Torque settings

3 -	Torque settings

Frame torque settings


Part	Thread (mm)	Nm tolerance ±10%	Note
Chain, front sprocket
Front sprocket retaining screw	M 5x0.8	6 *	LOCK 1
Front sprocket guard screw	M 6x1	6
Light units
Headlight retaining screw	M 8x1.25	12
Tail light nuts	M 6x1	6
Screw securing headlight holder to subframe on silent block		4
Number plate light nuts	M 5x0.8	2.5
Cat's eye mounting nut	M 4x0.7	2
Cable guide to headlight bracket screw	M 6x1	9
Turn indicators retaining screw	M 6x1	6
Headlight holder retaining screw	M 6x1	10
Headlight reflector retaining screw	M 4x0.7	2.3
Warning lights and indicators
Instrument panel silentblock fasteners		4
Screw retaining instrument panel to silentblock	M 5x0.8	5
Temperature/air pressure sensor retaining screw	M 5x0.8	3
Front fork
Steering head retaining screw, center position	M 8x1.25	23 *	GREASE B
Steering head retaining screws	M 8x1.25	24 *	GREASE B
Bottom yoke screw	M 8x1.25	20 *	GREASE B - sequence 1-2-1
Fork bottom end bolt	M 8x1.25	20 *	GREASE B - sequence 1-2-1
Steering lock nut	M 8x1.25	18	LOCK 2 (apply Loctite to nut thread only)
Steering bearings ring nut	M 35x1	30 *	GREASE B
Front fork splashguard retaining screw	M 5x0.8	5.5	LOCK 2
Electric system
Coil-to-frame retaining screw	M 5x0.8	1.5
Coil-to-airbox nut	M 5x0.8	3
LH and RH switch screw	M 5x0.8	2.1
Key cover blind nut	M 6x1	7
Key-operated switch bolt	M 6x1	**	** Shear bolt head LOCK 2
Battery cable screw	M 6x1	6
Starter motor nut	M 6x1	5
Nut securing cable to contactor	M 6x1	4
Speed sensor retaining screw	M 6x1	10
Screw retaining voltage regulator to oil breather tank and frame	M 6x1	6
Screw retaining regulator to oil breather tank	M 6x1	6
Screw retaining battery mount to silentblocks	M 6x1	6
Nut retaining battery mount to cylinder head	M 8x1.25	13
Control unit retaining screw	M 6x1	10
Screw retaining ground cable to engine	M 8x1.25	12
TPRT sensor retaining screws	M 4x0.7	2
Horn mount screw	M 8x1.25	15	LOCK 2
Warning horn retaining screw	M 8x1.25	25	LOCK 2
Immobilizer antenna			Assemble in production line, apply Lock 11 between Antenna and Switch cover
Nut securing temperature sensor support to subframe		5
Relay mount retaining screw	M 5x0.8	1
Front brake
Front brake caliper retaining screw	M 10x1.25	43 *	GREASE B
Front brake master cylinder retaining screw	M 6x1	10	sequence 1 (UP) -2-1
Front/rear brake bleed coupling	M 10x1	23
Brake lever pin	M 8x1.25	24	LOCK 2
Rear brake
Rear brake caliper retaining screw	M 8x1.25	24 *	GREASE B
Brake bleeding fitting	M 10x1	23
Rear brake master cylinder retaining screw	M 6x1	10
Screw retaining rear brake hose clip to swingarm	M 5x0.8	6
Rear brake fluid reservoir retaining screw	M 6x1	2
Rear swingarm
Chain adjuster safety screw	M 3x0.5	1.8
Chain adjuster screw	M 8x1.25	8	GREASE B
Swingarm shaft screw	M 10x1.5	43 *	GREASE C
Aluminium swingarm shaft retaining screw	M 8x1.25	18 *	GREASE C
Chain sliding shoe retaining screw	M 6x1	6	LOCK 1
Rear brake caliper plate retaining pin	M 8x1.25	25 *	LOCK 1
Handlebar
Handlebar clamp screw	M 8x1.25	20 *	GREASE B - sequence 1-2-1
Clutch master cylinder retaining screw	M 6x1	10	sequence 1 (UP) -2-1
