Torque settings

Frame torque settings

Nm ±10%
Part Thread (mm) Note
Tolerance
Top fairing
Right rear-view mirror retaining screw M8x1.25 25
Left rear-view mirror retaining screw M8x1.25 25
Stand
Side stand plate retaining screw on shock absorber support M10x1.5 44
Stand sensor screw M6x1 5
Front sprocket
Front sprocket retaining nut M25x1.5 186* GREASE B
Sprocket cover retaining screw M6x1 6 LOCK 2
Lights and reflectors
Bracket support subframe retaining screw M5x0.8 6 LOCK 2
Headlight - subframes (upper and lower) retaining screw M5x0.8 6 LOCK 2
Lower subframe - bottom yoke retaining nut M6x1 10
Tail light - gloves compartment retaining screw M6x1 6
Front turn indicators - external conveyor retaining screw AF4.5 2
Instruments
Silent block on instrument panel supporting clip M5x0.8 2
Instrument panel to support retaining screw AF5 3
Instrument panel support to handlebar U-bolts retaining nut M5x0.8 2
Tank instrument panel to tank plug cover retaining screw M5x0.8 2
Front fork
Steering shaft nut M35x1 30* GREASE B
Steering head - fork leg closing screw M8x1.25 20* GREASE B
Steering head - central closing screw M8x1.25 24* GREASE B
GREASE B: Sequence
Steering head - upper closing screw M8x1.25 22*
1/2/2001
GREASE B: Sequence
Steering head - lower closing screw M8x1.25 12*
1/2/2001
Handlebar U-bolts closing screw M8x1.25 25*
Lower handlebar U-bolts to steering head retaining screw M10x1.25 45*
Supporting bracket - steering head retaining pin M6x1 10
LOCK 2 to nut thread
Steering limit adjusting counter nut M8x1.25 18
only
Clutch cable grommet to steering head retaining screw M6x1 10 LOCK 2
Brake cable grommet to steering head retaining screw M6x1 8 LOCK 2
Hose clip to bottom yoke retaining screw M6x1 10
Hose clip to left calliper retaining screw M6x1 10
Fork calliper closing screw 10*
Electrical/electric system
Electrical components support (rear) bracket to engine retaining screw M8x1.25 10
Electrical components supporting box to electrical components supporting (rear) bracket solid threadlocker on
M8x1.25 24
retaining screw screw
Electrical components support to radiator supporting bracket retaining screw M6x1 10
Radiator cover to electrical components support retaining screw M5x0.8 4
solid threadlocker on
Electrical components cover - electrical components support retaining screw M6x1 4
screw
Horn to battery support retaining screw M8x1.25 18
Voltage regulator to clip on electrical components support retaining screw M6x1 10
Hands free switch retaining screw M6x1 4 LOCK 2
Hands free switch retaining nut M6x1 4
Speed sensor retaining screw M6x1 10
Relay support retaining screw M5x0.8 5
Front brake
Screw securing front brake master cylinder to handlebar M6x1 10 Sequence 1-2-1
Front and rear brake bleed valve M6x1 23
Front brake calliper pre-tightening M10x1.25 2
Front brake calliper retaining screw M10x1.25 44* GREASE B
ABS control unit
ABS control unit to bracket retaining screw M6x1 10
ABS control unit bracket to airbox retaining screw M6x1 10
ABS pipe control unit fittings M10x1 23
Rear swingarm
GREASE B: Sequence 1-2-
Eccentric hub tightening screw M12x1.25 35 *
1
Swingarm shaft screw M15x1.25 72*
Rear brake calliper mounting bracket locking pin M12x1.25 33* LOCK 8
Lower and upper chain sliding shoes retaining screw M5x0.8 4
Rear brake
Rear brake master cylinder screw M6x1 10 LOCK 2
Brake bleeder M10x1 23
Rear brake fluid reservoir to support retaining screw M5x0.8 4
Brake oil reservoir to footrest bracket retaining screw M5x0.8 4
Rear pipe clip to swingarm retaining screw M6x1 10
Screw securing rear brake hose guide to swingarm M5x0.8 4 LOCK 2
Rear brake calliper screw M10x1.25 44* GREASE B
Number Plate Holder
Number plate holder to swingarm retaining screw M8x1.25 25
Number plate holder fixing screw M5x0.8 5
Handlebar - Clutch lever
