Frame Tightening Torque Values

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Frame tightening torque values

PART Q.ty Thread Pitch 1409 1409 NOTES


S

Accessories and outfit

PASSENGER FOOTPEGS to rear subframe retainer 4 M8 22.0

REAR­VIEW MIRRORS to front subframe retainer 4 M5 6.0

Twin­seater SIDE BODY PANEL BRACKET to tail guard compartment


2 M5 8.0
retainer

Twin­seater SIDE BODY PANELS to side body panel bracket retainer 6 M4 3.0

Side stand assembly

MAGNET retainer for side stand sensor 1

Side stand PIN retainer 1 M6 8.0

Side stand PIVOT fastener 1 M8 25.0 GREASE B

HINGE PIN retainer for spring on stand 1 M6 5.0 LOCK 5

Chain­sprocket assembly

SPROCKET to shaft retainer 1 M10 55.0* GREASE B

COVER and METAL SHEET to engine block retainer 1 M6

METAL SHEET COVER and SLAVE CYLINDER to engine block retainer 1 M6

CHAIN SPLASH GUARD to silencer cover retainers 1 M5

Light assembly

SUBFRAME to frame retainer 4 M6 10.0 GREASE B

HEADLIGHT to subframe retainer 2 M5 5.0 GREASE B

HEADLIGHT to headlight fairing retainer 2 M5 5.0

RESONATOR to conveyor retainer 2 AF 0.5

RESONATOR to headlight retainer 2 AF 0.5

CONVEYOR to headlight retainer 2 AF 0.5

Rear TURN INDICATOR retainer 2 M5 3.0

TAIL LIGHT to tail guard compartment retainer 1 AF 3.0

Instrument panel assembly

SILENT BLOCK to instrument panel tightening 3 M5 1.0

SILENT­BLOCK to front subframe retainer 3 M5 3.0

Front fork assembly

SHAFT to bottom yoke tightening 1 40.0

Steering DOWEL to bottom yoke retainer 2 10.0 LOCK 2

Front wheel shaft CLAMP tightening 2+2 19.0* GREASE B

Front wheel shaft CLAMP tightening 1+1 19.0* GREASE B

FORK SLEEVES to bottom yoke tightening 6 8.0* GREASE B

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SPLASH GUARD to bottom yoke retainer 3 5.0

