Torque settings

3 -	Torque settings

Frame torque settings


Part	Thread/pitch (mm)	Nm ±10% Tolerance	Note
Headlight fairing
Screw securing Plexiglas to headlight fairing	M4x0.7	0.2	Wellnut fixing
Screw securing headlight fairing bracket to headlight support Lower screws initial tightening Upper screws final tightening Lower screws final tightening	M6x1	1.5 8 8
Screw securing headlight fairing to bracket	M5x0.8	5
Rear-view mirror screw	M8x1.25	25
Side stand
Nut securing side stand rotation pivot screw	M10x1.25	20
Screw securing side stand bracket to crankcase	M10x1.5	36	LOCK 2
Stand sensor screw	M6x1	5	LOCK 2
Front sprocket
Front sprocket retaining screw	M25x1.5	186 *
Front sprocket cover screw	M6x1	6
Lights and reflectors
Screw securing headlight to support	M5x0.8	5	LOCK 2
Screw securing headlight support to bottom yoke	M6x1	10
Screw securing front turn indicator to headlight support	M5x0.8	3	LOCK 2
Screw securing headlight to support	M5x0.8	3
Instruments
Screw securing instrument panel to support		3
Instrument panel cover retaining screw	M4x0.7	1.5
Front Fork
Steering shaft nut	M35x1	30 *	GREASE B
Screw securing front brake hose guide to bottom yoke	M6x1	8	LOCK 2
Steering limit lock nut	M8x1.25	18	LOCK 2 (apply Loctite to nut thread only)
Screw securing steering head to pivot	M8x1.25	24 *	GREASE B
Bottom yoke to fork retaining screws (RH + LH)	M8x1.25	22 *	GREASE B In the sequence 1-2-1
Fork bottom end retaining screws (RH + LH)	M8x1.25	18 *	GREASE B In the sequence 1-2-1
Nut securing clamp to steering head	M10x1.25	45 *
Screws securing brake/clutch hose guide to steering head	M6x1	10	LOCK 2
Screw securing headlight support plate to steering head	M6x1	10	LOCK 2
Electric system
Screws securing coil to battery support	M5x0.8	5
RH/LH handlebar switch screw	M5x0.8	2.5
Screw securing battery lead to battery terminal	M6x1	10
Nut securing contactor cable to starter motor	M6x1	5	GREASE C
Nut securing battery leads/starter motor to contactor	M6x1	4
Speed sensor retaining screw (796)	M6x1	10
Nut securing battery support to airbox	M5x0.8	5
Screws securing ECU to airbox	M6x1	10
Screw securing earth cable to engine	M6x1	10
Screw securing relay support to battery support	M5x0.8	2
Screw securing battery support/airbox to frame	M6x1	10
Oil pressure sensor wiring clamp screw	M6x1	10	LOCK 2
ABS control unit to bracket retaining screw (796 ABS)	M6x1	8±2
ABS sensor retaining screw (front + rear) (796 ABS)	M6x1	7	LOCK 2
ABS control unit bracket to airbox retaining screw (796 ABS)	M6x1	10
ABS fuse bracket retaining screw (796 ABS)	M5x0.8	7
Front brake
Screw securing front brake master cylinder to handlebar	M6x1	10	Sequence 1 (UP)-2-1
Front/rear brake bleed valve	M10x1	23
Front brake calliper retaining screws (RH + LH)	M10x1.25	45 *	GREASE B
Front brake calliper initial tightening for bedding (RH + LH)	M10x1.25	2	GREASE B
Coupling to brake master cylinder retaining screw (796 ABS)	M10x1	23
ABS control unit to unions retaining screw (796 ABS)	M10x1	23
Brake calliper bleeder retainer (RH/LH) (796 ABS)	M6x1	4
Rear swingarm
Calliper mounting bracket peg fastener	M12x1.25	33 *	LOCK 8