Clutch bleed valve M6x1 4
Clutch hose connector M10x1 23
clutch transmission unit screw M6x1 10 Sequence 1-2-3-1
Throttle twistgrip retaining screw M6x1 6
“Sequence 1-2-1 starting
Clutch master cylinder screw M6x1 10
from upper screw“
Throttle twistgrip housing retaining screw M4x0.7 1.8
Throttle control cable retainer retaining screw tightening M10x1.25 4
Throttle control cable adjuster retainer counter nut M6x1 2.5
Rear suspension
Shock absorber support to left casing retaining screw pre-tightening M10x1.5 2
 After tightening of free
Shock absorber support to left casing retaining screw M10x1.5 45*
play adjuster ring nuts
Nut on free play adjuster screw M20x1 100*
Shock absorber support to right casing retaining screw M10x1.5 45*
Shock absorber support to suspension linkage retaining screw M10x1.5 45*
Suspension linkage to rocker arm retaining screw M12x1.5 45*
Shock absorber to rocker arm retaining screw M10x1.25 45*
Rocker arm to swingarm retaining screw M10x1.25 45*
Front mudguard
solid threadlocker on
Mudguard to fork calliper retaining screw M6x1 5
screw
Front brake pipe clip on mudguard retaining screw AF3.5 0.35
Fluid cooling
Fan to fan support retaining screw M4x0.7 1
Internal conveyor and fan support to radiator upper retaining screw M5x0.8 5
Fan support to radiator lower retaining screw M5x0.8 5
Internal conveyor - radiator - external conveyor retaining screw M5x0.8 5
LH internal conveyor to RH internal conveyor retaining screw M5x0.8 4
Air conveyor and radiator to bracket retaining screw M6x1 10
Radiator support to chassis retaining screw M6x1 10
Radiator support to frame retaining screw M6x1 10
External conveyor to radiator lower retaining screw M5x0.8 5
Radiator to external conveyor support retaining screw M5x0.8 5
Separated union retaining screw M5x0.8 5
Expansion reservoir on bracket retaining screw M6x1 8
Expansion reservoir on drift retaining screw M6x1 8
Water pipe on radiator unions clamps 2.5
Water pipe to pump intake clamp 2.5
Water pipe on thermostat outlet clamp 2.5
Vertical and horizontal head inlet water pipe clamp 2.5
Clamp of expansion tank bleed pipe on plug 1
Clamp on bleeder fitting 1
Clamp on vertical head breather pipe 1
Clamp on expansion tank “overflow“ pipe 1
Footrest and linkage
Rider footrest bracket to subframe retaining screw (left - right) M8x1.25 25
Rear footrest retaining threaded pin M16x1.5 30
Passenger footpeg spring plate to subframe retaining screw M6x1 10
Right side (rear brake)
Brake lever pin on footrest bracket M8x1 24 LOCK 2
Stop switch on footrest bracket M8x1 10
Stop switch on brake lever drive screw M6x1 5
Brake lever adjuster lock nut M6x1 8
Brake master cylinder pushrod retaining nut M6x1 7.5
Left side (gearbox)
Gearbox lever pin on footrest bracket M8x1 24 LOCK 2
Gearchange linkage pivot to gearchange lever / transmission lever retaining screw M6x1 10
Gearbox transmission lever on pawl closing screw M6x1 10
RH lock nut for gearchange linkage pivot M6x1 5 LOCK 2
LH lock nut for gearchange linkage pivot M6x1 5 LOCK 2
Rear mudguard
Solid threadlocker on
Rear mudguard to swingarm retaining screws M5x0.8 5
screw
Front wheel
Brake disc screw M8x1.25 25* LOCK 2
Front wheel nut M25x1.25 63* GREASE B
Rear wheel
GREASE B (apply to the
Wheel retaining nut (left and right) 48x1.5 230* thread and the nut
underside)
Rear wheel cush drive bush retaining nut M10x1 44 LOCK 2
solid threadlocker on
Phonic wheel to disc fixing screw M5x0.8 6
screw
Brake disc to pin fixing screw M8x1 27*
Fuel tank
Tank to frame retaining screw M6x1 10
Solid threadlocker on
Bitron flange to tank retaining screw M5x0.8 6
screw
Hose clip retaining screw M5x0.8 5
Tank filler cap screw M5x0.8 3
Exhaust
Nut securing exhaust pipe flange to horizontal/ vertical cylinder head M6x1 10
Heat guard to vertical manifold retaining nut M6x1 10