Steering RING NUT to pin tightening 1 35.0 GREASE D

Steering head CLAMPS on forks tightening 1 22.0 GREASE B

Steering head CLAMP on steering shaft tightening 2 22.0 GREASE B

Steering DAMPER to frame retainer 1 10.0 LOCK 1

Steering DAMPER EYELET to linkage tightening 1 10.0* LOCK 2

STEERING DAMPER to handlebar retainer 1 10.0 LOCK 1

Electric­electronic system assembly

Electric system LOWER SUPPORT to upper support retainer 9 1.0

BATTERY MOUNT to airbox retainer 4 3.0

Cable EYELETS to battery retainers 2

Cable EYELETS to solenoid starter retainers 2 M6 4.0

EYELETS to starter motor retainer 1 M5 3.0 GREASE D

Engine WIRING CABLEWAY to airbox bottom retainer 3 AF 1.0

Voltage REGULATOR to battery mount retainer 2 M5 5.0

Exhaust VALVE MOTOR to bracket retainer 3 M5 6.0

Exup CLOSING CABLE to silencer bracket tightening 1 M6 2.5

Exup OPENING CABLE to silencer bracket tightening 1 M6 2.5

BLACK BOX control unit to airbox retainer 1 M4 3.0

SMART EC control unit to airbox retainer 1 M4 3.0

Instrument panel/GPS cover PLUG to cover retainer 2 M4 1.5

IMU to bracket retainer 2 M6 4.0

SILENT BLOCK for IMU bracket to bracket retainer 3 M5 3.0

SILENT BLOCK for IMU bracket to subframe retainer 3 M5 3.0

STOP SWITCH to LH footpeg tightening 1 M8 1 5.0

Seat LOCK PLATE to subframe lower cover retainer 4 M5 4.0

Seat LOCK PLATE to subframe lower cover retainer 1 M22 1.5 3.0

Ignition switch to frame fastener 2 M6 10.0

Horn to bottom yoke retainer 1 M8 18.0 LOCK 2

STAND SWITCH to swingarm pivot support retainer 2 M4 3.0 LOCK 2

VIS actuator to bracket retainer 3 M5 6.0

SECONDARY AIR actuator to support retainer 2 M5 4.0

MAP SENSOR support to airbox retainer 2 M4 3.0

Front MAP SENSORS to airbox retainer 2 M4 3.0

AIR TEMPERATURE sensor to duct retainer 2 AF 1.0

SPEED sensor to fork axle lug retainer 1 M6 10.0

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SPEED sensor to calliper holder plate retainer 1 M6 10.0

LAMBDA SENSOR to front manifold tightening 1 M12 1.25 25.0 Pre­applied grease

LAMBDA SENSOR to rear manifold tightening 1 M12 1.25 25.0 Pre­applied grease

LH FAN to LH extractor retainer 3 AF 3.0

RH FAN to RH extractor retainer 3 AF 3.0

Front brake assembly

Rear swinging arm assembly

LH PIN SUPPORT to engine block retainer 2 M8 25.0 GREASE B

LH PIN SUPPORT clamp tightening 1 M8 20.0* GREASE B

RH PIN SUPPORT to engine block retainer 2 M8 25.0 GREASE B

RH PIN SUPPORT clamp tightening 1 M8 20.0* GREASE B

LH SWINGARM SHAFT to engine block tightening 1 M20 1.5 100* GREASE B

RH SWINGARM SHAFT to engine block tightening 1 M20 1.5 100* GREASE B

Footpeg holder plate PIN to swinging arm tightening 1 M12 1.25 33.0* LOCK 5

GREASE B
SWINGING ARM HUB tightening 2 M10 25.0*
(Seq.: 1­2­1)

CHAIN SLIDING SHOE to swinging arm retainer 4 M6 5.0

CHAIN TUNNEL to swinging arm retainer 2 M6 5.0

Rear brake assembly

REAR BRAKE CALLIPER to calliper holder plate retainer 2 M8 25.0* GREASE B

ABS brake system assembly

ABS CONTROL UNIT SUPPORT to engine block retainer 2 M6 10.0 Pre­applied threadlocker

FRONT BRAKE MASTER CYLINDER to handlebar tube retainer 2 M6 10.0 (Seq.: 1­(UP)­2­1)

FLUID RESERVOIR PLATE to master cylinder retainer 1 M6 10.0

FLUID RESERVOIR to plate retainer 1 M5 5.0 LOCK 1

BRAKE LINES to master cylinders retainer 2 M10 1 23.0

BRAKE LINES to control unit retainer 4 M10 1 23.0

BRAKE LINES to callipers retainer 3 M10 1 23.0

ABS CONTROL UNIT SEALS to support tightening 1 M6 6.8 LOCK 2

ABS CONTROL UNIT SEALS to support tightening 1 M6 6.8 LOCK 2

GREASE B
FRONT BRAKE CALLIPER to fork axle lug retainer 4 M10 1.25 45.0*
Pre­tightening 2Nm

REAR BRAKE MASTER CYLINDER to footpeg holder plate retainer 2 M6 8.0 LOCK 2

FLUID RESERVOIR to bracket on cover retainer 1 M6 2.0

BRAKE LINE BRACKET on front MUDGUARD retainer 1 M6 4.0

HOSE GUIDE BRACKET to clutch cover retainer 3 M5 6.0

FRONT BRAKE LINE to frame retainer 1 M5 5.0 LOCTITE 243

ABS HOSE GUIDE to swinging arm retainer 2 M5 5.0

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REAR BRAKE LINE to swinging arm retainer 1 M6 8.0