Clutch hose fitting	M 10x1	23
Clutch bleed nipple	M 6x1	4
Clutch transmission unit screw	M 6x1	10
Throttle control securing screw	M 6x1	10
Throttle control cover securing screw	M 4x0.7	1.8
Counterweight retaining screw	M 6x1	9
Rear shock absorber
Rear shock absorber upper screw	M 10x1.25	42 *	GREASE B
Rear shock absorber lower screw	M 10x1.25	42 *	GREASE B
Suspension linkage upper screw	M 10x1.25	42 *	GREASE B
Suspension rocker arm to frame fixing screw	M 12x1.5	75 *	GREASE B
Ball joints to actuating rod nut	M 12x1.5	36
Front and rear mudguard
Front mudguard retaining screw	M 6x1	3	LOCK 2
Rear mudguard retaining screw	M 6x1	3	LOCK 2
Number plate holder protection screw	M 6x1	5.5
Splashguard to underseat retaining screw	M 6x1	1.8
Number plate holder to splashguard nut	M 6x1	1.9
Footpegs and Levers
Lever and gearbox pin	M 8x1.25	24	LOCK 2
Gear change lever fixing screw	M 6x1	10	LOCK 1
Actuating rod ball joints screw on gear change lever	M 6x1	10
Footpeg holders to engine retaining screws	M 10x1.5	36
Footpeg holders to frame retaining screws	M 8x1.25	24
Heat guard to footpeg holder retaining screw	M 6x1	3
Front and Rear wheel
Front wheel nut	M 25x1.25	63 *	GREASE B
Rear wheel shaft nut	M 25x1.25	83 *	GREASE B
Brake disc mounting screw	M 8x1.25	24 *	DRILOC 218 as OE at BREMBO, Lock 2 for spare parts
Rear chain sprocket nut	M 10x1.25	46 *	LOCK 2
Fuel Tank
Retaining screw of plastic fuel tank flange	M 6x1	10
Fuel hose clamp		1.5
Fuel filler plug fixing screw	M 5x0.8	6
Fuel tank hinge bracket retaining screw	M 6x1	10
Fuel tank pads retaining screw	M 6x1	10
Exhaust
Nut securing exhaust pipe clamp to silencers	M 10x1.25	42.4	Screwdriver max. number of revolutions 400rpm
Special screw securing exhaust manifolds to crankcase	M 12x1.5	25	LOCK 1
Exhaust pipe to casing retaining screw	M 6x1	9
1/8” gas stainless steel plugs fastener for exhaust pipes	M 10x1.25	25
Exhaust silencer to footpeg holder retaining screw	M 6x1	10
Exhaust pipe to head nut	M 8x1.25	24
Lambda sensor fastener	M 18x1.5	45
Seat
Seat lock ring nut	M 22x1.5	1	LOCK 3
Seat lock holder retaining screw	M 5x0.8	6
Seat cover holder retaining screw	M 5x0.8	3
Seat pulley screw	Self-tapping		LOCK 2
Screw retaining seat cover and tool box compartment cover to seat	M 6x1	2
Seat lock retaining screw	M 5x0.8	6
Oil inlet/breather
Airbox hose clip		2
Airbox stud to airbox fixing	M 6x1	6
Peg to airbox stud fixing	M 6x1	4
Oil breather valve hose clip	M 6x1	1.2
Oil breather tank hose clip		2
Oil breather tank to frame retaining screw	M 6x1	6
Fuel system, Canister
Throttle body mounting clip		2
Pressure regulator to throttle body retaining screw	M 6x1	5
Canister mount plate nut		8
Fairing
Side body panel retaining screw	M 5x0.8	0.8
Headlight fairing to bracket retaining screw	M 6x1	8
Side stand
Side stand plate retaining screw	M 10x1.5	36	LOCK 5
Side stand sensor wire retainer screw	M 6x1	10
Side stand pivot nut	M 8x1.25	24
Side stand sensor retaining screw	M 6x1	10
Frame
Engine to frame mounting bolt nut	M 12x1.5	60 *	GREASE B
Oil pipe fitting on casing	M 9/16"UNF"	19
Fitting for oil delivery pipe to heads	M 8x1.25	15

