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ST4s Table of Fasteners and Torques

- reprinted from work by Richard White and unknown authors

 

CATEGORY FASTENER LOCATION REPL W/ QTY STOCK DESCRIPTION NM NOTES
           
SUSPENSION Front wheel axle nut   1 SPL NUT M25x1.25 63 Grease
  Steering bearing ring nut   1 SPL NUT M35x1 30
  Steering stop screw   2 SSS M8X1.25 x 25  
  Steering stop nut   2 NUT M8x1.25 18 Loctite 243
  Top triple clamp to steering stem clamp screw   1 LHCS M8x1.25 x 25 23 Grease
  Top triple clamp to fork screw   2 SHCS M8x1.25 x 25 20
  Bottom triple clamp to fork screw   4 SHCS M8x1.25 x 30 20
  Fork bottom end clamp screw BHCS 4 FHH M8x1.25 x 45 19 (.) Grease
  Fork splashguard screw BHCS 2 FHH M5x0.8 x 10 5.5 Loctite 243
  Fork damper rod bolt   2 SHCS M14x1 x 25
  Suspension rocker pivot screw   1 SPL M12xl.5 x 130  
  Suspension rocker pivot nut   1 SPL NUT M12x1.5 75 Grease
  Ride height rod joint retaining nut   1 NUT M12x1.5 RH 36
  Ride height rod joint retaining nut   1 NUT M12x1.5 LH 36
  Ride height rod upper screw   1 SHCS M10x1.25 x 50 42
  Swing arm pivot shaft lock screw   2 SPL M6x1.5 x  43 Grease
  Swing arm pivot shaft lock nut   2 NYLOCK FNUT M6x1
  Chain tensioner adjusting bolt   2 FHH M8x1.25 x 90 8 Grease
  Chain slide screw   6 SPL BHCS M6x1 x 16 5.5 Grease
  Rear wheel axle nut   1 SPL M25x1.25 83 Grease
  Rear sprocket nut   6 FNUT MI0xl.25 46 Loctite 243
  Rear wheel cush drive rubber pin   6 SPL M14x1.5 x 33 46 Loctite 601
  Shock absorber upper screw   1 SHCS M10xl.25 x 55 42 Grease
  Shock absorber lower screw   1 SPL M10xl.25 x 82 42 Grease
  Shock absorber lower nut   1 SPL NUT M10x1.25
  Shock remote reservoir mounting screw SHCS 2 LHCS M6x1 x 16
  Shock preload adjustment  to bracket screw   2 SHCS M6x1 x 25
  Shock preload adjustment to bracket nut   2 FLNUT M6x1
  Shock preload adjustment bracket to frame nut   1 FLNUT M8x1.25
           
BRAKES Front brake caliper retaining screw 4 SHCS M10xl.25 x 25 43 Grease
Front brake master cylinder reservoir retaining screw BHCS 1 LHCS M6x1x 10 9 Sequence 1 (UP)-2-1
Front brake master cylinder reservoir cap screw 2 FHCS M4x0.7 x 45
Front brake master cylinder reservoir cap nut 2 NUT M4X0.7
Front brake disc fastening bolt 12 SHCS M8x1.25 x 16 25 Loctite 243
Front brake cable guide screw SHCS 2 FHH M6x1 x 10 10
Front brake bleed connector 2 SPL 4
Rear brake bleed connector 1 SPL 4
Rear brake caliper retaining screw 2 SHCS M8x1.25 x 20 25 Grease
Rear brake master cylinder reservoir retaining screw SHCS 1 FHH M6x1 x 10 10 (o)
Rear brake master cylinder to bracket retaining screw SHCS 2 FHH M6x1 x 16 43 Loctite 128455
Rear brake lever pin 1 SPL M10x1.5 29 Loctite 128455
Rear brake cable clamp screw SHCS 1 FHH M5x0.8 x 16 5
Rear brake cable guide wire screw SHCS 1 FHH M5x0.8 x 16  
Rear brake cable guide wire nut 1 FLNUT M5x0.8 5
Rear brake disc fastening bolt 6 SHCS M8x1.25 x 16 25 Loctite 243
Rear brake pedal light switch screw 1 SPL M6x1 x 16 5
Rear brake pedal light switch nut 1 NUT M6x1
Rear brake pedal adjusting dowel nut 1 NUT M6x1 2.3
Rear brake torque stud screw 1 SHCS M8x1.25 x 25
           