Lower grommet/chain slider to swinging arm fastener	M5x0.8	5	LOCK 2
Swinging arm pivot fastener	M8x1.25	18 *	GREASE B
Chain tensioner eccentric fastener	M12x1.25	31 *	GREASE B in the sequence 1-2-1
Speed sensor wiring clamp fastener	M4x0.7	1	LOCK 2
Grommet and lower hose guide to swinging arm fastener (796 ABS)	M5x0.8	5
Upper chain slider fastener (796 ABS)	M5x0.8	5
Chain guard to chain slider fastener		1.2	Australia version only
Rear brake
Brake hose couplings to master cylinder/calliper fastener	M10x1	23
Screws securing rear brake fluid reservoir to subframe	M6x1	2
Rear brake calliper screw	M8x1.25	25 *	GREASE B
Rear brake master cylinder screw	M6x1	10	LOCK 2
Screw securing rear brake hose guide to swingarm	M5x0.8	5	LOCK 2
Hose guide on vertical cylinder head retaining screw (796 ABS)	M6x1	10
Hose guide on crankcase fastener (796 ABS)	M6x1
Hose guide on crankcase screw tightening (796 ABS)	AF 3.5	0.4
Number Plate Holder
Screw securing rear turn indicators to number plate holder	M5x0.8	3	LOCK 2
screw securing upper to lower number plate holder	M5x0.8	3.5
Tail light self-tapping screws		3
Bold/nut securing X plate to number plate holder	M6x1	5	LOCK 2
Reflector nut	M4x0.7	2
Number plate holder to protection fastener (Australia version only)	M6x1	5	LOCK 2
Handlebar clutch lever
Handlebar clamp screw	M8x1.25	25 *	GREASE B Sequence 1-2-3-4-3
Clutch bleed valve	M6x1	4
Clutch hose connector	M10x1	23
clutch transmission unit screw	M6x1	10	Sequence 1-2-3-1
Throttle twistgrip fixing screw	M6x1	6	Sequence 1 (UP)-2-1
Clutch master cylinder screw	M6x1	10	Sequence 1 (UP)-2-1
Throttle twistgrip housing screw	M4x0.7	1.8
Throttle control cable retainer screw	M10x1.25	4
Throttle control cable adjuster lock nut	M6x1	2.5
Rear suspension
Nut/screw securing shock absorber to mounting clevis	M10x1.25	42 *	GREASE B
Screw securing shock absorber to swing arm	M10x1.5	42 *	GREASE B
Front mudguard
Front mudguard retaining screw	M6x1	5	LOCK 2
Front pipe grommet to mudguard fixing screw	AF 3.5	0.35
Rear mudguard
Rear mudguard retaining screw	M5x0.8	5	LOCK 2
Rear mudguard to brake pipe grommet retaining screw (796 ABS)	M5x0.8	5	LOCK 2
Front wheel
Brake disc screw	M8x1.25	25 *	LOCK 2
Front wheel nut	M25x1.25	63 *	GREASE B
Rear wheel
Brake disc screw	M8x1.25	25 *	LOCK 2
Rear sprocket nut	M10x1.25	48	LOCK 2
Rear sprocket side wheel shaft retaining nut (LH)	M33x1.5	156 *	GREASE B
Rim side wheel shaft retaining nut (RH)	M38x1.5	176 *	GREASE B
screws securing driving pins	M6x1	11	LOCK 2
Phonic wheel retaining screw (796 ABS)	M5x0.8	5
Footrests and Levers
Screws securing front footrest brackets to swingarm pivot	M12x1.25	55 *	GREASE B
Brake side
Brake lever pivot screw on RH footrest bracket	M8x1.25	24	LOCK 2
Rear stop switch	M6x1	5
Brake master cylinder pushrod retaining nut	M6x1	7.5
Screw securing footrest bracket to engine (RH side)	M10x1.5	36
Brake lever adjuster lock nut	M6x1	2.3
Gearshift side
RH lock nut for gearchange linkage pivot	M6x1	5	LOCK 2
Screw securing footrest bracket to engine (LH side)	M10x1.5	36
LH lock nut for gearchange linkage pivot	M6x1	5	LOCK 2