* critical point for dynamic safety. Tightening torque tolerance must be: ± 5% Nm.

Note

For product specifications and symbols, refer to "Product specifications" (A 2).

Engine torque settings


Part	Thread (mm)	Nm	Min.	Max.	Note
Blow-by valve	M 40x1.5	40	36	44
Mesh filter duct plug	M 32x1.5	42	38	46
Oil temperature sensor ring nut	M 30x1.5	38	34	42	LOCK 4
Wet clutch drum nut	M 25x1.5	190	180	200	GREASE B
Generator rotor nut	M 24x1	270	256	284	LOCK 5
Crankshaft gear fixing nut	M 22x1	190	171	209	GREASE B
Oil drain plug	M 22x1.5	42	38	46
Oil mesh filter	M 22x1.5	42	38	46
Oil filler plug	M 22x1.5	5	5	6
Steel/alum. crankshaft blanking plug	M 20x1	15	13.5	16.5	THREE BOND 1375B
Gearbox drum locating screw	M 16x1.5	30	27	33
Oil filter nipple	M 16x1.5	42	38	46	LOCK 2 or THREE BOND 1324
Oil cartridge filter	M 16x1.5	11	10	12	Engine oil on seal
Mesh filter duct plug	M 15x1	20	18	22	LOCK 5 or THREE BOND 1375B
By-pass pump plug	M 15x1	25	22	28	LOCK 5 or THREE BOND 1375B
Ring nut for belt rollers on lay shaft	M 15x1	71	64	78	GREASE A
Ring nuts for belt rollers on heads	M 15x1	71	64	78	GREASE A
Generator cover inspection plug	M 15x1	20	18	22	THREE BOND 1215
Nut for timing lay shaft gear	M 14x1	55	50	60	GREASE A
Radiator preset blanking plug	M 14x1.5	27	24	30	LOCK 5 or THREE BOND 1375B
Pick-up inspection screw	M 12x1	15	13	17	LOCK 2 or THREE BOND 1324
Earth screw	M 12x1	15	13	17	LOCK 2 or THREE BOND 1324
Oil temperature sensor	M 12x1.5	18	16	19	LOCK 4
Spark plugs	M 12x1.25	20	18	22
Head nuts: 1st snug torque 2nd snug torque final torque	M 10x1.5	15 25 40	23 38	27 42	Smear GREASE C on the underhead and thread of the stud bolt
Con-rod bolts: 1st tightening Stop for 2 sec. and loosen by 360° 1st snug torque 2nd snug torque Tightening Check angle: > 30°	M 10x1	35 20 35 70.5	66	73	Smear GREASE B on thread
Oil pump duct plug	M 10x1.5	Fully home with tool 15 13 17			LOCK 5 or THREE BOND 1375B
Head stud bolts	M 10x1.5	25	23	26	LOCK 2 or THREE BOND 1324
Pressure switch	M 10x1	19	17	21
Reduction bushing	M 10x1				LOCK 5 or THREE BOND 1375B
Spark plug	M 10x1	15	13	17
Neutral light switch	M 10x1.25	10	9	11
Clutch-side casing service plug	M 10x1.5	15	13	17	LOCK 5 or THREE BOND 1375B
Crankshaft dowels	M 8x1.25	13	11	15	THREE BOND 1375B
Gearbox pawl screw	M 8x1.25	25	22	28
Gear stopper screw	M 8x1.25	18	16	20	LOCK 2 or THREE BOND 1324
Intake and exhaust flange stud bolts	M 8x1.25	15	13	17	LOCK 2 or THREE BOND 1324
Intake manifold nuts	M 8x1.25	23	20	26
Oil pump screws	M 8x1.25	26	23	29
Casing jointing screws: 1st snug torque final torque	M 8x1.25	19 25	17 22	21 28
Casing drilled screw	M 8x1.25	20	18	22
Fixed tensioner	M 8x1	20	18	22	LOCK 2 or THREE BOND 1324
Mobile tensioner	M 8x1.25	26	23	29
Ground screw	M 8x1.5	13	11	15
Clutch spring screw	M 6x1	6	5	7
Stator cable guide screws	M 6x1	10	9	11	LOCK 2 or THREE BOND 1324
Starter motor screws	M 6x1	10	9	11	LOCK 2 or THREE BOND 1324
Starter idle gear pin screw	M 6x1	10	9	11	LOCK 2 or THREE BOND 1324
Generator stator retaining screws	M 6x1	10	9	11	LOCK 2 or THREE BOND 1324
Flywheel / rotor screws	M 6x1	13	11	15	LOCK 2 or THREE BOND 1324
Gearbox bearing stop plate screws	M 6x1	10	9	11	LOCK 2 or THREE BOND 1324
Head service screws (aluminium)	M 6x1	3	2	3	LOCK 5 or THREE BOND 1375B
Intake manifold fuel pump fitting	M 6x1	2.5	2	3	LOCK 2 or THREE BOND 1324
Bosch pick-up retaining screws	M 6x1	10	9	11
Nut securing fluid recovery tank bracket	M 6x1	9	8	10
Battery mount lower stud bolt	M 6x1	10	9	11	LOCK 2 or THREE BOND 1324
Gearbox pawl screw	M 6x1	9	8.5	9.5	LOCK 2 or THREE BOND 1324
Inspection cover screws	M 6x1	4.5	4.5	6
Rocker arm shaft cover screws	M 6x1	10	9	11
Intake / exhaust valve cover screws	M 6x1	10	9	11
Casing jointing screws	M 6x1	9	8.5	9.5
Clutch cover screws	M 6x1	9	8.5	9.5
Generator cover screws	M 6x1	10	9	11
Clutch spring screws	M 5x0.8	5	5	7
Driven belt roller flange retaining screws	M 5x0.8	5	5	7
Manifold nipple	M 5x0.8	3	2	3	LOCK 2 or THREE BOND 1324
Split belt roller flange retaining screws	M 5x0.8	5	5	7
Head cover plug	M 5x0.8	2.5	2.5	3
Screws	M 10x1.5	45	40	50
Screws	M 8x1.25	25	22	28
Screws	M 6x1	10	9	11
Screws	M 5x1	5	5	7

Note

For product specifications and symbols, refer to "Product specifications" (A 2).