XL750 engine and frame tightening torques

Front upper cover A screw

3

4

0.9 (0.1, 0.7)

Windscreen mounting screw

4

5

0.75 (0.1, 0.6)

Rearview mirror adaptor bolt

2

10

20 (2.0, 15)

Rearview mirror lock nut

2

10

20 (2.0, 15)

Left hand threads

Rear carrier mounting socket bolt

4

8

35 (3.6, 26)

Rear reflector mounting nut

1

5

1.8 (0.2, 1.3)

License light bolt

2

4

2.0 (0.2, 1.5)

Front reflector mounting nut

2

5

1.8 (0.2, 1.3)

Drive chain case rear socket bolt

1

6

1.0 (0.1, 0.7)

Replace with a new one.

Drive chain case rear nut

1

6

10 (1.0, 7)

Main step mounting socket bolt (10 mm)

2

10

54 (5.5, 40)

Main step mounting socket bolt (8 mm)

2

8

37 (3.8, 27)

Pillion step mounting bolt

4

8

37 (3.8, 27)

Muffler mounting nut

1

8

20 (2.0, 15)

Muffler band bolt

1

8

20 (2.0, 15)

Muffler cover bolt

1

6

12 (1.2, 9)

Exhaust pipe joint nut

4

8

20 (2.0, 15)

Exhaust pipe mounting bolt

1

8

20 (2.0, 15)

Exhaust pipe stud bolt

4

8

–

Sidestand pivot bolt

1

10

10 (1.0, 7)

Sidestand pivot nut

1

10

39 (4.0, 29)

Air cleaner cover screw

9

5

1.2 (0.1, 0.9)

Air cleaner element screw

5

4

1.2 (0.1, 0.9)

Spark plug

2

10

16 (1.6, 12)

Valve adjusting screw lock nut

4

5

10 (1.0, 7)

Apply engine oil to the threads and seating surface.

Timing hole cap

1

45

17.5 (1.8, 13)

Apply grease to the threads.

Oil drain bolt

1

12

30 (3.1, 22)

Oil filter boss (crankcase side)

1

20

–

Apply locking agent to the threads.

Oil filter cartridge

1

20

26 (2.7, 19)

Apply engine oil to the threads and O-ring.

Rear axle nut

1

18

100 (10.2, 74)

Self-lock nut

Drive chain adjusting bolt lock nut

2

8

27 (2.8, 20)

Drive sprocket bolt

1

10

54 (5.5, 40)

Driven sprocket nut

5

12

100 (10.2, 74)

Self-lock nut

Apply engine oil to the threads.

Rear master cylinder push rod lock nut

1

8

17 (1.7, 13)

Front spoke

36

BC3.5

3.7 (0.4, 2.7)

Rear spoke

32

BC3.5

3.7 (0.4, 2.7)

GP sensor bolt

1

6

12 (1.2, 9)

Shift spindle switch

1

10

12 (1.2, 9)

Shift spindle switch terminal nut

1

4

1.7 (0.2, 1.3)

MAP sensor mounting screw/washer

1

6

4.9 (0.5, 3.6)

IAT sensor mounting screw

2

5

1.1 (0.1, 0.8)

A/F sensor

1

12

24.5 (2.5, 18)

Starter motor cable nut

1

6

10 (1.0, 7)

Starter motor setting bolt

2

5

4.9 (0.5, 3.6)

Negative brush mounting screw

1

5

3.7 (0.4, 2.7)

Starter motor terminal nut

1

6

11 (1.1, 8)

Fuel tank mounting bolt

2

6

10 (1.0, 7)

Fuel tank mounting nut

1

6

12 (1.2, 9)

Self-lock nut

Fuel fill cap mounting bolt

3

4

1.8 (0.2, 1.3)

Fuel pump mounting nut

6

6

12 (1.2, 9)

Connecting hose plate socket bolt

6

6

7.0 (0.7, 5.2)

Air cleaner connecting hose band screw

2

4

1.5 (0.2, 1.1)

Insulator band screw

2

5

–

Insulator mounting bolt

4

5

1.2 (0.1, 0.9)

Fuel injector mounting bolt

5

5

5.1 (0.5, 3.8)

Cooling fan mounting nut

1

5

2.7 (0.3, 2.0)

Apply locking agent to the threads.

Fan motor mounting screw

3

5

5.2 (0.5, 3.8)

Shroud mounting bolt/washer

4

6

8.5 (0.9, 6.3)

Water hose band (short)

2

–

–

Water hose band (long)

4

–

–

Oil filter cartridge

1

20

26 (2.7, 19)

Apply engine oil to the threads and O-ring.