PLASTIC Side panel lower screw SHCS 2 HH M5x0.8 x 45 4 Loctite 222
  Side panel clamp retaining screw BHCS 2 FHH M6x1x 10 6 Loctite 243
  Side panel to rear sub frame   2 SPL BHCS M6x1 x 16
  Front mudguard retaining screw   4 SPL BHCS M6x1 x 20 3 Loctite 243
  Air scoop mounting screw   4 #2PSTS M4x 12
  Front fairing screw   6 BHCS M5 x 0.8 X 20 1.5
  Fairing front shield   2 SPL BHCS M6 x 1 x 20 1.5
  Fairing RH LH lower   8 BHCS M5 x 0.8 x 20 1.5
  Fairing RH LH lower   4 SPL BHCS M6 x 1 x 20 1.5
  Fairing RH LH upper   4 BHCS M5 x 0.8 x 20 1.5
  Fairing RH LH upper   2 LHCS M6 x 1  X 20 1.5
  Windscreen to front fairing screw   6 BHCS M5 x 0.8 x 20
  Dashboard LH and RH panel screw   4 BHCS M4x0.7 x 16 5
  Instrument panel surrounds screw   3 BHCS M4x0.7 x 16
  Front turn signal housing mounting screw   4 #1PSTS M3x 6
  Fairing front piece wind scoop screw   4 BHCS M5 x 0.8 x 20 1.5
  Fairing front piece grille screw   2 FHCS M4x0.7 x 30
  Fairing front piece grille screw nut   2 NYLOK NUT M4x0.7
  Fairing / coil bracket screw SHCS 2 FHH M6x1 x 10 9
  Rear-view mirror fixing screw SHCS 4 FHH M6x1 x 20 3.5
  License plate holder screw SHCS 2 FHH M6x1 x 16 9
  License plate bracket nut   2 FLNUT M6x1
  Rear hugger retaining screw   4 SPL BHCS M6x1 x 20 3 Loctite 243
  Upper rear fender to frame screw SHCS 4 FHH M5x0.8 x 20
  Upper rear fender to frame screw   2 SHCS M6x1 x 20
  Lower rear fender to upper rear fender screw SHCS 1 FHH M5x0.8 x 20
           
TANK Fuel pump to tank closure nut 3 SPL NUT M6x1 8
Tank hold down strap brkt to tank screw 2 SPL NUT M6x1
Fuel tank drain screw 1 SPL  M10xl.25 x 10 10 Loctite 577
Fuel cap plug retaining screw 5 SHCS M5x0.8 x 10 5
Fuel cap lock detent spring screw 1 #1PS M3x0.5 x 5
Tank hinge to frame screw BHCS 2 FHH M6x1 x 10 9
Tank rubber pad nut 4 FLNUT M6x1 8
Tank cover to tank screw 2 SPL BHCS M6x1 x 16 1.5
Fuel tank lock to cap screw 2 #1PS M4x0.7 x 14
Fuel tank flange to inner neck screw 1 SHCS M5x0.8 x 15
Fuel tank lock assy to tank cap screw 1 #1PS M4x0.7 x 6
           
HAND CONTROL Handlebar retaining screw   4 SHCS M8x1.25 x 25  24(.)
  LH switch screws SHCS 2  #2PS M5x0.8 x 25 3
  RH switch screws SHCS 2  #2PS M5x0.8 x 45  
  Bar end / Counterweight screw   2 LHCS M8x1.25 x 30 23 Loctite 222
  Control lever cap screw BHCS 4 SHCS M6x1 x 20 9
  Twist throttle body to bar screw BHCS 2 FHH M6x1 x 20
  Twist throttle cap to body screw SHCS 2 #2PS M4x0.7 x 10
  Rising handle to footpeg support screw   1 SPL M8x1.25 20
           
