Tech Tip: GSX1400 Torque Settings

[gsxbarmy]

NOTE: This thread is also available to download as a PDF file from the Downloads (General) Section

General Servicing

Brake hose banjo bolts 23Nm
Engine oil drain plug 23Nm
Fork clamp bolts 23Nm
Handle bar clamp bolts 23Nm
Rear axle nut 100Nm
Spark plugs 11Nm
Steering stem nut 65Nm
Timing rotor cover bolts 11Nm
Torque arm nuts Front 28Nm Rear 34Nm

Engine, Clutch and Transmission

Balancer weight cover bolts 10Nm
Balancer weight shaft holder mounting bolt 10Nm
Balancer weight shaft holder pinch bolt 10Nm
Cam chain tensioner cap bolt 35Nm
Cam chain tensioner mounting bolts 10Nm
Cam chain top guide bolts 10Nm
Cam Cover Bolts M8 Bolts - 20Nm, M7 bolts - 14Nm
Camshaft holder bolts 10Nm
Camshaft sprocket bolts 25Nm
Clutch centre nut 90Nm
Clutch cover bolts 11Nm
Clutch hose banjo bolts 23Nm
Clutch master cylinder clamp bolts 10Nm
Clutch release cylinder bleed valve 8Nm
Clutch spring bolts 10Nm
Clutch spring bolt holders 23Nm
Connecting rod cap bolts Initial setting 21Nm Final setting +90°
Crankcase bolts Crankshaft journal 9mm bolts Initial setting 18Nm Final setting 32Nm 8mm bolts 26Nm 6mm bolts 11Nm
Crankcase breather cover bolts 10Nm
Cylinder block nut 10Nm
Cylinder head
- 6mm bolts 10Nm
- 10mm nuts and bolts Initial setting 25Nm Final setting 37Nm
Engine mounting bolts
- Upper rear mounting bolt nut 85Nm
- Lower rear mounting bolt nut 88Nm
- Cradle to frame bolts/nuts 50Nm
- Cradle/frame to engine bolts (middle) 55Nm
Left hand front mounting bracket to engine 55Nm
Left hand front mounting bracket to frame 50Nm
Front mounting bolt/nuts 55Nm
Middle bracket to cradle/frame bolts 23Nm
Gearchange selector drom cam centre bolt K2 models 10Nm All other models 13Nm
Gearchange stopper arm bolt 10NM
Main oil gallery plugs (below timing rotor cover and alternator) 35Nm
Main oil gallery plug (inside crankcase) 21Nm
Sub oil gallery plug ( in upper crankcase forward of timing rotor cover) 10Nm
Sub oil gallery plug ( in upper crankcase inside clutch housing) 35Nm
Oil control control valve plug 35Nm
Oil hose (external) banjo bolts 20Nm
Oil hose union bolts 10Nm
Oil pipe (internal) bolts 10Nm
Oil strainer bolts 10Nm
Oil sump bolts 11Nm
Piston oil jet bolts 10Nm
Starter clutch bolts 25Nm
Timing rotor cover bolts 11Nm
Valve cover bolts Centre (small head) bolts (M8 thread) 20Nm Outer (Large head) bolts (M7 thread) 14Nm

Oil Cooling System

Oil cooler hose union bolts 10Nm
Oil hose union bolts 10Nm
Cooling fan switch 17Nm
Engine oil temperature (EOT) sensor retaining plate bolts 10Nm
Oil pressure switch 14Nm
Timing cover rotor bolts 11Nm

Engine Management Systems

Camshaft position (CMP) sensor bolt 8Nm
Exhaust system Downpipe clamp bolts 20Nm
Downpipe flange bolts 23NM
Downpipe assembly mounting bolt 23Nm
Silencer mounting bolt nut 23Nm
Silencer clamp bolt 24Nm
Fuel rail screws 5Nm
Fuel level sensor bolts 10Nm
Fuel pump bolts 10Nm
Intake air temperature (ITA) sensor 18Nm
PAIR system reed valve cover bolts 10Nm
Secondary throttle position (STP) sensor screws 3.5Nm
Throttle position (TP) sensor screws 3.5Nm
Timing rotor bolt 25Nm
Timing rotor cover bolts 11Nm

