Professional Documents
Culture Documents
Application Cam cover to cylinder head Secondary air injection valve covers to cam Cam chain tensioner to crankcase Cam chain tensioner centre bolt Camshaft bearing caps and camshaft bearing ladder to head Camshaft sprocket to camshaft Cam chain tensioner blade to crankcase Cam chain top pad to head Cylinder head to crankcase (M6 screws) Cylinder head to crankcase bolts Sound suppression bolt in head Airbox front bracket to cam cover Oil feed pipe union to head Application Clutch centre nut Clutch pressure plate to centre Clutch lever clamp bolt
Clutch
10.0 15.0 18.0 10.0 10.0 See Manual, section 3 10.0 10.0 25.0 Torque (Nm) 105.0 10.0 18.0
Torque (lb/ft) 7.4 6.6 6.6 16.9 7.4 11.0 13.2 7.4 7.4 7.4 7.4 18.4
Notes
Application Crankcase upper to lower (M8 fixings) Crankcase upper to lower (M6 fixings) Connecting rod big end nut Balancer retaining bolt
Big end bearings Sprag clutch to crankshaft Crankshaft position sensor to crankcase
Application Clutch cover to crankcase Clutch cover sound suppression plate to cover Sprocket cover to crankcase Water outlet cover Alternator cover to crankcase Crank cover to crankcase Starter cover to crank cover Plug, crank cover Rear brake disc fixings Rear brake pedal pivot bolt
Engine Covers
Notes Torque (Nm) Torque (lb/ft) See Manual, section 6 See Manual, section 6 See Manual, section 6 60.0 44.2 Apply Three-bond 1305 to the threads See Manual, section 6 54.0 39.7 10.0 7.4 Torque (Nm) 9.0 9.0 9.0 9.0 9.0 9.0 9.0 18.0 22.0 27.0 Notes Torque (lb/ft) 6.6 6.6 6.6 6.6 6.6 6.6 6.6 13.2 16.2 Always use new bolts 19.9
Notes
Application Output sprocket to output shaft Detent wheel to selector drum Detent arm bolt Selector drum bearing retaining screw Selector shaft retainer Spring abutment bolt Neutral switch Gearchange crank pinch bolt Gear pedal pivot bolt Sprag clutch to crankshaft Application Sump to crankcase Sump drain plug to sump Oil pressure relief valve to crankcase
Transmission
Notes Use new tab washer Encapsulated fixing Encapsulated fixing Encapsulated fixing Encapsulated fixing
Lubrication System
Low oil pressure warning light switch to crankcase Oil filter to adapter Oil filter adapter to crankcase Oil pump to crankcase Oil pump drive sprocket to pump shaft Oil feed pipe union to head Transmission oil feed pipes to crankcase Oil cooler pipe unions Oil cooler to bracket {lower fixing) Oil cooler to radiator
Notes Torque (lb/ft) 8.8 Use a new washer 18.4 11.0 Apply Three-bond 1305 to the threads 9.6 Use new washers 7.4 7.4 10.3 11.0 18.4 5.9 18.4 6.6 3.7 Encapsulated fixing Encapsulated fixing Use new washers Use new washers Use new washers
Application Rear sprocket to cush drive -ST model only Rear sprocket to cush drive -RS model only Chain rubbing strip to swing arm - ST model Cush drive housing to shaft -ST model only Application Water pump to crankcase Radiator to frame Water elbow to cylinder head Coolant drain plug in crankcase Cooling fan to radiator Radiator bleed screw
Final Drive
Cooling System
Torque (Nm) 33.0 55.0 4.5 146.0 Torque (Nm) 10.0 9.0 12.0 13.0 5.0 12.0
Notes Torque (lb/ft) 24.3 40.5 3.3 Use a new nut 107.5 Torque (lb/ft) 7.4 6.6 8.8 9.6 3.7 8.8 Notes