Vertical main heat guard retaining screw M6x1 8
Lambda sensor fixing M12x1.25 25
Exhaust gas plug M10x1.25 25
Starter motor valve to support fixing screw AF5 3
Exhaust valve motor support to RH subframe retaining screw M6x1 10
Silencer to bracket retaining screw M8x1.25 20
Silencer retaining clamp 16
Silencers support to footrest bracket retaining screw M8x1.25 25
Silencer to heat guard retaining screw M6x1 8
Seat
Seat cover retaining screw M5x0.8 4
Frame
GREASE B (apply to the
Frame-engine retaining nut M12x1.25 60* thread and the nut
underside)
GREASE B only on thread
Clearance adjuster M20x1 0.6 - do not grease the union
surface
Nut on free play adjuster screw M20x1 100* GREASE B
Tank bearing drift on compartment retaining screw M6x1 10
Gloves compartment - handle guide retaining screw M8x1.25 20*
Handle guide - latch retaining screw M6x1 10
Handle releasing ring nut on pin M5x1 5
Seat lock nut M22x1.5 3
Subframes - gloves compartment retaining screws M8x1.25 14*
Frame - subframes retaining screw M10x1.5 55* GREASE B
Blackbox support silent block on LH subframe M5x0.8 2
Blackbox support to LH subframe retaining nuts M5x0.8 2
Blbox cover and blbox on support retaining screws AF5 3
GAC cover to subframe/compartment retaining screw M5x0.8 4
Underseat compartment cover to compartment retaining screw M5x0.8 4
Hands free antenna to compartment retaining screw M4x0.7 2
Oil cooler
Fixing union to radiator (nipple) M14x1.5 23 LOCK 1
Fixing tube to radiator coupling M16x1.5 18* Lubricate with engine oil
Fixing tube to radiator coupling M16x1.5 18* Lubricate with engine oil
Oil hose clamp to horizontal head retaining screw M6x1 10
Radiator bracket to horizontal head retaining screw M6x1 10
Radiator to bracket retaining screw M6x1 6
Pressure switch on oil cooler retainer 24
Air intake oil breather
Wiring protection on airbox lower half-housing M5x0.8 5
Oval intake funnel on airbox lower half-housing retaining screw M5x0.8 5
Conveyors to airbox retaining screw M5x0.8 3.5
Map sensor bracket to airbox upper half housing retaining screw M6x1 10
Air temperature sensor to LH conveyor retaining screw M4x0.7 2
Map sensor on bracket retaining screw M6x1 10
Blow-by pipe to airbox retaining clamp 1.5
Fuel system
solid threadlocker on
Throttle body on intake funnels retaining screw M5x0.8 3.5
screw
Intake ducts throttle body retaining clamp 2.5
Injectors to funnels retainer M5x0.8 5
Canister to fuel tank (USA version) retainer M5x1 4
Fairings
Plug cover to cover retaining screw M5x0.8 2 LOCK 1
Plug cover and central cover to plug retaining screw M5x0.8 2 LOCK 1
Central cover to tank retaining screw M5x0.8 2 LOCK 1
Side cover to tank rear retaining screw M5x0.8 2 LOCK 1
Central cover to plug cover retaining screw M5x0.8 0.33
Central cover to side cover retaining screw M5x0.8 0.33
solid threadlocker on
Clip air inlets on tank plug cover retaining screw M5x0.8 2
screw
LH conveyor / LH conveyor support retaining screw M4x0.7 1.5
LH conveyor support to tank side cover retaining screw M5x0.8 0.33
LH conveyor cover to LH conveyor support retaining screw M5x0.8 5
solid threadlocker on
Central to lateral belly fairings retaining screw M5x0.8 4
screw
LH belly fairing / radiator closure / central belly fairing retaining screw M5x0.8 4 LOCK 1
RH belly fairing / radiator closure / central belly fairing retaining screw M5x0.8 4 LOCK 1
LH belly fairing to electrical components retaining screw M5x0.8 4 LOCK 1
RH belly fairing to electrical components retaining screw M5x0.8 4 LOCK 1
LH belly fairing / electrical components cover / electrical components support retaining
M5x0.8 4 LOCK 1
screw
RH belly fairing / electrical components cover / exhaust protection retaining screw M5x0.8 4 LOCK 1
*dynamic safety-critical point; tightening torque must be within Nm ±5%.

