Torque table for KZ550-C3 anyone?

Though I was able to find this in the Kawasaki factory service manual (downloaded from Lou's link's), I'm not sure if I'm looking at the correct one. Especially since the diameter for the steering stem bolt is shown as 16mm though I know it's close to 30mm (I measured). I also know that the front wheel axle is 19mm (I actually used a wrench on it) while the torque table in the doc says 14mm. The rear wheel axle bolt is listed at 16mm but it's close to 40mm. So I'm thoroughly confused at this time and need some guidance on where to fine the correct settings for my bike. It's a KZ550 1982 LTD. Thanks much in advance.

Keep in mind that the torque tables reference the diameter of the bolt - not the size of the wrench used to tighten the bolt. Ed

Yes, I understand and all the numbers I referenced above were for the diameters of various nuts and bolts.

Anyone have the torque table and the correct diameters of the various bolts/nuts of my KZ550-C3?

[my mistake edited to delete

I didn't even know that wrench size is not the same as the bolt size; assumed they would be the same. In fact, when I measured the diameter on the front axle nut, I thought I measured close to 20mm and not 14mm. I'm so confused.

My apologies 650ed!! Maybe I should stop trying pretending to be a mechanic.

So I can understand why the wrench size would have to be a bit larger than the bolt size for it to fit correctly. But is there some formula or something so I can easily figure out the required wrench size for a given bolt?

Don't give up on learning to be a mechanic; we have all gone through (and are still going through) the learning stage and have run into the same questions.

I am not aware of a chart or table that shows the relationship between the hex head and the diameter for bolts used on Kawasakis. While many bolts of a given diameter will have the same size hex head some will vary. It depends on the standard being used. For example, you can buy 10mm (diameter) bolts with a 14mm or 17mm hex head. Ed

On the 550's, generally speaking, a 6mm bolt will have a 10mm hex, an 8mm bolt will have a 12mm hex, and a 10mm bolt will have a 14mm hex.

However, the torques will vary based on the application. A bolt into a threaded hole will generally have a lower torque than a bolt fastened with a nut on the backside.

Also, obviously, a bolt threaded into aluminum will not be able to handle the torque of one threaded into steel.

If you download the "3rd party" manual from my link, there will be torque tables specific to the actual bolt being turned, as opposed to a "general rule" torque table. But I think the factory one should definitely have torques for specific bolts as well.

The area to really be careful is in the camshaft caps, valve cover, and clutch tension-plate bolts. Those all apparently have a way of stripping.

One thing that will go a long way to prevent stripping is to make sure there is no gunk (gasket sealer) in the threaded hole. Also make sure the hole is not full of oil. It's ok to have some oil in there, but not a puddle. Silicone sealant, and sometimes oil, will make the bolt feel like it can turn easily because they are lubed, but because they are not compressible materials, the bolt won't go in further, and thus strip the threads out.

I use an inspection light and a dental hook to get every crumb of sealant out, and use a tiny rag to wick the excess oil out of the holes.

Thanks a lot for making me understand this stuff in such great detail. I really appreciate it very much.

And yes, there is a torque table in the main service manual for every model of the KZ out there. But I'm also confused about with KZ model I should be referring thought. I believe I have a 82 KZ550-C3 LTD. However, when I look at the supplement for the 82 model, the carbs don't look anything like the one I have on my KZ. In fact, the carbs I have look like the one on the 1980 model. Is there a definite way to know which year of the vehicle I really have so that I use the correct torque numbers?

Lots of good info on kawasaki.com, including parts diagrams, part names, part numbers, models sharing same part, availability, etc. Here's a link for help with navigating the site and finding information.
Click > kzrider.com/index.php?option=com_kunena&...w&catid=13&id=376734

Could post a pic of the carbs at hand, for help in getting them identified.





Good Fortune!

... Is there a definite way to know which year of the vehicle I really have so that I use the correct torque numbers?

Try the VIN lookup in the diagrams at Kawasaki.com. Also, CycleChaos.com has frame number & engine number info for a number of Kawasaki models.

oops

Bunty27 wrote: ... But I'm also confused about with KZ model I should be referring thought. I believe I have a 82 KZ550-C3 LTD. However, when I look at the supplement for the 82 model, the carbs don't look anything like the one I have on my KZ. In fact, the carbs I have look like the one on the 1980 model. Is there a definite way to know which year of the vehicle I really have so that I use the correct torque numbers?

You have the 82 KZ550C3 if your carbs are the TK-22's. The supplement is for bikes with significant changes from the 1980 base models. Your bike is basically the same as the 1980 base C model, with some minor differences, maybe in the brakes, if I recall.

The supplement is mostly for '82 bikes using the TK-26 carbs. That would be the H (Gpz) model.

Later, there were shaft-drive LTD models, KZ550M (LTD) and KZ550F (LTD aka Spectre) that used the TK-26 carb as well. However, the shaft drive models are not included in the FSM's I have posted.

On a side note, the '83 KZ550A4 (standard) also switched over to the TK-26 carbs.

Basically the KZ550's come in two major engine configurations: the early one with rounded valve cover and engine castings, which uses the TK-22 slide carbs, and then there is the later one with squared off valve cover and engine castings, which use the TK-26 CV carbs, and is sometimes a shaft-drive output.

The KZ550 A (standard) model is the only model that had both types of engines depending on the year.