Frame and Suspension

Brake hose banjo bolt 23Nm
Brake torque arm to swing arm bolt nut 28Nm
Clutch master cylinder clamp bolts 10Nm
Fork clamp bolts (top and bottom yoke) 23Nm
Fork damper cartridge 40Nm
Fork top bolt 23Nm
Front axle clamp bolts 23Nm
Front brake master cylinder clamp bolts 10Nm
Handle bar clamp bolts 23Nm
Handle bar holder nuts 45Nm
Rear shock absorbers Upper bolt 23Nm Lower bolt nut 34Nm
Sidestand pivot bolt 50Nm
Sidestand pivot bolt nut 40Nm
Steering head bearing adjuster nut initial setting 45Nm
Steering stem nut 65Nm
Swingarm pivot bolt nut 120Nm

Brakes Wheels and Final Drive

Brake caliper bleed valves 8Nm
Brake hose banjo bolts 23Nm
Brake torque arm to caliper bolt nut 34Nm
Clutch release cylinder housing housing bolts 10Nm
Front brake caliper body joining bolts 21Nm
Front brake caliper mounting bolts 25Nm
Front brake disc bolts 23Nm
Front brake master cylider clamp bolts 10Nm
Front brake pad retaining pin 16Nm
Front axle 100Nm
Front axle clamp bolts and axle nut clamp bolts 23Nm
Front Sprocket nut 115Nm
Rear axle nut 100Nm
Rear brake caliper body joining bolts 37Nm
Rear brake caliper mounting bolts 26Nm
Rear brake disc bolts 23Nm
Rear brake master cylider mounting bolts 10Nm
Rear brake pad retaining pin 17Nm
Rear sprocket nuts 102Nm
Speed sensor rotor bolt 20Nm

Electrical System

Alternator rotor bolt 160Nm
Alternator cover bolt 11Nm
Alternator stator and wiring clamp bolts 10Nm

[toastedjoost]

 I've just bought some replacement bolts from Fastec Racing. 5 Oilway bungs are included. Any chance you know what the torque settings should be for the bungs???

[gsxbarmy]

Off the top of my head - no. But if you go to the Downloads section (look along the bar at the top of the screen - the same one with the logout option there) within that go into manuals and then choose the workshop manual to download. All torque information for all bolts required is in that manual (you'll need to be logged in to see the downloads)

(must admit - never been asked for the oil bungs torque before, still, always a first time!)

[toastedjoost]

Champion. I'll take a look at the download. Thanks for your help.

[T 24]

Great! Thank you! I made a copy of your list and put it on the wall of my garage.

[Dusty ST]

Brilliant! Much easier than thumbing through Haynes... thanks 

[Andre]

There is an issue with the torque setting for the rear sprocket nuts in the workshop manual which has been causing some grief.

6-32 Table item B: "102 N.m (10.2 kgf.m, 74.0 lb-ft)"
6-38 "Rear sprocket nut: 102 N.m (10.2 kgf.m, 74.0 lb-ft)"
8-35 Table last item: "Rear sprocket nut: 102 N.m (10.2 kgf.m, 74.0 lb-ft)"

2-25 Table last item (position 24) "Rear sprocket nut: 60 N.m (6.0 kgf.m, 43.5 lb-ft)

Various calls by members of a german forum (gsx-1400-forum.de) to "Suzuki" confirmed the info in 2-25. An experienced mechanic on the forum referred to a DIN-Norm Table for threaded steel bolts in aluminum which confirmed the 60 N.m.

Do secure with threadlock even though the service manual does not specify it. I use "LiquiMoly Medium Strength".