Engine torque settings

Part Thread (mm) Nm Min. Max. Note

Idler and tensioner pulley bolts M20x1 50 45 55 LOCK 2 or TB1324
Camshaft pulley retaining nut M17x1 71 64 78 GREASE A
Rocker arm shaft covers M12x1.25 15 14 16 LOCK 2 or TB1324
LOCK 4 – Restrain the insert when
Coolant temperature sensor on coolant outlet union M12x1.5 23 20 26
tightening
Cylinder head nut:
Snug torque 20 Apply GREASE C to the underside of the
M10x1.5
Preload torque 40 38 42 nut and the thread of the stud
Tightening torque 60 57 63
Cam cap screw:
Preload torque M8x1.25 10 9 11 Engine oil
Tightening torque 22.5 21 25
Coil retaining screw M6x1 10 9 11
Pulley flange retaining screws M6x1 10 9 11
Cylinder head cover screw M6x1 10 9 11
Exhaust manifold stud M6x1 10 9 11 LOCK 5
Vacuum gauge connection screw on cylinder head (EU only) M6x1 5 4 6 LOCK 2 or TB1324
Evaporative emissions canister fitting on cylinder head (California only) M6x1 5 4 6 LOCK 2 or TB1324
Air breather fitting on horizontal cylinder head M6x1 2.5 2 3 LOCK 2
Air breather blanking screw on vertical cylinder head M6x1 10 9 11 LOCK 6
Intake manifold screw M6x1 10 9 11
Water temperature sensor M6x1 6 5 7
Screw securing coolant unions to cylinder head M5x1 6 5 7 Pre-applied Tecnologic 150 threadlocker
Oil cartridge M16x1.5 11 10 12 Engine oil on gasket
Oil cartridge nipple M16x1.5 42 38 46 LOCK 2 or TB1324
Oil pick-up pipe plug M14x1.5 24 21 27 LOCK 5
Oil cooler nipple M14x1.5 32 29 35 LOCK 5
Oil drain plug with magnet M12x1.5 20 18 22 THREEBOND TB1215
Gear sensor recognition M12x1.25 12 11 13
Clutch cover oilway blanking plug M10x1.5 15 13 17 LOCK 5
Neutral sensor M10x1.25 10 9 11
Oil pump adapter screw M10x1 LOCK 5
Clutch cover inner oilway screw M10x1.5 15 13 17 LOCK 5
Cylinder head/barrel stud M10x1.5 30 28 32 LOCK 2 or TB1324
Vertical cylinder zone crankcase screw:
Preload torque M8x1.25 19 17 21 GREASE B or Agip GR SM on thread
Tightening torque 25 22 28
Central crankcase screw + swingarm pivot bolt:
Preload torque M8x1.25 19 17 21 GREASE B or Agip GR SM on thread
Tightening torque 25 22 28
Gear stop lever screw M8x1.25 18 16 20 LOCK 2 or TB1324
Blow-by valve fixing screw M6x1 10 9 11
Chain side secondary bearing retaining screw M6x1 10 9 11 LOCK 2 or TB1324
Clutch side primary bearing retaining screw M6x1 10 9 11 LOCK 2 or TB1324
Crankcase screw – idler area M6x1 10 9 11
Outer crankcase screw M6x1 10 9 11
Oil pick-up mesh filter screws M6x1 10 9 11 TB1215
Chain cover oil circuit blanking screw M6x1 8 7 9 LOCK 2 or TB1324
Under-piston oil jet retaining screw M5x0.8 8 7 9 LOCK 2 or TB1324
Starter motor mounting screw M6x1 10 9 11 Loctite 516 pre-applied to thread
Starter motor rear screw M6x1 10 9 11 Loctite 516 pre-applied to thread