Torque (Nm) 8.0 5.0 3.0 5.0 6.0 4.0 5.0 12.0 2.0 19.0 15.0 30.0 22.0 15.0 5.0 40.0 6.0 6.0 5.0 10.0 3.0
Torque (lb/ft) 5.9 3.7 2.2 3.7 4.4 2.9 3.7 8.8 1.5 14.0 11.0 22.1 16.2 11.0 3.7 29.4 4.4 4.4 3.7 7.4 2.2
Wheels
Application Torque (Nm) Swinging arm spindle bolts 60.0 Swinging arm spindle adjuster 15.0 Swinging arm spindle adjuster locknut 30.0 Swinging arm rubbing strip bolts 4.5 Caliper carrier location peg 40.0 Rear hub/eccentric adjuster clamp bolt 55.0 Chain guard bolts 4.5 Rear wheel drive pin to axle 9.0 Rear suspension unit upper mounting bolt 48.0 Rear suspension unit lower mounting bolt/drop 48.0 to drag link pivot Drag link pivot at frame 48.0
Torque (lb/ft) 44.9 14.7 107.5 81.0 Torque (lb/ft) 44.2 11.0 22.1 3.3 29.4 40.5 3.3 6.6 35.3 35.3 35.3
Notes
Notes
Torque (Nm) 110 15.0 30.0 7.0 27.0 48.0 48.0 48.0 48.0 48.0
Torque (lb/ft) 81.0 11.0 22.1 5.2 19.9 35.3 35.3 35.3 35.3 35.3
Notes
Front Suspension
Application Torque (Nm) Front brake caliper to fork 40.0 Front brake pad retaining pin 20.0 Front brake caliper bleed screw 7.0 Front brake hose to caliper 25.0 Front brake master cylinder to handlebar 15.0 Front brake master cylinder reservoir to 12.0 handlebar Front brake hose to master cylinder 25.0 Front brake disc to wheel 22.0 Rear brake caliper to carrier 40.0 Rear brake pad retaining pin 20.0 Rear brake caliper bleed screw 7.0 Rear brake hose to caliper 25.0 Rear brake master cylinder to frame 27.0 Rear brake master cylinder reservoir to battery 7.0 box Rear brake hose to master cylinder 25.0 Rear brake disc fixings 22.0 Rear brake pedal pivot bolt 27.0
Brakes
Torque (Nm) 20.0 35.0 30.0 20.0 65.0 25.0 22.0 22.0
Torque (lb/ft) 14.7 25.8 22.1 14.7 47.8 18.4 16.2 16.2
Notes
Notes Torque (lb/ft) 29.4 14.7 5.2 Use new washers 18.4 11.0 8.8 Use new washers 18.4 16.2 29.4 14.7 5.2 18.4 19.9 5.2 18.4 16.2 19.9
Application Front mudguard to fork - front section Front mudguard to fork - rear section Rear side panels to brackets Rear side panels brackets to frame Seat cowl to seat Cockpit to brackets/side panels Mirrors to cockpit Windscreen to cockpit Cockpit subframe to frame Windscreen to cockpit Big end bearings Sprag clutch to crankshaft Crankshaft position sensor to crankcase Application Upper crankcase to frame Lower crankcase to frame Cylinder head to frame Engine mounting adjuster locknuts Control plate to frame Rear footrest hanger to frame Centre stand pivot bolts Side stand mounting bracket Side stand pivot bolt Rear brake pedal pivot bolt Bank angle indicators to front footrest Front footrest rubbers to footrest
Torque (Nm) Torque (lb/ft) 5.0 3.7 7.0 5.2 6.0 4.4 7.0 5.2 5.0 3.7 6.0 4.4 9.0 6.6 6.0 4.4 28.0 20.6 6.0 4.4 See Manual, section 6 54.0 39.7 10.0 7.4 Torque (lb/ft) 40.5 22.1 22.1 26.5 29.4 14.7 19.9 6.6 6.6
Torque (Nm) 5.0 7.0 3.0 27.0 3.0 5.0 7.0 5.0 5.0 9.0 28.0 6.0
Torque (lb/ft) 3.7 5.2 2.2 19.9 2.2 3.7 5.2 3.7 3.7 6.6 20.6 4.4
Notes
Notes
Notes
ST model only
Electrical
Torque(Nm) 5.0 4.0 2.0 2.0 105.0 12.0 7.0 10.0 3.0 9.0 6.0 18.0 4.0 10.0 18.0 5.0
Torque (lb/ft) 3.7 2.9 1.5 1.5 77.3 8.8 5.2 7.4 2.2 6.6 4.4 13.2 2.9 7.4 13.2 3.7
Notes