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Old 04-11-2008, 04:41 PM   #1 (permalink)
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Z400 Valve Clearance & Torque specs
03-04 LT-Z400

Valve clearance
Cold engine, set at TDC..
IN: 0.10~0.20mm (0.0039~0.0079 in)
EX: 0.20~0.30mm (0.0079~0.0118 in)

ENGINE TORQUE SPECIFICATIONS

Engine oil drain plug crankcase 21nm 15.0ft-lb

Engine oil drain plug oil tank 12nm 8.5ft-lb

Engine oil level screw 5.5nm 4.0ft-lb

Crankcase bolt outer 11nm 8.0ft-lb

Neutral switch bolt 6.5nm 4.7ft-lb

Oil hose banjo bolt on crankcases 23nm 16.5ft-lb

Starter motor wire lead nut 6nm 4.5ft-lb

Starter motor ground wire bolt 10nm 7.0ft-lb

TDC plug 23nm 16.5ft-lb

Engine mounting nut and bolt 66nm 47.5ft-lb

Engine mounting bracket bolt 26nm 19.0ft-lb

Exhaust manifold nut 23nm 16.5ft-lb

Muffler connecting bolt 23nm 16.5ft-lb

Muffler mount bolts 23nm 16.5ft-lb

Counter shaft sprocket bolt 10nm 7.0ft-lb

Fuel valve mounting bolt 4.6nm 3.3ft-lb

Valve cover bolt 14nm 10.0ft-lb

Cylinder head bolt, 10 mm 46nm 33.5ft-lb

Cylinder head bolt, 6 mm 10nm 7.0ft-lb

Cylinder head side bolt 14nm 10.0ft-lb

Cylinder nut 10nm 7.0ft-lb

Camshaft journal holder bolts 10nm 7.0ft-lb

Balancer driven gear nut 50nm 36.0ft-lb

Primary drive gear nut 140nm 101.5ft-lb

Flywheel nut 120nm 87.0ft-lb

Clutch hub nut 70nm 50.5ft-lb

Gearshift arm stopper bolt 19nm 13.5ft-lb

Gearshift cam driven gear bolt 24nm 17.5ft-lb

Cam chain tension adjuster bolt 10nm 7.0ft-lb

Cam chain tensioner mounting bolt 10nm 7.0ft-lb

Cam chain tension spring holder bolt 30nm 21.5ft-lb

Cooling fan thermo switch 20nm 14.5ft-lb

Engine coolant temperature switch 13nm 9.5ft-lb

CHASSIS TORQUE SPECIFICATIONS

Cushion rod nut 78nm 56.5ft-lb

Cushion lever nut 78nm 56.5ft-lb

Rear shock absorber mounting nut lower 55nm 40.0ft-lb

Rear shock absorber mounting nut upper 60nm 43.5ft-lb

Rear swing arm pivot nut 84nm 61.0ft-lb

Rear axle housing bolt, 12 mm 100nm 72.5ft-lb

Rear axle housing bolt, 10 mm 73nm 53.0ft-lb

Rear axle nut 180nm 130.0ft-lb

Rear sprocket mounting bolt 54nm 39.0ft-lb

Seat rail mounting bolts, 10 mm 55nm 40.0ft-lb

Seat rail mounting bolts, 8 mm 26nm 19.0ft-lb

Foot rest mounting bolts 55nm 40.0ft-lb

Parking brake adjuster lock nut 18nm 13.0ft-lb

Parking brake bolt 28nm 20.5ft-lb

Rear brake caliper holder slide pin 23nm 16.5ft-lb

Rear brake caliper holder pin 18nm 13.0ft-lb

Rear brake pad mounting pin 18nm 13.0ft-lb

Rear brake pedal nut 11nm 8.0ft-lb

Rear brake master cylinder rod locknut 18nm 13.0ft-lbft-lb

Front brake pad mounting pin 18nm 13.0ft-lb

Front brake pipe nut 16nm 11.5ft-lb

Front brake caliper holder slide pin 23nm 16.5ft-lb

Front brake caliper holder pin 18nm 13.0ft-lb

Brake master cylinder mounting bolt rear 10nm 7.0ft-lb

Brake master cylinder mounting bolt front 10nm 7.0ft-lb

Brake caliper mounting bolt rear 26nm 19.0ft-lb

Brake caliper mounting bolt front 26nm 19.0ft-lb

Brake bleeder (air ) valve 7.5nm 5.5ft-lb

Brake disc bolt rear 23nm 16.5ft-lb

Brake disc bolt front 23nm 16.5ft-lb

Brake hose banjo bolt 23nm 16.5ft-lb

Wheel lug nuts rear 50nm 36.0ft-lb

Wheel lug nuts front 50nm 36.0ft-lb

Wheel hub nut rear 100nm 72.5ft-lb

