DS800X Rally
2025 - 2026
Torque specifications
Notes from the manual (2)
- Engine-only torque values from the KEL800 workshop manual. Bike-level chassis torques are provided separately in the LX800-2 chassis workshop manual.
- Multiple torque-to-yield procedures use 'starting torque + angle' - read the notes column carefully.
Cylinder Head & Cam
| Fastener | Thread | Qty | Torque |
|---|---|---|---|
| Spark plug M10 · Qty 2 | M10 | 2 | 17 N·m |
| Cylinder head cover bolt M6 · Qty 5 | M6 | 5 | 12 N·m |
| Cylinder head bolt (main) M9 · Qty 6 Torque-to-yield. Coat thread with oil. Sequence matters. | M9 | 6 | 5 N·m + 15 N·m + 90° + 90° |
| Cylinder head bolt (secondary) M6 · Qty 2 | M6 | 2 | 11 N·m |
| Camshaft bracket bolt M7 · Qty 12 Coat thread and seat with oil. Pre-tighten to 5 N·m in several passes, then 15 N·m in the numbered sequence 1 to 12 (engine manual PDF pages 12, 22 and 52). | M7 | 12 | 5 N·m, then 15 N·m |
| Camshaft sprocket bolt M6 · Qty 6 Sources differ: The timing chain procedure in the same manual (PDF page 53) gives 14 N·m. We cannot verify which is correct. | M6 | 6 | 15 N·m |
| Tensioner base end bolt M10 · Qty 1 Add seal ring. | M10 | 1 | 16 N·m |
| Tensioner base fixing screw M6 · Qty 2 Engine manual PDF pages 13 and 48. | M6 | 2 | 11 N·m |
| View hole cap M14 · Qty 1 | M14 | 1 | 7 N·m |
| Left decorative cover M32 · Qty 1 | M32 | 1 | 10 N·m |
Bottom End
| Fastener | Thread | Qty | Torque |
|---|---|---|---|
| Connecting rod bolt M9 · Qty 4 Torque-to-yield. Coat with oil. Engine manual PDF page 16. Sources differ: The crankshaft procedure in the same manual (PDF page 107) gives 5 N·m + 15 N·m + 90°. We cannot verify which is correct. | M9 | 4 | 10 N·m + 15 N·m + 90° |
| Magneto rotor bolt M12 · Qty 1 Coat thread with oil. | M12 | 1 | 135 N·m |
| Clutch central nut M22 · Qty 1 | M22 | 1 | 190 N·m |
| Front sprocket nut M22 · Qty 1 Engine manual PDF pages 16 and 24. Sources differ: The LX800-2 chassis workshop manual (PDF page 51) removes a mounting bolt for the driving sprocket and gives M10, 55 N·m. We cannot verify which is correct. | M22 | 1 | 127 N·m |
Lubrication
| Fastener | Thread | Qty | Torque |
|---|---|---|---|
| Oil drain seal plug M24 · Qty 1 22 N·m in the KEL800 engine workshop manual (PDF pages 14 and 23) and the LX800-2 chassis workshop manual (PDF page 11). 30 N·m in the DS800 owner’s manual (PDF page 99). We cannot verify which value is correct. | M24 | 1 | Uncertain: 22 / 30 N·m |
| Secondary oil filter M20 · Qty 1 The DS800 owner’s manual specifies 11 N·m on PDF page 101. The KEL800 engine workshop manual specifies 12 N·m on PDF pages 14 and 23, as does the chassis workshop manual on PDF page 11. We cannot verify which value is correct. | M20 | 1 | Uncertain: 11 / 12 N·m |
| Secondary filter joint M24 · Qty 1 27 N·m with Loctite 243 on the thread in the KEL800 engine workshop manual (PDF page 15). 28 N·m in the DS800 owner’s manual (PDF page 101). We cannot verify which value is correct. | M24 | 1 | Uncertain: 27 / 28 N·m |
Cooling
| Fastener | Thread | Qty | Torque |
|---|---|---|---|
| Coolant drain bolt M6 · Qty 1 11 N·m in the KEL800 engine workshop manual (PDF pages 12 and 27, where it is counted with the water pump cover bolts). 6 N·m in the LX800-2 chassis workshop manual (PDF page 32). We cannot verify which value is correct. | M6 | 1 | Uncertain: 11 / 6 N·m |
| Water pump cover bolt M6 · Qty 4 Engine manual PDF pages 12 and 29. | M6 | 4 | 11 N·m |
| Water pump impeller installation nut M6 · Qty 1 Engine manual PDF pages 12 and 29. | M6 | 1 | 12 N·m |
| Thermostat cover bolt M6 · Qty 2 10 N·m on PDF page 12 and 11 N·m on PDF pages 13 and 28 of the KEL800 engine workshop manual. We cannot verify which value is correct. | M6 | 2 | Uncertain: 10 / 11 N·m |
| Water and oil exchanger bolt M20 · Qty 1 Engine manual PDF pages 12 and 30. | M20 | 1 | 59 N·m |