4
* w/Blue Loctite #243 ** w/Red Loctite #271
*** w/Green Loctite #270 **** w/“Patch-Lock”
Torque Conversions
(ft-lb/N-m)
Gasoline — Oil — Lubricant
FILLING GAS TANK
Since gasoline expands as its temperature rises, the gas tank
must be filled to its specified capacity only. Expansion room
must be maintained in the tank particularly if the tank is filled
with cold gasoline and then moved to a warm area.
Tighten the gas tank cap securely after filling the tank.
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates are added to
the gasoline. Oxygenated gasolines containing up to 10%
ethanol or 5% methanol are acceptable gasolines.
Part Part Bolted to
Torque
ft-lb N-m
SUSPENSION COMPONENTS (Front)
A-Arm Frame 35 48
Knuckle Ball Joint 35 48
Shock Absorber Frame/Upper A-Arm 32.5 44
SUSPENSION COMPONENTS (Rear)
A-Arm Frame 35 48
Shock Absorber Lower A-Arm/Frame 32 43.5
Knuckle A-Arm 35 48
DRIVETRAIN COMPONENTS
Gear Case Frame 39 53
Front Differential Frame 39 53
Differential Gear Stay Frame 23 31.3
Pinion Housing Differential Housing 16.5 22
Driveshaft Flange (Front/Rear) Engine Flange 20 27.2
Front/Rear Drive Flange Secondary Output Shaft 59 80
Differential Housing Cover*** Differential Housing 16.5 22
Drive Bevel Gear Nut*** Shaft 72 98
Driven Bevel Gear Shaft 101 137
Hub Nut Front/Rear Shaft/Axle
(min)
200 271
Oil Drain Plug/Check Plug Rear Gear Case 15 20.4
Filler Cap Rear Gear Case 11 15
Drain Plug Front Differential 23 in.-lb 2.6
Check Plug Front Differential 7.2 9.8
Oil Fill Plug Front Differential 25 34
Engine Oil Drain Plug Engine 18 24.5
Wheel (Steel) Hub 45 61
Wheel
(Aluminum w/black nuts) Hub 60 81
Wheel
(Aluminum w/chrome
nuts)
Hub 80 108
ENGINE/TRANSMISSION
Engine Cradle Frame 25 34
Engine Cradle Engine 43 58
Cam Sprocket** Camshaft 10 14
Valve Cover Cylinder Head 8.5 11.5
Tappet Cover Valve Cover 8.5 11.5
Cylinder Head (Cap Screw) Crankcase 28 38
Cylinder/Cylinder Head (Nut) Cylinder 8 11
Clutch Shoe** Crankshaft 147 199
Driven Pulley** Driveshaft 85 115
Ground Wire Engine 8 11
Magneto Cover Crankcase 10 14
Speed Sensor Housing Crankcase 8 11
CVT Cover Clutch Cover/Housing 8 11
Movable Drive Face Centrifugal Clutch Housing 85 115
Starter Clutch** Flywheel 16 22
Rotor Crankshaft 107 145
Stator Coil
**
Magneto Cover (New) 13 18
Stator Coil
Magneto Cover (Existing)
11.5 15
Oil Strainer Crankcase 54 in.-lb 6
Oil Pump** Crankcase 8.5 11.5
Water Pump/Housing Magneto Cover 8 11
Crankcase Half (6 mm) Crankcase Half 10 14
Crankcase Half (8 mm) Crankcase Half 21 28
Starter Motor Crankcase 10 14
Shift Cam Plate Shift Cam Shaft 8 11
Oil Pump Drive Gear** Crankshaft 63 85
Cam Chain Tensioner Guide Cylinder Head 11 15
Cam Chain Tensioner Cylinder 10 14
Water Pump Drive Gear Crankshaft 28 38
Water Pump Cover Water Pump Housing 8 11
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
1 1.4 26 35.4 51 69.4 76 103.4
2 2.7 27 36.7 52 70.7 77 104.7
3 4.1 28 38.1 53 72.1 78 106.1
4 5.4 29 39.4 54 73.4 79 107.4
5 6.8 30 40.8 55 74.8 80 108.8
6 8.2 31 42.2 56 76.2 81 110.2
7 9.5 32 43.5 57 77.5 82 111.5
8 10.9 33 44.9 58 78.9 83 112.9
9 12.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
! WARNING
Always fill the gas tank in a well-ventilated area. Never add
fuel to the gas tank near any open flames or with the engine
running. DO NOT SMOKE while filling the gas tank.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine to
cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.
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