Oil jet bolt

1

6

12 (1.2, 9)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip

Cylinder head cover bolt

3

6

10 (1.0, 7)

Rocker arm shaft bolt

1

6

12 (1.2, 9)

Cam chain tensioner pivot bolt

1

8

12 (1.2, 9)

Apply locking agent to the threads.

Coating width: 6.5 mm (0.26 in) except 2.0 mm (0.08 in) from tip

Camshaft holder bolt

6

6

12 (1.2, 9)

Apply engine oil to the threads and seating surface.

Cylinder head bolt/washer

6

12

30 (3.1, 22) + 115°

Apply molybdenum oil solution to the threads and seating surface.

Apply engine oil to the washer.

Engine hanger plate nut

4

10

44 (4.5, 32)

Engine hanger bolt

2

12

59 (6.0, 44)

Stator bolt

5

6

12 (1.2, 9)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip

Alternator wire clamper bolt

1

6

12 (1.2, 9)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip

Flywheel mounting bolt

1

12

157 (16.0, 116)

Apply engine oil to the threads and seating surface.

Left hand threads

Starter clutch bolt

6

8

29 (3.0, 21)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) from tip

Clutch center lock nut

1

22

147 (15.0, 108)

Apply engine oil to the threads and seating surface.

Stake.

Clutch set plate bolt

3

6

12 (1.2, 9)

Primary drive gear mounting bolt

1

10

103 (10.5, 76)

Apply engine oil to the threads.

Shift drum stopper arm pivot bolt

1

6

12 (1.2, 9)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip

Shift drum center bolt

1

8

23 (2.3, 17)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) from tip

Gearshift spindle set plate bolt

1

6

12 (1.2, 9)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip

Gearshift pedal pivot bolt

1

8

27 (2.8, 20)

Tie rod lock nut (upper)

1

6

10 (1.0, 7)

Left hand threads

Tie rod lock nut (lower)

1

6

10 (1.0, 7)

Clutch lever pivot bolt

1

6

3.3 (0.3, 2.4)

Clutch lever pivot nut

1

6

6.5 (0.7, 4.8)

Self-lock nut

Main journal bolt

6

10

20 (2.0, 15) + 65°

Apply molybdenum oil solution to the threads.

Crankcase 10 x 70 bolt

1

10

39 (4.0, 29)

Crankcase 8 x 55 bolt

1

8

24 (2.4, 18)

Front balancer shaft journal 8 x 45 bolts

2

8

18 (1.8, 13)

Apply molybdenum oil solution to the threads.

Front balancer shaft journal 8 x 75 bolts

4

8

17.5 (1.8, 13)

Apply molybdenum oil solution to the threads.

Crankcase 6 x 90 bolt

2

6

14 (1.4, 10)

Baffle plate bolt

4

6

12 (1.2, 9)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip

Mainshaft bearing set plate bolt/washer

3

6

12 (1.2, 9)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip

Shift drum bearing setting bolt/washer

2

6

12 (1.2, 9)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip

Rear balancer shaft bolt/washer

1

6

12 (1.2, 9)

Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ± 0.04 in) from tip

Lower crankcase 20 mm cap

1

20

23 (2.3, 17)

Apply grease to the thread.

Crankpin bearing cap bolt (new)

4

8

27 (2.8, 20) + 120°

Apply engine oil to the threads and seating surface.

Main journal bolt

6

12

20 (2.0, 15) + 65°

Apply molybdenum oil solution to the threads.

Crankpin bearing cap bolt (reuse)

4

8

27 (2.8, 20) + 90°

Apply engine oil to the threads and seating surface.

Rear lower engine hanger nut

1

12

64 (6.5, 47)

Rear upper engine hanger nut

1

10

44 (4.5, 32)

Engine hanger plate nut

4

10

44 (4.5, 32)

Engine hanger bolt

2

12

59 (6.0, 44)

Drive sprocket bolt

1

10

54 (5.5, 40)

EOP switch terminal bolt/washer

1

4

2.0 (0.2, 1.5)

Starter motor cable nut

1

6

10 (1.0, 7)

APS screw

4

4

2.0 (0.2, 1.5)

Handlebar upper holder bolt

4

8

32 (3.3, 24)

Right handlebar switch screw/washer

2

5

2.5 (0.3, 1.8)

Left handlebar switch screw/washer

2

5

2.5 (0.3, 1.8)

Handlebar lower holder nut

2

10

39 (4.0, 29)

Self-lock nut

Front brake disc bolt

12

6

20 (2.0, 15)

Replace with new ones.