FOOT CONTROL Gear change lever pivot pin 1 SPL M8x1.25 23 Loctite 243
Shift rod rod end RH nut 1 NUT M6x1
Shift rod rod end LH nut 1 LH NUT M6x1
Gear change shaft lever retaining screw SHCS 1 LHCS M6x1 x 20 9 Loctite 222
Shift rod rod end retaining screw SHCS 2 LHCS M6x1 x 20
Shift rod rod end retaining screw nut 2 LNUT M6x1
Footrest rubber to footpeg screw FHCS 8 #2PFHS M5x0.8 x 16
Front and rear footrest support retaining screw 7 SHCS M8x1.25 x 25 24 Loctite 243
Front and rear footrest support retaining screw 1 SHCS M8x1.25 x 45 24
Front footrest heel guard retaining screw BHCS 4 FHH M5x0.8 x 12 5 Loctite 243
           
INSTRUMENTS Rev counter to support screw   2 ACORN NUT M5x0.8 w/ FW 5
  Odometer to support plate nut   2 ACORN NUT M5x0.8 w/ FW 5
  LCD display mounting nut   1 ACORN NUT M5x0.8 w/ FW 5
  Instrument bracket to intake runner casing screw   1 SHCS M5x0.8 x 25
  Instrument bracket to front sub frame screw   2 SPL SHCS M
           
LIGHTING Headlamp support top retaining nut 2 LNUT M6x1 w/ FW 24
Headlamp support bottom retaining screw 2 SHCS M6x1 x 20
Instrument surround center support post screw 1 SHCS M5x0.8 x 10 5 Loctite 222
Instrument plastic tray to instrument bracket nut 3 FNUT M5x0.8 5
Tail light lens screw 2 #2PSTS M4x 30 6
License plate light nut 2 FLNUT M5x0.8 w/ FW 1.5
Rear reflector retaining nut 6 LNUT M4x0.7 w/ FW 2
Rear turn indicator screw 2 BHCS M6x1 x 16 3.2
           
FRAME MOUNTED Rear handle/ tail light housing retaining screw SHCS 4 FHH M6x1 x 20 9 Loctite 243
  Ignition key switch retaining nut   2 ACORN NUT M6x1 9 Loctite 222
  Air pressure sensor screw SHCS 2 #2PPHS M4x0.7 x 20
  LH sub frame bracket screw SHCS 3 FHH M6x1 x 16
  LH sub frame bracket screw SHCS 2 FHH M6x1 x 20
  LH sub frame bracket screw SHCS 1 FHH M6x1 x 25
  Immobilizer control unit screw SHCS 1 FHH M6x1 x 20
  Junction box on front LH subframe screw   2 BHCS M5x0.8 x 10 2.3
  Regulator mounting screw SHCS 2 FHH M6x1 x 30 9
  Fuse holder plate screw   2 BHCS M5x0.8 x 16 1.8
  Coil bracket to frame screw SHCS 2 FHH M6x1 x 10 9
  Coil to bracket screw   4 SHCS M4x0.7 x 25  
  Coil to bracket nut   4 LNUT M4x0.7 3
  Seat lock lever screw   2 #1PSTS M3x 6 2.5
  Seat latch mounting screw   2 FHH M6x1 x 16
  Seat locking mechanisms cover screws   2 FHH M6x1 x 16
  Underseat unused bracket screw BHCS 1 FHH M5x0.8 x 16
  Underseat unused bracket nut   1 FLNUT M5x0.8
  Lower Nonfango bracket to footpeg screw   2 BHCS M8x1.25 x 16
  Upper Nonfango bracket to frame screw BHCS 4 FHH M8x1.25 x 16
  Seat lock ring nut   1 SPL NUT M22x1.5 1 Loctite 270
  Power outlet ring nut   1 SPL NUT M18x1 2.5
  Round fairing stay screw   2 SHCS M6x1 x 35
           
BATTERY Battery box to engine/frame screws SHCS 3 FHH M6x1 x 20 w/ FW
Battery cable to battery screws SHCS 2 #2PHH M6x1x 10 6
Battery holding bracket bolt SHCS 1 FHH M6x1 x 10 9 Loctite 243
ECU to battery box screw SHCS 2 FHH M6x1 x 60
ECU to battery box screw nut 2 FLN M6x1w/ FW
Starter solenoid/fuse mount screw 1 BHCS M6x1 x 20 w/ HN FW 4
Battery cables to starter solenoid nut 2 NUT M6x1  w/ FW
Fuse 7.5 A to battery box - accesssory 1 SHCS M6x1 x 10
Battery ground to engine screw HHCS 1 SPL M8x1.25 x 10 13
           