Idler gear shaft retaining screw M6x1 10 9 11 LOCK 2 or TB1324
Primary sprocket nut retainer M24x1 190 171 209 GREASE B
Ring nut fastening wet clutch primary pinion M24x1 190 171 209 GREASE B
Flywheel retaining nut M24x1 330 313 346 LOCK 5
Balancing cap M12x1.25 28 26 30 LOCK 5
Con-rod bolts:
Tightening of 45°±1° M10x1 30 Apply GREASE B to thread
Torque check 65 to 95
Crankshaft grub screw M8x1.25 13 11 15 LOCK 5
Drilled crankshaft grub screw M8x1.25 13 11 15 LOCK 5
Selector drum locating screw M16x1.5 30 27 33
Selector claw screw M8x1.25 36 34 38 LOCK 2 or TB1324
Selector claw locator nut M6x1 10 9 11
Selector claw screw M6x1 16 15 17 LOCK 2 or TB1324
Idler and tensioner pulley bolts M20x1 50 45 55 LOCK 2 or TB1324
Timing belt driveshaft pulley retaining nut M15x1 71 64 78 GREASE A
Timing belt driveshaft gear nut M14x1 55 50 60 GREASE A
Fixed tensioner bearing locking screw M14X2 50 45 50 GREASE A
Idler and tensioner pulley nut M8x1.25 25 22 28 GREASE A
Carbon fibre cover screw M6x1 6 5.5 6.5 Loctite 516 pre-applied to thread
Plastic cover screw M6x1 10 9 11 Loctite 516 pre-applied to thread
Carbon filter cover support fixing screw M4x0.7 1.75 1.5 2
Self-tapping screw for timing belt cover filter M3.5
Coolant inlet union M30x1.5 25 23 27 LOCK 5
Coolant outlet union M22x1.5 25 23 27 LOCK 5
Oil filler plug M20x2.5 Tighten as far as it will go
Generator cover inspection plug M15x1 20 18 22 TB1215
Pick-up sensor inspection screw M12x1 15 13 17 LOCK 2 or TB1324
Water pump cover plug M10x1 20 18 22
Oil pressure sensor M10x1 19 17 21
Clutch oil pan cap M10x1 15 13.5 16.5
Oil way blanking plug M10x1 20 18 22 LOCK 5
Coolant pump bearing stop screw M6x1 10 9 11 LOCK 2 or TB1324
Stator wiring clamp bracket screw M6x1 10 9 11 LOCK 2 or TB1324
Water pump cover screw M6x1 10 9 11
Generator-side crankcase cover screw M6x1 10 9 11
Generator cover to idle gear screw M6x1 10 9 11
Generator-side crankcase cover + water pump screw M6x1 10 9 11
Inspection cover screw M6x1 5 4.5 5.5
Generator-side crankcase cover screw M6x1 10 9 11
Alternator stator retaining screw M6x1 10 9 1 LOCK 2 or TB1324
Clutch cover screw M6x1 10 9 11
Clutch cover screw M6x1 10 9 11
Wet clutch cover closing screw M6x1 10 9 11
Wet clutch cover closing screw M6x1 10 9 11
Wet clutch cover closing screw M6x1 10 9 11
Wet clutch drum nut M25x1.5 190 180 200 GREASE B
Wet clutch spring screw M6x1 10 9 11
Spark plug M10x1 12 11 13
Alternator rotor/flywheel screw M6x1 13 11 15 LOCK 5
By-pass pump cap M15x1 25 22 28 LOCK 5
Oil pump retaining screw M6x1 10 9 11
Oil pump assembly screw M6x1 10 9 11
Oil pump retaining screw M8x1.25 26 23 29
Coolant outlet union M22x1.5 25 23 27 LOCK 5
Coolant circuit hose clamps 2.5 2 3
*dynamic safety-critical point; tightening torque must be within Nm ±5%.