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Old 11-25-2010, 12:13 PM   #1 (permalink)
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Default Torque values - Z400

I had these posted in an old thread and noticed the link was disabled. Hate when I go to a web site for info and that happens. Thought it might be helpful to re-post them...
Regards, Ken

Engine and Chassis Torque Specifications (Go to the lower half of the list for 2005 thru 2007)
DVX400 2003-2004
KFX400 2003-2004
LT-Z400K4 2004

ENGINE TORQUE SPECIFICATIONS N-m / ft-lb

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 N-m / ft-lb

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


DVX400 2005-2006
KFX400 2005-2007
LT-Z400K5 - K7 2005-2007

ENGINE TORQUE SPECIFICATIONS N-m / ft-lb

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

Generator rotor 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 SPECIFICATION N-m / ft-lb

Cushion rod nut 78nm 56.5ft-lb

Cushion lever nut 78nm 56.5ft-lb

Rear shock absorber mounting nut lower 60nm 43.5ft-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 240nm 173.5ft-lb

Rear sprocket mounting bolt 60nm 43.5ft-lb

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

Seat rail mounting bolts, 8 mm 55nm 40.0ft-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-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 60nm 43.5ft-lb

Wheel lug nuts front 60nm 43.5ft-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 29nm 21.0ft-lb

Steering shaft nut 49nm 35.5ft-lb

Steering shaft holder bolt 23nm 16.5ft-lb

Handlebar clamp bolt 26nm 19ft-lb
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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 12-05-2010, 02:31 PM   #2 (permalink)
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Factory service manual has the rear axle nuts at 130ft lb, not 173.5ft lb Not sure if I would trust a list someone typed in on the net vs a factory service manual. You can get a factory service manual on ebay for like 25 bucks. Well worth it for the information if you do your own work.

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Old 12-05-2010, 02:39 PM   #3 (permalink)
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Quote:
Originally Posted by markw View Post
Factory service manual has the rear axle nuts at 130ft lb, not 173.5ft lb Not sure if I would trust a list someone typed in on the net vs a factory service manual. You can get a factory service manual on ebay for like 25 bucks. Well worth it for the information if you do your own work.

Mark
If you look at the 2003-2004 torque specs, it says 130ft/lbs. You are looking at the 2005+ torque specs.
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Old 01-24-2011, 10:17 PM   #4 (permalink)
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great info, I was about to post a thread asking for some torque specs
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Old 01-27-2011, 12:57 PM   #5 (permalink)
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Default Z400 / LTZ400 Torque Specifications

Did a little fact checking and chinoduca is correct....

From the 2008 Suzuki OEM manual -

Check the rear axle lock nut and rear axle nut tightening. If the rear axle lock nut or rear axle nut is loose, follow the procedure below.
1. Loosen the loose nut(s).
2. Clean the threads and apply SUZUKI BOND 1322 to the threads.
3. Tighten the nut(s).
Rear axle nut and lock nut tightening torque:
240 Nm (24.0 kgf-m, 173.5 lb-ft)
NOTE: Ask your Suzuki dealer or a qualified mechanic to retighten the axle nut because this job requires special tool.


************************************************** **************

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.
Personally, I like that I can go online and find specific info / procedures, etc., that others have posted when I don't I need a complete manual.
Don't mind helping out others with the same train of thought.

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 03-04-2011, 12:53 PM   #6 (permalink)
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I need the torque setting of the front sprocket. That doesn't seem to be covered in the manual I have.
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Need to install:
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Raptor 660 Petcock
YFZ Thumb Throttle
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Old 03-04-2011, 01:00 PM   #7 (permalink)
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I have the manual on my other computer, I'll take a look at it in a while and post back if no one else did. If you tighten it by hand be careful, they snap very easily, I'm speaking from experience
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Old 03-04-2011, 01:06 PM   #8 (permalink)
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Thanks. I was looking through my manual I downloaded and couldn't find where they listed this one.
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04 Kawasaki KFX 400 (Dec. 2012 QOTM)
07 Can Am DS 250 (Oldest Son's)
07 Yamaha Raptor 50 (Youngest son)
07 Yamaha TT R50 (A Fun Little Toy)

Need to install:
DRZe Kit
RatStack
FCI Intake
Ferrea Valves
Athena 434 BBK
Dynatech NP CDI
IMS 4g Fuel Tank
Titanium Wrist Pin
Raptor 660 Petcock
YFZ Thumb Throttle
DID 520 ERT2 Chain
K&N Crank Case Filter
Web Cams 539/539+3
CP 94mm 12.5:1 Piston
FCR-39 from 450 Outlaw
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Old 03-04-2011, 01:50 PM   #9 (permalink)
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Alright dude, it's 7.0 ft/lbs (10 nm or 1.0kgf-m) for the front sprocket bolts.
Use thread lock.

Page 8 section 3 on the original manual for a 03.
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Last edited by chinoduca; 03-04-2011 at 01:52 PM.
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Old 03-04-2011, 01:54 PM   #10 (permalink)
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thanks. You're right. That exactly where it was in mine too. 7FTlbs? seems not very tight. I wonder why it's that low of torque.
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07 Suzuki LT Z400 (Future QOTM )
04 Kawasaki KFX 400 (Dec. 2012 QOTM)
07 Can Am DS 250 (Oldest Son's)
07 Yamaha Raptor 50 (Youngest son)
07 Yamaha TT R50 (A Fun Little Toy)

Need to install:
DRZe Kit
RatStack
FCI Intake
Ferrea Valves
Athena 434 BBK
Dynatech NP CDI
IMS 4g Fuel Tank
Titanium Wrist Pin
Raptor 660 Petcock
YFZ Thumb Throttle
DID 520 ERT2 Chain
K&N Crank Case Filter
Web Cams 539/539+3
CP 94mm 12.5:1 Piston
FCR-39 from 450 Outlaw
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Old 03-04-2011, 02:01 PM   #11 (permalink)
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Quote:
Originally Posted by yOGi420 View Post
thanks. You're right. That exactly where it was in mine too. 7FTlbs? seems not very tight. I wonder why it's that low of torque.
I don't know, but don't go over it, they snap easily, trust me! I was surprised too at how little force I had to do to loosen mine.
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Old 03-04-2011, 04:56 PM   #12 (permalink)
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Dont use the red lock tight!!! Some one did that on a used bike i bought once and sprocket bolt up with a torch to get it to come off... still then i had to jump on a breaker bar to get it lose. Think the hulk was tightening bolts at the repair shot that day. Use blue.
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Old 09-30-2012, 02:25 PM   #13 (permalink)
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Just want to confirm if the head bolts are 33.5 lb. torque?
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