Side cover torque requirement? HELP!!!

CaseySmithersxs

XS650 Junkie
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I just changed oil and everything, Im wondering what the torque requirements are for the side cover, the oil filter on the side, and the sump filter, and also the oil drain plugs. Just kinda in a rush because im about to load up my bike to have some carb work done on it. THANKS!!!!!
 
You can look them up in your manual. If you don't use a torque wrench for these kind of things one trick is to choke up on the wrench so you have the least leverage, which will help keep you from overtightening.
 
I go 80 in/lbs on the M6 fasteners, no more. That's about 6 2/3 ft/lbs. The spec for M6 fasteners is usually 5 - 8 ft/lbs but these being 30+ year old machines, I don't recommend using the max.
 
And obviously the PO lost the washers for the bolts that holds the plate(thats the sump filter fits on) to the bottom of the motor, shouldnt just use some regular flat washers for this? Ive gotta get this thing to stop leaking. Im also going to get a different torqe wrench when i pit the bolts back on.
 
Haynes manual page 17 has the torque specs on the oil filter cover, 6.0-7.2 ft/lbs. Crank case drain plug, 25-29 ft/lbs. All the sump plate bolts are the same as the oil filter cover.
The stock bolts were designed to break off if over torqued to prevent stripping out the case. If some one has replaced them with nonstock bolts it is easy to strip out the case.
They can be rethreaded with inserts.
Leo
 
No, it will let the bolt heads gouge into the sump plate. If the bolts have started to pull the threads this leaves a raised ridge around the bolt holes in the case. These ridges prevent the sump plate from seating fully to the case. Feeling with a finger tip will tell you if there is a ridge.
There are several ways to remove the ridges. A sharp knife can trim the ridge off. A file or sandpaper with a backer block. I like to use a large drill bit. 3/8 inch or so. Just spin it by hand, it will remove the ridge and leave a very small countersink to the lip of the hole.
Leo
 
I had one sump bolt strip, then used a insert. when I put it back on, I stripped two more. slow drip. not worried.
 
^Well, there's no washers there...is there a gasket?

I use a torque wrench on my fork bolts and a few of the large nuts but that's it. With the variability of torque wrenches and the complex variability of the bike's threads and fasteners themselves it's a lot safer to do it by feel. Even if you're inexperienced. If you had been doing this without a torque wrench you might not have stripped that hole. But with the torque wrench you did.
 
Im a gear head, not just an experienced bike guy... Yea there is a gasket, I got it from mikesxs, but since i got the bike a few weeks ago there was never washers on those bolts. Im going to put washer on tomorrow and see if that helps. And idea for a temporary fix just for while its at my carb guys house?
 
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