STANDS Center stand screw   1 M10xl.25 x 230 43 Loctite 128455
  Center stand screw nut   1 NUT PREVAILING M10x1.25  
  Center stand/ master cylinder screw   2 SHCS M10x1.5 x 25 43 Grease
  Side stand sensor retaining screw   1 SPL M6x1 x 16 10
  Side stand to engine mounting screw   2 SHCS M10x1.5 x 25 43 Loctite 128455
  Side stand pivot nut   1 NUT PREVAILING M10x1.25  
  Side stand pivot screw   1 SPL M10x1.25 x 30 24
           
ENGINE Cylinder head nut 8 FNUT M10x1.5 15/30/51 Grease
Spark plug 2 SPL M12x1.25 x 19 20
Alternator rotor nut 1 SPL M24x1 270 Oil
Engine to frame mounting stud 2 SPL M12x1.25 x 250 60 Grease
Engine to frame mounting nut 2 FNUT M12x1.25
Front sprocket stopper screw SHCS 2 FHH M5x0.8 x 16 6 Loctite 222
Cam belt tensioner shaft - Fixed and Mobile 2 SPL M8x1.25 26 Lock2
Cam belt tensioner eccentric nut FNUT M8x1.25  25 Grease
Cam position holder tool screw BHCS 4 SS M5 x0.8 x 10 w/ FW
Cam position adjuster screw 12 SHCS M5x0.8 x 16
Horn retaining screw 1 SHCS M8x1.25 x 16 24 Loctite 243
Crank position sensor mounting screw 1 SHCS M6x1 x 20 LW 10 Loctite 243
Starter motor screw 3 SHCS M6x1 x 30 10
           
MAIN CASES Main case screw   3 SHCS M8x1.25 x 75 10
  Main case screw   7 SHCS M6x1 x 35 10
           
ENGINE COVERS LH engine cover screw 2 SHCS M6x1 x 20 10
LH engine cover screw 9 SHCS M6x1 x 25 10
LH engine cover screw 2 SHCS M6x1 x 30 w/ FW 10
RH engine cover screw 1 SHCS M6x1 x 70 10
RH engine cover screw 1 SHCS M6x1 x 65 10
RH engine cover screw 1 SHCS M6x1 x 35 10
RH engine cover screw 5 SHCS M6x1 x 25 10
Clutch cover bolts   2 SHCS M6x1 x 20 10
Clutch cover bolts   2 SHCS M6x1 x 70 10
Cam cover plate RH screw 8 SHCS M6x1 x 16 10
Cam cover plate LH screw 7 SHCS M6x1 x 16 10
Cam cover plate LH screw 1 SHCS M6x1 x 25 10
Valve cover screw 16 SHCS M6x1 x 16 10
Cam belt cover Horiz screw 3 SHCS M6x1 x 30 10
Cam belt cover Mid screw 3 SHCS M6x1 x 25 10
Cam belt cover Vert screw 3 SHCS M6x1 x 16 10
Rocker pin coverplate RH screw 10 SHCS M6x1 x 16 10
Front sprocket cover screw 2 SHCS M6x1 x 12 10
LH crankcase inspection cover screws 2 FHCS M6x1 x 15 10
           
AIRBOX Airbox runner case screw   5 SHCS M5x0.8 x 20 5
  Airbox runner case screw   1 SHCS M5x0.8 x 25 w/ FW 5
  Air box to frame screw SHCS 1 FHH M6x1 x 20 9
  Airbox snorkel clip screw   6 BHCS M5x0.8 x 12 3
  Air scoop casing to frame screw SHCS 2 FHHS M8 x 1.25 x 80
  Air scoop casing to frame nut FLNUT 2 FNUT M8 x 1.25
           
CLUTCH Clutch hub nut 1 SPL M20x1 190 Grease
Clutch basket screw 8 HHCS M8x1.25 x 20 35 Locktite 510
Clutch spring retaining screw 6 SHCS M5x0.8 x 20 5 Grease
Clutch master cylinder reservoir bracket mounting screw BHCS 1 LHCS M6x1 x 10 5
Clutch master cylinder reservoir to bracket screw 1 SPL M5x0.8 x 10 9 (.) Sequence 1 (UP)-2-1
Clutch master cylinder reservoir to bracket nut 1 FNUT M5x0.8 5
Clutch slave cylinder to engine screw 3 SCHS M6x1 x 16 10
Clutch bleed connector 1 SPL 4
           
