Description of the to tighten bolt CHAPTER 1: ROUTINE MAINTENANCE AND SERVICING Coolant drain plug Crankshaft end cap

Engine / transmission oil drain plug Fork bottom yoke clamp bolts Fork top yoke clamp bolts Handlebar clamp bolts Handlebar holder nuts Main oil gallery plug Rear axle nut X,Y, K1 and K2 models Rear axle nut K3 on models Rear brake torque arm nut Spark plugs Steering stem adjuster locknut, K3, K4 and K5 models Steering stem adjuster nut preload Steering stem nut X,Y, K1 and K2 models Steering stem nut K3 on models Timing mark inspection cap CHAPTER 2: ENGINE, CLUTCH AND TRANSMISSION Cam chain stopper bolt Cam chain tensioner blade pivot bolt Cam chain tensioner cap bolt Cam chain tensioner mounting bolts Camshaft holder bolts Clutch cover bolts Clutch nut Clutch pressure platte bolts Connecting rod bolts. Initial / Final Crankcase bolts 8mm / 6mm Crankshaft end cap Cylinder block nuts Cylinder head bolts 10mm. Initial / Final Cylinder head bolts 6mm Engine mounting adjuster bolts Engine mounting adjuster bolt locknuts Engine mounting lower middle mounting bolt nut Engine mounting lower rear mounting bolt nut Engine mounting front mounting bolts Engine mounting upper middle mounting bolts Engine mounting rear mounting bolt Engine mounting spacer pinch bolts Gear change mechanism centralizing spring locating pin Gear change selector drum cam platte bolt Gear change stopper arm bolt Inner crankcase cover bolts Main bearing retainer platte screws Oil cooler hose banjo union bolts Oil cooler mounting bolts Oil gallery jet bolt Oil pressure relief valve Oil pump screws Oil spray pipe screw Oil strainer platte bolts

Recommended Torque Setting in N 13 11 21 23 23 23 45 18 65 100 35 11 80 45 65 90 23

14 10 8 10 10 10 50 5.5 35 / 67 26 / 11 11 10 25 / 42 10 10 45 93 55 55 55 55 23 23 10 10 10 8 23 10 18 27 8 8 10

Piston oil jet retainer bolts Primary drive gear bolt Timing mark inspection cap Top cam chain guide bolts Selector drum bearing retainer screws Starter clutch bolts Valve cover bolts CHAPTER 3: COOLING SYSTEM Coolant temperature sensor Crankcase cover bolts right-hand side Fan switch Water pump cover screws Water pump impeller bolt (X and Y models) CHAPTER 4A: FUEL AND EXHAUST SYSTEMS X, Y, K1 AND K2 MODELS Carburetor heaters UK models Exhaust system nuts and bolts Fuel pump bolts CHAPTER 4B: FUEL, ENGINE MANAGEMENT AND EXHAUST SYSTEMS K3-ON Exhaust systems (all nuts/bolts) Fuel pump mounting bolts Fuel rail screws Intake air temperature (IAT) sensor K3 to K6 models Secondary throttle position (STP) sensor screw Throttle position (TP) sensor screws CHAPTER 5: IGNITION SYSTEM Throttle position sensor screws Timing mark inspection cap CHAPTER 6: FRAME, SUSPENSION AND FINAL DRIVE Brake hose banjo bolt Brake torque arm nuts Clutch lever bracket clamp bolt Footrest bracket bolts Footrest holder bolt Fork damper rod bolt X, Y, K1 and K2 Fork damper rod bolt K3-on models Fork top bolt Fork bottom yoke clamp bolts Fork top yoke clamp bolts Front brake master cylinder clamp bolts Front sprocket nut Handlebar clamp bolts SV650 and SV650S Handlebar holder nuts SV650 Handlebar positioning bolts SV650S Rear sprocket nuts Shock absorber mounting bolts/nut Side stand bracket bolts K3-on models Steering stem adjuster locknut Steering stem adjuster preload Steering stem nut X, Y, K1 and K2 models Steering stem nut K3-on models Suspension linkage bolts/nuts

10 70 23 10 8 25 14

10 10 13 4.5 13

3 23 10

23 10 5 18 2 3.5

3.5 23

23 35 10 23 39 30 20 23 23 23 10 145 23 45 10 60 50 100 80 45 65 90 78

Swing arm pivot bolt Swing arm pivot bolt locknut Swing arm pivot bolt nut CHAPTER 7: BRAKES, WHEELS AND TYRES Brake caliper bleed valves Brake hose banjo bolts Brake pipe gland nuts ABS models Front brake caliper mounting bolts Front brake disc bolts Front brake master cylinder clamp bolts Front wheel axle Front wheel axle clamp bolt Rear brake caliper body joining bolts X, Y, K1 and K2 models Rear brake caliper mounting bolts X, Y, K1, and K2 models Rear brake caliper mounting bolts K3-on models Rear brake caliper sliding pin K3-on models Rear brake caliper pad pin K3-on models Rear brake disc bolts Rear brake master cylinder bolts Rear brake torque arm nuts X, Y, K1 and K2 models Rear wheel axle nut X, Y, K1 and K2 models Rear wheel axle nut K3-on models CHAPTER 8: BODYWORK No torque settings required CHAPTER 9: ELECTRICAL SYSTEM Alternator cover bolts Alternator rotor bolt Alternator stator bolts Oil pressure switch Pulse generator coil bolts Starter motor long bolts Starter motor mounting bolts

15 90 100

7.5 23 16 39 23 10 65 23 30 26 23 27 18 23 10 35 65 100

-

10 120 10 14 5.5 3.5 6

Recommended Torque Setting in Nm 13 11 21 23 23 23 45 18 65 100 35 11 80 45 65 90 23 Made by www.motor-forum.nl user Disaster-Master

14 10 8 10 10 10 50 5.5 35 / 67 26 / 11 11 10 25 / 42 10 10 45 93 55 55 55 55 23 23 10 10 10 8 23 10 18 27 8 8 10

10 70 23 10 8 25 14

10 10 13 4.5 13

3 23 10

23 10 5 18 2 3.5

3.5 23

23 35 10 23 39 30 20 23 23 23 10 145 23 45 10 60 50 100 80 45 65 90 78

15 90 100

7.5 23 16 39 23 10 65 23 30 26 23 27 18 23 10 35 65 100

-

10 120 10 14 5.5 3.5 6

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