Number plate holder assembly

LOWER NUMBER PLATE HOLDER to upper number plate holder retainer 4 AF 5.0

NUMBER PLATE HOLDER PLATE to number plate holder retainer 2 M6 5.0

NUMBER PLATE HOLDER to rear subframe retainer 2 M5 6.0

CAT'S EYE to number plate holder retainer 2 M4 2.0

Handlebars ­ clutch control assembly

LH handlebar CLAMP tightening 1 M8 22.0 GREASE B

RH handlebar CLAMP tightening 1 M8 22.0 GREASE B

LH HANDLEBAR TUBE to clamp retainer 1 M16 1.5 15.0

RH HANDLEBAR TUBE to clamp retainer 1 M16 1.5 15.0

COUNTERWEIGHT to handlebar tube retainer 1+1 M6 8.0

CLUTCH MASTER CYLINDER to handlebar tube retainer 2 M6 10.0 (Seq.: 1­(UP)­2­1)

FLUID RESERVOIR PLATE to master cylinder retainer 1 M6 10.0

FLUID RESERVOIR to plate retainer 1 M5 5.0 LOCK 1

BRAKE LINES to master cylinders retainer 2 M10 1 23.0

BRAKE LINES to callipers retainer 3 M10 1 23.0

CLUTCH SLAVE CYLINDER to engine block retainer 1 M6 10.0

SLAVE CYLINDER AND METAL SHEET to engine block retainer 1 M6 10.0

Rear suspension assembly

GREASE B
UPPER HALF­SUPPORT to rear head retainer 2 M8 30.0*
(On thread only)

GREASE B
HALF­SUPPORTS to engine block retainer 2 M8 35.0*
(On thread only)

GREASE B
LOWER HALF­SUPPORT to engine block retainer 2 M8 35.0*
(On thread only)

GREASE B
ROCKER ARM to half­support retainer 1 M12 1.75 120.0*
(On thread only)

GREASE B
DAMPER to half­support upper retainer 1 M10 1.25 54.0*
(On thread and underhead)

GREASE B
DAMPER to rocker arm lower retainer 1 M10 1.25 54.0*
(On thread and underhead)

GREASE B
SUSPENSION LINKAGES to rocker arm retainer 1 M12 1.75 120.0*
(On thread only)

GREASE B
SUSPENSION LINKAGES to swinging arm retainer 1 M12 1.75 120.0*
(On thread only)

Front mudguard assembly

FRONT MUDGUARD to fork axle lug retainer 4 M6 8.0 Pre­applied threadlocker

Liquid cooling assembly

RAD DUCT to frame upper retainer 2 M5 6.0

EXPANSION RESERVOIR to rad duct retainer 3 M5 5.0

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CLAMP tightening on mixer pipe ­ all pipe 1 2.5

ALL SLEEVE SUPPORT BRACKET to frame retainer 1 M4 3.0

CLAMP tightening on all pipe ­ radiator 1 2.5

CLAMP tightening on radiator ­ mixer pipe 1 2.5

FRONT EXTRACTOR to rad duct upper retainer 2 M5 6.0

LH EXTRACTOR to front extractor retainer 4 AF 4.0

RH EXTRACTOR to front extractor retainer 4 AF 4.0

RH and LH EXTRACTORS to frame retainer 2 M5 6.0

RAD DUCT to air conveyor retainer 4 M5 6.0

Footpeg, lever and linkage assembly

LH FOOTPEG HOLDER PLATE to support retainer 2 M8 25.0* GREASE B

Gearchange transmission LEVER CLAMP tightening 1 M6 10.0

DQS to gearchange transmission rod tightening 1 M8 15.0 LOCK 1

DQS ROD to gearchange transmission lever retainer 1 M6 10.0 Pre­applied threadlocker

