Vulcan Classic & Nomad Torque Specs

These specifications are as accurate as the Kawasaki maintenance manual they came from. Please use judgement if anything seems way out of line and note the number of left hand threaded fasteners.

Basic Torque For General Fasteners

Threads Dia (mm)

Torque (ft-lb)

5

30 ~ 43 in lb

6

52 ~ 69 in lb

8

10.0 ~ 13.5

10

19.0 ~ 25.0

12

33 ~ 45

14

54 ~ 72

16

83 ~ 115

18

125 ~ 165

20

165 ~ 240

   

Notes

G: Apply grease to the threads EO: Apply engine oil to the threads and the seating surface L: Apply a non-permanentlockng agent to the threads LH: Left-hand threads MO: Apply molybdenum disulfide oil to the treads and seating surfaces S: Tighten the fasteners following the specified sequence SS: Apply silicone sealant ST: Stake the fasteners to prevent loosening R: Replacement parts

Major Fasteners Are Listed. If You Are Rebuilding Your Engine Purchase The Book

Fastener

Torque

Notes (above)

Fuel System    
Fuel Filter Nuts 87 in lb  
Fuel Hose Clamp Screws 22 in lb  
Vacum Sensor Nut 87 in lb  
Atmospheric Pressure Sensor Nut 87 in lb  
High Pressure Fuel Hose Clamp Screws 13 in lb  
Pressure Regulator Screws 43 in lb  
Delivery Joint Screws 30 in lb Throttle Body
Throttle Cable Holder Screw 30 in lb L
Throttle Body Flanged Bolts 43 in lb  
Throttle Assy Holder Bolts 104 in lb Right Side
Inlet Manifold Bolts 104 in lb On Cylinder Head
Exhaust Header Bolts 14 ft lb On Cylinder Head
Full Throttle Stopper Screw _ L, LH
Second Lead Holder Bolts 87 in lb Right side
Air Cleaner Duct Holder Bolts 87 in lb Left side
Right & Left Air Cleaner Base Bolts 104 in lb  
Right & Left Air Cleaner Base Screws 19 in lb L, Lower Duct
Left Air Cleaner Duct Tapping Screws 19 in lb  
Left Air Cleaner Cover Allen Bolt 12  
Right Air Cleaner Cover Allen Bolt 12  
Right Air Cleaner Allen Bolts 95 in lb Throttle Body
Choke Cable Plate Screw 26 in lb L, Throttle Body
Inlet Air Temperature Sensor Nut 69 in lb  
Water Temperature Sensor 13 SS
Fuel Pump Bolts 61 in lb S, L
Return Fuel Check Valve 14  
Cooling System    
Radiator Hose Clamp Screws 22 in lb  
Coolant Air Bleeder Bolt 69 in lb  
Radiator Fan Switch 13  
Water Temperature Switch 65 in lb SS
Water Pump Impeller Bolt 87 in lb Lh
Water Pump Cover Bolts 87 in lb  
Water Pump Drain Bolt 87 in lb  
Water Pipe Bolts 87 in lb  
Radiator Drain Bolt 65 in lb  
Clutch    
Clutch Lever Pivot Bolt 8.7 in lb  
Clutch Lever Pivot Bolt Locknut 52 in lb  
Clutch Reservoir Cap Screws 13 in lb  
Clutch Slave Cylinder Bleed Valve 69 in lb  
Clutch Slave Cylinder Bolts - L
Clutch Hose Banjo Bolts 18  
Clutch Master Cylinder Clamp Bolts 87 in lb S
Starter Lockout Switch Screws 10 in lb  
Push Rod Guide Bolts 87 in lb L
Clutch Cover Bolts 87 in lb  
Clutch Cover Damper Bolts (outside) 87 in lb L
Clutch Cover Damper Bolts (inside) 87 in lb EO
Clutch Cover Damper Screws 43 in lb L
Clutch Hub Nut 108 EO
Engine Top End    
Spark Plugs 13  
Spark Plug Retainer 104 in lb  
Air Suction Valve Cover Bolts 65 in lb  
Chain Tensioner Mounting Bolts 87 in lb S
Chain Tensioner Lockbolt 43 in lb S
Chain Tensioner Cap 14 S
Timing Inspection Plug 13 in lb  
Rotor Bolt Plug 13 in lb  
Camshaft Sproket Bolts 11 L
Oil Hose Flange Bolts 87 in lb  
Rocker Shafts 18  
Rocker Case Nuts 12 mm 58 EO, S
Rocker Case Nuts 8 mm 18 S
Rocker Case Bolts 6 mm 78 in lb S
Cylinder Head Nuts 18 S
Cylinder Head JAcket Plug 14 L
Rocker Case Cover Bolts 78 in lb S
Camshaft Chain Guide Bolts 87 in lb L
Cylinder Nuts 18 S
Inlet Manifold Bolts 104 in lb  
Exhaust Pipe Cover Clamp Bolts 61 in lb  
Engine Lubrication System    
Oil Filler Cap 13 in lb  
Oil Screen Plug 15  
Engine Oil Drain Plug 15  
Oil Filter (cartridge) 13 EO, ft
Oil Filter Bolt 18 SS
Oil Pressure Relief Valve 11 L
Oil Pressure Switch Terminal Bolt 13 in lb  
Oil Pressure Switch 11 SS
Oil Pump Cover Screws 69 in lb  
Oil Pump Mounting Bolts 87 in lb  
Oil Hose Banjo Bolts 87 in lb  