Front pulser ring bolt

3

5

7.0 (0.7, 5.2)

Replace with new ones.

Front spoke

36

BC3.5

3.7 (0.4, 2.7)

Front axle nut

1

16

65 (6.6, 48)

Front axle pinch bolt

4

8

22 (2.2, 16)

Fork center bolt

2

8

20 (2.0, 15)

Apply locking agent to the threads.

Fork bolt lock nut

2

10

20 (2.0, 15)

Bottom bridge pinch bolt

4

8

25 (2.5, 18)

Fork bolt

2

44.5

35 (3.6, 26)

Top bridge pinch bolt

4

8

22 (2.2, 16)

Steering stem adjusting nut

1

26

27 (2.8, 20)

Apply engine oil or grease to the threads .

Steering stem adjusting nut lock nut

1

26

–

Steering stem nut

1

24

103 (10.5, 76)

Rear axle nut

1

18

100 (10.2, 74)

Self-lock nut

Driven sprocket nut

5

12

100 (10.2, 74)

Self-lock nut

Apply engine oil to the threads.

Rear pulser ring bolt

4

5

7.0 (0.7, 5.2)

Replace with new ones.

Rear brake disc bolt

4

8

42 (4.3, 31)

Replace with new ones.

Rear spoke

32

BC3.5

3.7 (0.4, 2.7)

Driven flange stud bolt

5

12

–

Apply engine oil to the threads.

Shock absorber upper mounting nut

1

10

54 (5.5, 40)

Self-lock nut

Shock absorber lower mounting nut

1

10

44 (4.5, 32)

Self-lock nut

Cushion arm nut (cushion connecting rod side)

1

10

54 (5.5, 40)

Self-lock nut

Cushion arm nut (swingarm side)

1

12

74 (7.5, 55)

Self-lock nut

Cushion connecting rod nut

1

10

44 (4.5, 32)

Self-lock nut

Apply engine oil to the threads.

Drive chain slider screw

4

5

4.2 (0.4, 3.1)

Replace with new ones.

Drive chain adjusting bolt lock nut

2

8

27 (2.8, 20)

Drive chain guard bolt

2

6

10 (1.0, 7)

Swingarm pivot nut

1

16

88 (9.0, 65)

Self-lock nut

Apply engine oil to the threads.

Bleed valve

3

8

5.4 (0.6, 4.0)

Reservoir cap screw

4

4

1.5 (0.2, 1.1)

Front brake caliper pad pin

2

10

17 (1.7, 13)

Rear brake caliper mounting bolt

1

8

22 (2.2, 16)

Replace with a new one.

Rear brake caliper pad pin

1

10

17 (1.7, 13)

Brake hose oil bolt

7

10

34 (3.5, 25)

Front brake lever pivot bolt

1

6

1.0 (0.1, 0.7)

Front brake lever pivot nut

1

6

5.9 (0.6, 4.4)

Front brake light switch screw

1

4

1.2 (0.1, 0.9)

Main step mounting socket bolt (10 mm)

2

10

54 (5.5, 40)

Main step mounting socket bolt (8 mm)

2

8

37 (3.8, 27)

Rear master cylinder mounting bolt

2

6

12 (1.2, 9)

Front brake caliper mounting bolt

4

8

30 (3.1, 22)

Replace with new ones.

Front brake caliper pin bolt

2

8

17 (1.7, 13)

Rear brake caliper pin bolt

1

12

27 (2.8, 20)

Brake pipe joint nut

4

10

14 (1.4, 10)

Apply brake fluid to the threads.

Brake hose oil bolt

7

10

34 (3.5, 25)

Headlight mounting bolt/washer

4

6

8.5 (0.9, 6.3)

Combination meter mounting screw

3

5

1.3 (0.1, 1.0)

EOP switch

1

PT 1/8

12 (1.2, 9)

Apply sealant to the threads .

EOP switch terminal bolt/washer

1

4

2.0 (0.2, 1.5)

Ignition switch mounting bolt

2

8

26 (2.7, 19)

Replace with new ones.

Clutch switch screw

1

3

0.8 (0.1, 0.6)

Neutral switch

1

10

12 (1.2, 9)

Neutral switch terminal nut

1

4

1.7 (0.2, 1.3)

Sidestand switch mounting bolt

1

6

10 (1.0, 7)

Replace with a new one.

Shift return spring pin

1

8

23 (2.3, 17)