DQS ROD to gearchange lever retainer 1 M6 10.0 LOCK 1

GEARCHANGE LEVER pivot on LH footpeg holder plate 1 M8 25.0* GREASE D

HEEL GUARD to LH footpeg holder plate retainer 2 M5 6.0 LOCK 2

RH FOOTPEG HOLDER PLATE to support retainer 2 M8 25.0 GREASE B

GEARCHANGE LEVER pivot on LH footpeg holder plate 1 M8 25.0 GREASE D

Rear brake SPECIAL ADJUSTING SCREW tightening 1 M6 8.0

Rear BRAKE TRANSMISSION ROD NUT tightening 1 M6 7.5

Rear brake linkage FORK pivot to brake lever 1 M6 10.0 LOCK 2

HEEL GUARD to RH footpeg holder plate retainer 2 M5 6.0 LOCK 2

Rear mudguard assembly

REAR MUDGUARD to swinging arm retainer 5 M5 8.0 Pre­applied threadlocker

Front wheel assembly

VALVE to front wheel tightening 1 9.0 LOCK 2

FRONT BRAKE DISCS to front rim retainer 10 M8 30.0*

GREASE B
FRONT WHEEL SHAFT tightening 1 63.0*
(On thread and underhead)

Rear wheel assembly

Rear wheel eccentric assembly GREASE B

SILENT BLOCK to driving flange tightening 6 M10 44.0* LOCK 2

GREASE B
REAR WHEEL NUT on rear sprocket side tightening 1 M48 230.0*
(On thread and underhead)

Rear wheel DRIVING PIN tightening 4 M8 35.0* LOCK 2

PHONIC WHEEL to rear wheel shaft retainer 4 M5 8.0* Pre­applied threadlocker

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VALVE to rear wheel tightening 1 9.0 LOCK 2

GREASE B
REAR WHEEL NUT on rim side tightening 1 M48 230.0*
(On thread and underhead)

Tank assembly

FRONT BRACKETS to tank retainer 2 M6 6.0 LOCK 1

TANK to subframe FRONT retainer 2 M5 6.0

TANK to subframe REAR retainer 2 M5 6.0

DUAL LOCK to tank retainer 4 M4 3.0

Exhaust assembly

FRONT BANK guide surfaces on exhaust cross bar 2+2 GREASE B

GREASE B
FRONT PIPE SET to head retainer 1+1 M6 10.0
(On thread and underhead)

REAR PIPE SET to head retainer 3+3 M6 10.0

SILENCER to (LH) half­support retainer 1 M8 22.0

SILENCER to (RH) bracket retainer 1 M8 22.0

LH SILENCER COVER to silencer retainer 2 M5 5.0

RH SILENCER COVER to silencer retainer 2 M5 5.0

RH and LH SILENCER COVER to silencer retainer 2 M5 5.0

FRONT MANIFOLD HEAT GUARD to front bank retainer 3 M5 5.0

STARTER MOTOR HEAT GUARD to front heat guard retainer 1 M5 5.0

REAR MANIFOLD HEAT GUARD retainer 3 M5 5.0

PLASTIC HEAT GUARD to subframe retainer 4 M6 8.0 Pre­applied threadlocker

PLASTIC HEAT GUARD retainer 5 M5 5.0

METAL SHEET HEAT GUARD to central plastic heat guard retainer 2 M5 5.0

METAL SHEET HEAT GUARD to side plastic heat guard retainer 2 M5 5.0

GUIDE BRACKET to side plastic heat guard retainer 1 M6 8.0

WIRING COVER to central plastic heat guard retainer 2 M5 5.0

TIE BASE PLATE to plastic heat guard retainer 3 AF 2.0

Seat assembly

RIDER SEAT to tail guard compartment retainer 2 M5 5.0

Frame assembly

GREASE B
FRAME SUPPORT to rear head retainer 3 M8 24.0*
(On thread and underhead)

GREASE B
FRAME to engine retainer 4 M12 90.0*
(On thread and underhead)