Oil Hose Flange Bolt (outside) 87 in lb  
Oil Pipe Holder Bolts (inside) 78 in lb L
Oil Pipe Clamp Bolts (inside) 87 in lb L
Right & Left Crankcase Oil Nozzles 30 in lb x3
Oil Reserve Tank Bolt 78 in lb  
Crankcase Breather Hose Clamp Screw 13 in lb  
Engine Removal/Installation    
Downtube Bolts 32  
Engine Mounting Bolts & Nuts 32  
Engine Mounting Bracket Bolts 18  
Engine Ground Terminal Bolt 69 in lb  
Wheels & Tires    
Front Axle Clamp Bolt 25 S
Front Axle Nut 79.6 S
Rear Axle Nut 79.6  
Spoke Nipples 26 ~ 65 in lb  
Final Drive    
Oil Pipe Banjo Bolts (Front Gear) 104 in lb  
Oil Nozzle (Front Gear) 26 in lb  
Oil Nozzle (Front Gear) 13  
Neutral Switch 11  
Front Gear Case Bolts (6 mm) 104 in lb Mar 9
Front Gear Case Bolts (8 mm) 22  
Speed Sensor Bolt 87 in lb L
Damper Cam Nut (Front Gear 166 MO (threads)
Drive Gear Nut (Front Gear) 195 MO, ST
Driven Gear Assy Mounting Bolts 18  
Driven Gear Bolt (Front Gear) 101 MO, ST
Bearing Retainer Bolts (Front Gear) 78 in lb L
Final Gear Case Drain Plug 78 in lb  
Final Gear Case Mounting Nuts 25  
Final Gear Case Studs - L
Final Gear Case Cover Bolts (8 mm) 17  
Final Gear Case Cover Bolts (10 mm) 25  
Pinion Gear Nut (Final Gear) 86.8 St, MO
Pinion Bearing Retainer (Final Gear) 181 Lh
Retainer Stop Screw 12 L
Brakes    
Caliper Bleed Valves 69 in lb  
Brake Hose Banjo Bolts 18  
Brake Lever Pivot Bolt 8.7 in lb  
Brake Lever Pivot Bolt Locknut 52 in lb  
Front Brake Reservoir Cap Screws 13 in lb  
Front Brake Light Switch Screw 10 in lb  
Front Master Cylinder Clamp Bolts 78 in lb S
Front Caliper Mounting Bolts 25  
Rear Caliper Mounting Bolts 25  
Rear Caliper Holder Bolt 47  
Brake Disc Bolts 20 L
Rear Master Cylinder Mounting Bolts 18  
Rear Master Cylinder Push Rod Locknut 13  
Brake Pedal Clamp Bolt 18  
Suspension    
Piston Rod Nut 14  
Front Fork Top Plug 16  
Upper Front Fork Clamp Bolts 14  
Lower Front Fork Clamp Bolts 25  
Lower Front Fork Cover Bolts 65 in lb  
Front Fork Cover Screws 39 in lb  
Front Fork Bottom Allen Bolts 14 L
Front Axle Clamp Bolt 25 S
Spacer Bolt 35 in lb  
Rear Shock Absorber Nuts 25  
Shock Absorber Air Valves 47 in lb  
Swingarm Pivot Shaft 94 G
Steering    
Steering Stem Head Nut (the chrome one) 65  
Steering Stem Nut (the serrated one) 14 ft lbs for 1500's, 43 in lbs for 1600  
Handlebar Clamp Bolts 25 S
Handlebar Holder Nuts 25  
Handlebar End Caps - Lh, L
Handlebar Switch Housing Screws 30 in lb  
Upper Front Fork Clamp Bolts 14  
Lower Front Fork Clamp Bolts 25  
Headlight Cover Bolts 65 in lb  
Upper Fork Cover Bolts 39 in lb  
Brake Joint Bolts 65 in lb  
Turn Signal Light Holder Bolts 65 in lb  
Frame    
Front Fender Bolts 61 in lb  
Downtube Bolts 32  
Front Footboard Bracket Bolts 25  
Rear Footpeg Bracket Bolts 14  
Sidestand Nut 32  
Electrical    
Spark Plugs 13  
Pickup Coil Screws 26 in lb  
Stator Lead Holder Screw 87 in lb L
Pickup Coil Lead Holder Bolt 87 in lb L
Alternator Outer Cover Bolts 104 in lb  
Alternator Cover Joint Bolts 104 in lb  
Alternator Outer Cover Damper Bolts 87 in lb EO (tip)
Alternator Cover Bolts 87 in lb  
Alternator Inner Cover Bolts 87 in lb  
Alternator Rotor Bolt 57 EO
Alternator Outer Stator Bolts 113 in lb L
Alternator Inner Stator Bolts 113 in lb L
Timing Inspection Plug 13 in lb  
Starter Motor Terminal Locknut 95 in lb  
Starter Motor Terminal Nut 43 in lb  
Starter Motor Assembly Bolts 43 in lb  
Starter Motor Mounting Bolts 87 in lb  
Headlight Body Mounting Screws (inside) 26 in lb L
Headlight Rim Screws 8.7 in lb  
Handlebar Switch Housing Screws 30 in lb  
Starter Lockout Switch Screw 10 in lb  
Front Brake Light Switch Screw 10 in lb  
Sidestand Switch Bolt 78 in lb L
Radiator Fan Switch 13  
Water Temperature Switch 65 in lb SS
Oil Pressure Switch Terminal Bolt 13 in lb  
Oil Pressure Switch 11 SS
Neutral Switch 11  
Turn Signal Light Lens Screws 8.7 in lb  
Turn Signal Light Mounting Nuts 52 in lb