Been taking notes on a google sheet for a lot of hardware I am going to replace during my rebuild, I did find a site with a big list but cant find it anymore and figured at least one person would like a nut and bolt thread started on here.I am going to continue my list as I go on, I'll just throw in what's in a side cover bolt kit till I organize my list, if anyone want to add their own list for their bike that'd be cool.
1976 RD400 Bolt List| Size | Location | Quantity | Type | Notes |
| M6 x 1.0 x 25 | Clutch | 6 | Phillips SEMS Bolt | Clutch Bolts |
| | | | |
| Side Cover Bolts | | | | |
| M6 x 1.0 x 30 | Side Cover (Clutch) | 7 | M6 Allen Socket Head | |
| M6 x 1.0 x 40 | Side Cover (Clutch) | 2 | M6 Allen Socket Head (Partial Thread) | Dowel Pin Bolts |
| M6 x 1.0 x 45 | Side Cover (Oil Pump) | 3 | M6 Allen Socket Head (Partial Thread) | |
| | | | |
| M6 x 1.0 x 20 | Side Cover (Sprocket) | 3 | M6 Allen Socket Head | 2 Clutch Adjuster, 1 Top Center-Right Sprocket Cover |
| M6 x 1.0 x 25 | Side Cover (Sprocket) | 2 | M6 Allen Socket Head 1 Right, 1 Bottom | |
| M6 x 1.0 x 35 | Side Cover (Sprocket) | 1 | M6 Allen Socket Head (Partial Thread) | Top Center Bolt |
| M6 x 1.0 x 70 | Side Cover (Generator) | 3 | M6 Allen Socket Head (Partial Thread) | |
I have a list I did a while back for updated aftermarket hardware for a RD400 which is pretty detailed and even includes things like carb bowls, carb boots, generator, ignition points plates, reg/rectifier, seat hinges, etc. Not sure where it is now though.
A few comments on your list...
-I would recommend revising the location name from "Side Cover" to Crankcase Cover, Left or Engine Cover, Left and Clutch Cover. Side cover has a different meaning than what you are referring to.
-A few of your screw lengths don't look correct. For example, the oil pump cover is M6 x 45 and the left cover top center bolt is M6 x 35.
-Is your list for updated hardware or are you trying to create a list for correct OE-type replacement hardware for a restoration?
-You may want to also specify head shape in addition to type. (e.g., for updated hardware: Allen socket head, Phillips hex head, etc., or for OE type hardware: JIS pan head, flanged hex head, etc.)
fyi the part numbers will sometimes give the info you need. for example, on the engien covers, the number contains the size and length.
1st one: 06 = m6 040 = 40mm
etc. ;)
Quote from: SoCal250 on July 06, 2024, 12:03:52 PMA few of your screw lengths don't look correct. For example, the oil pump cover is M6 x 45 and the left cover top center bolt is M6 x 35
You'd be correct, I changed the oil pump cover screws to M6 x 50 because 45mm did not have enough threads to fully grab in my opinion and after measuring 50mm worked a lot better, just forgot to put this list back to standard sizes.
The list is more of just for sizes not really specific to factory types, of course really all that is different are the head types.
Quote from: m in sc on July 14, 2024, 12:14:13 PMfyi the part numbers will sometimes give the info you need. for example, on the engien covers, the number contains the size and length.
1st one: 06 = m6 040 = 40mm
etc. ;)
Interesting, did not catch that.
and.. the lengths are always measured from under whatever head it has. jis crosshead, hex, allen, a 50mm will have same shank/thread length regardless. just fyi. ( i have to deal with this for a living, not being snarky)
Do we have a similar list for the RD350, in Allen socket head type?
Quote from: m in sc on July 15, 2024, 11:40:33 AMand.. the lengths are always measured from under whatever head it has. jis crosshead, hex, allen, a 50mm will have same shank/thread length regardless. just fyi. ( i have to deal with this for a living, not being snarky)
Totally correct, EXCEPT FOR countersunk screws, as used on the RD neutral switch and that steel ring behind the clutch. On countersunk screws, the head is included in the nominal length. If the heads have a dome, the dome is not included, only the countersunk part of it.
technically, that's 'under' the head since the taper is part of the shank.
"They're angled under the head to sit flush within countersunk holes. Length is measured from the top of the head."
I know, you're right. but yes, its overall from the head to the end.