FUEL Intake manifold to engine nut   8 FNUT PREVAILING M6x1
  Throttle body intake stack spring screw BHCS 4 #2PHS M5x0.8 x 6 1.6
  Throttle body steel bracket screw BHCS 4 T20 M5x0.8 x 16 w/ FW 1.5
  Throttle body aluminum bracket screw   4 FHCS M
  Throttle body belcrank nut FLNUT 1 SPL FLNUT M8x1.25
  Throttle body butterfly linkage nut   1 NUT M5x0.8 
  Throttle body idle stop screw   1 HHCS M5x0.8 x 20
  TPS mounting screw   2 #2PHHS M4x0.7 x 16 w/ LW
  Fast idle cable holding screw SHCS 1 SHHS M4x0.7 x 6
  Fast idle position lock screw SHCS 1 SHS M4x0.7 x 6 w/ wave washer
  Injector hold down screw BHCS 4 T20 M4x0.7 x 10
  Throttle cable slack adjuster nut   1 NUT M6x1
  Fast idle cable slack adjuster nut   1 NUT M6x1
  Throttle body balance port screw SHCS 2 SS M5x0.8 x 6 w/  Soft FW 5 Loctite 243
  Throttle body balance port screw - repl. for removed charcoal canister hoses   2 SHCS M5x0.8 x 6 w/ Soft FW 5
           
EXHAUST Exhaust pipe joint clamp screw 1 SHCS M8x1.25 x 25 23
Exhaust silencer mount to footpeg (Nonfango)  support screw SHCS 1 LHCS M8x1.25 x 30 24
Exhaust silencer mount to footpeg (Nonfango)  support screw SHCS 1 LHCS M8x1.25 x 40
Exhaust pipe to head fixing nut 6 FNUT M6x1PREVAILING  10
Exhaust CO port 2 SPL  25
           
COOLANT Coolant pump cover drain screw   1 SPL SHCS M10xl.25 x 9 18
  Fan assy mounting screw SHCS 3 FHH M6x1 x 10
  Coolant outlet flange screw   6 SHCS M6x1 x 16
  Coolant outlet flange drain screw   2 SHCS M6x1 x 10 w/ CU GASK 10
  Water pump cover screw   4 SHCS M6x1 x 18 10
  Water pump cover screw   1 SHCS N6x1 x  25 10
  Horiz cyl temp sensor housing screw   3 SHCS M6x1 x 40 10
  Vert cyl temp sensor housing screw   3 SHCS M6x1 x 30 10
  Coolant reservoir tank screw BHCS 4 SHCS M6x1 x 20 9
           
OIL Oil cooler mounting screw 1 SHCS M6x1 x 25 9
Oil cooler mounting screw 1 SPL M6x1 x 12 9
Rocker oil coverplate LH screw 7 SHCS M6x1 x 16 10
Rocker oil inlet coverplate LH screw 2 SHCS M6x1 x 25 10
Rocker oil inlet coverplate LH Horiz cyl screw 1 SPL M6x1 x 16 10
Oil line vert cyl clamp screw 1 SHCS M6x1 x 16 10
Oil drain plug 1 SPL M22x1.5 42
Oil fill plug 1 SPL M21x1.5
Oil filter 1 SPL M16x1.5 11
Oil screen screw 1 SPL M22x1.5 42
Oil screen cover screw 1 SPL M32x1.5 42
Oil pipe union on cooler with twin seals 2  
Oil pipe union on casing with twin seals 2  
Oil breather cap 1 SPL M40x1.75 x 10 40
Oil breather tank screw BHCS 2 FHH M6x1 x 10 6
Oil breather tank screw BHCS 1 FHH M6x1 x 16 6
Fastener count 634
           
LEGEND:
#1PFHS #1 Phillips flat head screw    
#1PSTS #1 Phillips self tapping screw    
#2PFHS #2 Phillips flat head screw
#2PPHS #2 Phillips pan head screw
BHCS Button head cap screw
FHH Flanged hex head screw
FLNUT Flanged locking nut (Nyloc)
FNUT Flanged nut
FW Flat washer
LHCS Low head cap screw
LNUT Lock nut prevailing torque
SHCS  Socket head cap screw
SS Slotted screw
SSS Socket set screw