Torque specs - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 8 (permalink) Old 3-26-2010, 2:17 PM Thread Starter
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Torque specs

I've found myself without the trusty Clymer's and not remembering important torque specs (like brake calipers), so I'm starting to build a wiki for torque specs listed in the service manuals. I've just added the brake specs from the Clymer's so far, and I'll add to it pending what you guys think

https://www.ex-500.com/wiki/index.php...Specifications
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post #2 of 8 (permalink) Old 3-26-2010, 4:27 PM
Pogo
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Re: Torque specs

Hey man.

Post what sections you'll be doing! I'll pick up a couple chapters from the Clymers. However, I don't have the addendum for the 94-2009 model years, so if you have that and there are any changes, grab those chapters first and make sure you label them as the 2nd generation model.
post #3 of 8 (permalink) Old 3-26-2010, 5:25 PM
smith.p.sean
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Re: Torque specs

Quote:
Originally Posted by Pogo
Hey man.

Post what sections you'll be doing! I'll pick up a couple chapters from the Clymers. However, I don't have the addendum for the 94-2009 model years, so if you have that and there are any changes, grab those chapters first and make sure you label them as the 2nd generation model.
Ive got the factory manuals and can help out if assigned a chapter or 2. Otherwise... may not happen lol cause I am hella unorganized.
post #4 of 8 (permalink) Old 3-26-2010, 5:36 PM Thread Starter
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Re: Torque specs

Awesome, thanks for pitching in!

I'll do up the 1994+ chapter first then; as far as main chapters Susp/Engine/Trans are the easy ones that can be added first (since they have tables at the end of the chapters).

The harder part will be sifting through the chapters themselves and pulling out the actual values. All help is appreciated
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post #5 of 8 (permalink) Old 3-26-2010, 6:07 PM Thread Starter
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Re: Torque specs

... also, any thoughts on improving the formatting and layout are very welcome!
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post #6 of 8 (permalink) Old 3-27-2010, 5:29 AM
Pogo
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Re: Torque specs

I'm skimming through to catch any odds and ends (first number is N-m, second is ft-lb).
These are all Gen 1 figures, and even identical parts of the engine seem to have different numbers from Gen 2.

Valve adjuster locknut 25 18

Oil pressure relief valve 15 11
Oil pan bolts 12 8.5

Starter clutch housing 34 25

Lower case mounting bolts
--8mm Stage 1 14 10
--8mm Stage 2 27 20
--6mm 12 9

Upper crankcase bolts
--8mm 27 20
--Allen bolts 12 9
--6mm 12 9

Engine (page 105): (in all honesty, anyone doing this work needs the repair manual, so I'm only listing stuff that the average Joe would encounter)
Rocker arm shafts 39 29
Rocker arm bearing caps 12 9
Cylinder head cover bolts 9.8 7.2
Cylinder head bolts
--6mm 9.8 7.2
--10mm 39 29
Oil line banjo bolts
--6mm 12 9
--8mm 27 20
--Allen bolts 12 9
Camshaft cap bolts 12 104 in.-lb
Camshaft chain tensioner bolts 8.8 17in.-lb
Engine mount bolts
--long bolts 39 20
--short bolts 24 17.5
Oil pan bolts 12 8.5

Water pump impeller shaft (reverse thread) 9.8 87 in.-lb
Water temp sensor 7.8 69 in.-lb

Front brake caliper bolts 32 24
Axle clamp bolt 14 10

Front Suspension
Front axle nut 88 65
Front fork
--Upper clamp bolts 20 14.5
--Lower clamp bolts 29 22
--Bottom allen bolt 29 22
Handlebar holder/mounting bolts 23 16.5
Handlebar mounting bolts 23 16.5
Steering locknut 7.4 65 in.-lb
Steering stem head bolt 47 35

Rear Suspension
Rear axle nut 110 80
Front sprocket bolt 9.8 87 in.-lb
Rear sprocket nuts 88 65
Shock absorber bolts/nuts 49 36
Pivot shaft nut 88 65
Uni-Trak nuts 49 36
Brake stay arm nuts 29 22

Front Brake
Disc bolts 23 16.5
Caliper bolts 32 24
Union (banjo) bolts 29 22
Torque link nuts 29 22
Brake lever pivot nut 5.9 52 in.-lb
Front master cylinder bolts 11 95 in.-lb
Bleed valve 7.8 69 in.-lb

Come to think of it... that's all of it for Gen 1.

Alright I'm tired, don't have the energy to figure out the Wiki editing.
It'd also be good to cross-reference the general bolt torques with the M# designation of the Japanese bolts for easy replacement.
post #7 of 8 (permalink) Old 3-28-2010, 3:00 AM Thread Starter
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Re: Torque specs

Awesome! I'll put them in the wiki table when I get a chance later this week. Thanks!

Good point on needing the manual anyway. Might compile a quick-reference list for torque values that might be more commonly used. Oil drain, brake calipers, axle nuts, etc.
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post #8 of 8 (permalink) Old 5-27-2010, 8:56 AM
fog
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Re: Torque specs

Put a note that says use you godamn head. or get out of there before you snap something off and then cause 27 posts about how stupid you are.

FOG

I hate PMs if you want to contact me, find my email address.Look in the for sale section.
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