Clutch spring bolt torque spec
 

I think we may have an issue.

I have a 2009 service manual which says to torque the clutch spring bolts to 69 inch/pounds. I have twisted off two of the bolt heads at this setting. IDRIDR has a 2007 service manual which says to torque them to 29 inch pounds. Would you guys out there in KLX land mind checking your manuals (both 07 and 09) and post up what it says? This may save someone some hassle down the road. :o

ps,,,looking at Planet KLX the spec listed there is 29

29 in-lb in the KLX300 and old model KLX250 manual.

Ride on
Brewster

Thanks Brewster

Yes, that's the manual referenced above for "2007" but is really an earlier model manual that many of us '06 & '07 owners use all the time. Why such a big difference? Those bolt heads should not be breaking off!

my 09 manual says 69. typo ?

The micro fiche says they are 5mm by 35mm, are they possible different bolts? I don't think so.

were you useing ft/lbs instead? i have always just lockedtited(blue) them and ran them in to a snug feeling with a wrench, maybe you have some bad bolts because a clucth bolt shouldnt break at 6'/lbs

definitely 5.7 ft/lbs…(69 in/lbs)…. (.8kg/m)

my best guess it your wrench is off or the bolts were bad i've never snaped a clucth bolt even using a 3/8 air impact on them in the pits but i'd say get them out and order or get some higher grade replacments and do it like i posted before

The issue is that the 09 manual is telling you to torque the clutch spring bolts to more than twice that of the earlier manual. If you look in the general torque spec for a 5 mm bolt, it says 30 to 43 inch-pounds.
The wrench is new and it may still be off as well, but I doubt it. I will snug them by hand with loctite next time.

Sorry to here about your problem.
I checked the manual I used for my '09. It does say 69 in/lbs. That is what I used when I changed my springs to the Barnett ones while I did my BB351. I luckily did not snap any bolts off. They were pretty tight when I removed them and it did seem to be alot of torque when I was reinstalling them.
Seems odd that they would change it if nothing else changed in the clutch basket. It would be nice to know if this is a typo. Any way to contact Kawasaki to find the proper torque?
Good luck.