Wheel hub nut front 65nm 47.0ft-lb

a-arm pivot nut 65nm 47.0ft-lb

Front shock absorber mounting nut upper 60nm 43.5ft-lb

Front shock absorber mounting nut lower 60nm 43.5ft-lb

Tie rod lock nut on shaft 29nm 21.0ft-lb

Tie rod lock nut on steering knuckle 60nm 43.5ft-lb

Steering knuckle nut upper and lower 43nm 31.0ft-lb

Steering shaft nut 49nm 35.5ft-lb

Steering shaft holder bolt 23nm 16.5ft-lb

Handlebar clamp bolt 23nm 16.5ft-lb


The valve info is out of the book. The torque specs were mostly copied from another post I found somewhere. Be aware, I haven't checked them against the book.


I've lost count of how many different bikes, quads, etc., I've owned over the years.

For different reasons, sometimes I buy a service manual for them, sometimes I don't. I had the need and bought the Suzuki version for the Z400.

For whatever reason, if you haven't bought a manual yet and are in need of some quick info on the Z400, here ya go.
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Z400 Torque Specs Swingarm Grease fitting Mod KC's Keyswitch Relocation Mod
03 Z400 - DJ kit, Pro Circuit T4 full pipe, Airbox mod/UNI filter, DrD reverse, Nerfs & skids, 13t sprocket, 05 shocks
05 Z400 - DJ kit, Carbon Fiber Yoshi half pipe, Airbox mod/UNI filter, KFX450 reverse mod,
Nerfs & skids skids, 13t sprocket
05 Z250 - Stock, for family and friends
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Old 04-11-2008, 06:45 PM   #2 (permalink)
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so you got these specs from another post. and re-posted it? I dont get it? and the specs for the valves are right by the way.
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Old 04-16-2008, 02:16 PM   #3 (permalink)
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These seem to be two common items of interest. I think it might be helpful to others to have one post containing this info under an appropriate title. I believe I got the the torque info from a post made by 03z435. I did take the valve specs out of the book, they should be correct.
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Z400 Torque Specs Swingarm Grease fitting Mod KC's Keyswitch Relocation Mod
03 Z400 - DJ kit, Pro Circuit T4 full pipe, Airbox mod/UNI filter, DrD reverse, Nerfs & skids, 13t sprocket, 05 shocks
05 Z400 - DJ kit, Carbon Fiber Yoshi half pipe, Airbox mod/UNI filter, KFX450 reverse mod,
Nerfs & skids skids, 13t sprocket
05 Z250 - Stock, for family and friends
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Old 03-31-2012, 01:05 AM   #4 (permalink)
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Updating this thread with a link. Link to 2005-2007 specs
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Do it once, do it right!!
Z400 Torque Specs Swingarm Grease fitting Mod KC's Keyswitch Relocation Mod
03 Z400 - DJ kit, Pro Circuit T4 full pipe, Airbox mod/UNI filter, DrD reverse, Nerfs & skids, 13t sprocket, 05 shocks
05 Z400 - DJ kit, Carbon Fiber Yoshi half pipe, Airbox mod/UNI filter, KFX450 reverse mod,
Nerfs & skids skids, 13t sprocket
05 Z250 - Stock, for family and friends
cr125honda is offline   Reply With Quote
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