/lb

Brake hose ring to front fairing fastening screw ø 3,5 1,9 Nm 0,2 Kgm 1.4 ft/lb

Turn signals fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb

Front headlamp fastening screw ø 3,9 1,45 Nm 0,15 Kgm 1 ft/lb

Electric start remote control switch cables fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb

Fuel tank front rubber pad fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb

Fuel cock fastening screw ø5,5 2,45 Nm 0,25 Kgm 1.8 ft/lb

Fuel tank rear fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb

Air filter box front fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb

Air filter box flange fastening nut M5x0,8 3,45 Nm 0,35 Kgm 2.5 ft/lb

Front brake caliper fastening screw (TE- TC) M8x1,25 25,5 Nm 2,6 Kgm 18.8 ft/lb

Brake hoses lower fastening screw M10x1 19 Nm 1,95 Kgm 14 ft/lb

Front wheel axle fastening screw (SMR) M10x1,5 51,45 Nm 5,25 Kgm 38 ft/lb

Front brake caliper fastening screw (SMR) M10x1,5 25,5 Nm 2,6 Kgm 18.8 ft/lb

Brake caliper holding plate to front fork (SMR) M10x1,5 25,5 Nm 2,6 Kgm 18.8 ft/lb

Front wheel axle fastening screw (TE-TC-TXC) M20x1,5 51,45 Nm 5,25 Kgm 38 ft/lb

Front brake disc fastening screw (TE-TC-TXC) M6x1 (LOCTITE 243) 14,7 Nm 1,5 Kgm 1 0.8 ft/lb

Front brake disc fastening screw (SMR) M8x1,25 34,7 Nm 3,54 Kgm 25.6 ft/lb

Rear brake disc fastening screw M6x1 (LOCTITE 243) 14,7 Nm 1,5 Kgm 10.8 ft/lb

Front wheel nipple M4,07x0,75 4,4 Nm 0,45 Kgm 3.2 ft/lb

Rear wheel nipple M4,5x0,75 4,4 Nm 0,45 Kgm 3.2 ft/lb

Rear wheel sprocket fastening nut M8x1,25 (+LOCTITE 243) 34,3 Nm 3,5 Kgm 25.3 ft/lb

Rear wheel axle fastening nut M20x1,5 142,1 Nm 14,5 Kgm 104.8 ft/lb

Drive sprocket cover fastening screw M6x1 10,4 Nm 1 Kgm 7.7 ft/lb

Exhaust silencer fastening screw M6x1 10,4 Nm 1 Kgm 7.7 ft/lb

Exhaust pipes to cylinder head fastening screw M6x1 10,4 Nm 1 Kgm 7.7 ft/lb

Instrument fastening screw ø4,8 3,45 Nm 0,35 Kgm 2.5 ft/lb

Radiator fastening screw M6x1 7 Nm 0,72 Kgm 5.2 ft/lb

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Rear wheel axle fastening nut M20x1,5 142,1 Nm 14,5 Kgm 104.8 ft/lb

Wow, that sounds like a lot. Last week I tightened that bolt by feel and I know it's no way near that. Better check it with my torque wrench.

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