EXTRACTOR SPECIAL SCREW to frame tightening 2 M5 5.0

EXTRACTOR SPECIAL SCREW to frame tightening 2 M5 5.0

LH SUBFRAME COVER to subframe retainer 2 M4 3.0

RH SUBFRAME COVER to subframe retainer 2 M4 3.0

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SUBFRAME to frame retainer 1+1 M8 31.0* Replace upon every


removal/refitting

Replace upon every


SUBFRAME to rear head retainer 1+1 M8 35.0*
removal/refitting

SUBFRAME JOINTING CROSS MEMBER to subframe retainer 2 M8 18.0

Rider SEAT SUPPORT BRACKET to subframe retainer 4 M6 8.0

TAIL GUARD COMPARTMENT to subframe FRONT retainer 2 M8 22.0*

TAIL GUARD COMPARTMENT to subframe REAR retainer 1 M8 22.0*

LATCH PLATE to tail guard compartment retainer 2 M5 5.0

Passenger STRAP to subframe retainer 2 M8 18.0

Oil cooler

OIL COOLER to rad duct retainer 2 M5 6.0

OIL HOSE to cooler tightening 2 M20 1.5 15.0

OIL HOSE GUIDE PLATE to sump retainer 2 M6 10.0 LOCTITE 1

Air intake­oil breathing assembly

UPPER AIRBOX to lower airbox retainer 2 M4 3.0

FRONT AIR DUCT to frame retainer 4 M5 6.0

REAR AIR DUCT to frame retainer 4 M5 6.0

CYCLONE SEPARATOR to frame retainer 1 M4 3.0

Fuel supply assembly

GAC to tank retainer 6 M5 5.0 GREASE B

INTAKE MANIFOLD to head retainer 8 M8 10.0*

THROTTLE BODY to intake manifolds retainer 16 M5 8.0 Pre­applied threadlocker

FIXED FUNNELS to throttle body retainer 8 M5 6.0 Pre­applied threadlocker

FUNNEL SLIDING STUD BOLT to throttle body tightening 4 M12 1.25 5.0 LOCK 5

LINKAGE SUPPORT to throttle body retainer 4 M5 8.0 LOCK 1

INJECTOR CAPS to intake manifold retainer 4 M4 3.0

FUEL DISTRIBUTOR to airbox bottom retainer 1 AF 1.0

INJECTOR CAPS to airbox cover retainer 4 M4 3.0

CANISTER BRACKET to engine block retainer 2 M6 10.0

Fairing assembly

HEADLIGHT FAIRING to subframe retainer 2 M5 5.0

PLEXIGLAS to headlight fairing retainer 6 M4 0.2

LH HALF­FAIRINGS retainer 3 M5 2.5

LH HALF­FAIRING to frame extractor retainer 1 M5 5.0

LH HALF­FAIRING to headlight fairing retainer 2 M5 2.5

RAD­DUCT to LH half­fairing retainer 1 M5 2.5

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LH HALF­FAIRING to footpeg support rear retainer 1 M5 6.0

RH HALF­FAIRINGS retainer 3 M5 2.5

RH HALF­FAIRING to frame extractor retainer 1 M5 5.0

RH HALF­FAIRING to headlight fairing retainer 2 M5 2.5

RAD­DUCT to RH half­fairing retainer 1 M5 2.5

RH HALF­FAIRING to footpeg support rear retainer 1 M5 6.0

FAIRINGS/DUCT to headlight fairing retainer 1 M5 2.5

LOWER HALF­FAIRINGS to rad­duct retainer 1 M5 5.0

LOWER HALF­FAIRINGS retainer 2 M5 2.5

TANK COVER to upper half­fairings retainer 2+2 M5 2.5

LH FRAME EXTRACTOR to radiator cowl retainer 1 M5 2.5

RH FRAME EXTRACTOR to radiator cowl retainer 1 M5 2.5

INSTRUMENT PANEL COVER to front subframe retainer 4 M5 3.0

SWITCH COVER to special screw retainer 2 M5 8.0

PANELS to instrument panel cover retainer 1+1 M5 2.5

PANELS to switch cover and upper half­fairings retainer 1+1 M5 2.5

SUBFRAME COVER to subframe retainer 2 M5 6.0

SUBFRAME COVER to tail guard compartment retainer 2 M5 2.5

TAIL GUARD to subframe cover retainer 4 M5 2.5

*dynamic safety­critical point; tightening torque tolerance must be Nm ±5%.

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