Screw/nut securing gearchange linkage pivot to gearchange lever	M6x1	10
Screw securing gearchange lever to selector claw	M6x1	10	LOCK 1
Gearchange pedal pivot screw	M8x1.25	24	LOCK 2
Fuel tank
Screw securing fuel tank support brackets to fuel tank	M6x1	8
Screw securing fuel pipe guide to fuel tank	M5x0.8	5
Screw securing flange to fuel tank	M5x0.8	5	LOCK 2
Tank filler cap screw	M5x0.8	3
Special screw (twin male thread) securing flange to fuel tank	M5x0.8	5	LOCK 2
Flange cover retaining nut	M5x0.8	3
Screw securing fuel tank side covers and central cover to fuel filler cap	M5x0.8	2	LOCK 1
Screw securing front central clip cover to side covers	M5x0.8	2	LOCK 1
Screws securing tank side covers to fuel tank (lower side)	M5x0.8	2	LOCK 1
Screw securing cover to fuel tank (hidden)	M5x0.8	2	LOCK 1
Exhaust
Screw securing exhaust crosspiece to support under RH footrest	M6x1	5
Exhaust secondary to RH footrest bracket and to tank/exhaust support bracket (LH) retaining screw (796 ABS)	M6x1	5
(Horizontal/vertical) exhaust pipe clamp fastener	M8x1.25	11
Screws securing silencers to subframe	M6x1	10
Nut securing exhaust pipe flange to horizontal/ vertical cylinder head 1st nut initial tightening 2nd nut final tightening 1st nut final tightening	M8x1.25	6 24 24
1/8“ gas stainless steel plugs to exhaust pipes	M10x1.25	25
Rear screw securing heat shield to silencer	M6x1	10	LOCK 5
Screw securing silencer to silencer support on subframe	M8x 1.25	22
Lambda sensor fixing		45
Front screw securing heat shield to silencer	M6x1	8	LOCK 2
Screw securing heat shield to horizontal exhaust	M6x1	8	LOCK 2
Exhaust valve cover screw	M6x1	10
Exhaust secondary to tank/exhaust support bracket (RH) retaining screw (796 ABS)	M6x1	10
Seat
Seat retaining screw	M6x1	5
Frame
Nut securing subframe/frame to engine	M12x1.25	60 *	GREASE B
Screw securing subframe to frame	M12x1.25	60 *	GREASE B
Nut on free play adjuster screw	M25x1	100 *	GREASE B
Free play adjuster screw		0.6	GREASE B (on thread only)
Screw securing LH side fuel tank pin to frame	M6x1	10
Keyswitch cover cap nut	M6x1	7
Keyswitch screw	M6x1	Tighten down the screw until head fails – solid threadlocker
Screw securing horn bracket to frame	M6x1	10	LOCK 2
Screws securing fuel tank support plate to subframe	M6x1	10
Screws securing subframe joining plate	M8x1.25	22
screws securing subframe joining plate to rear tile assembly	M6x1	8
Screws securing exhaust support plate to fuel tank support plate	M6x1	5
Screw securing fuel tank to bracket on rear subframe	M8x1.25	10	LOCK 1
Seat lock nut	M22x1.5	3
Screw securing under seat storage compartment	M5x0.8	5
Screw securing latch to subframe joining bracket	M6x1	10
Screw securing wiring clips to RH rear subframe	M4x0.7	2
Nut securing shock absorber upper mounting clevis to subframe	M10x1.25	42 *	GREASE B
Exhaust valve actuator retaining screw	M6x1	10
Oil cooler
Radiator fixing screw	M6x1	10
Oil hose grommet retaining screw	M6x1	10
Oil cooler nipple to cooler fastener	M14x1.5	23	LOCK 1
Oil pipe union to cooler nipple fastener with O-ring (TWIN SEAL)	M16x1.5	18 *	Engine oil
Oil pipe union to casing nipple fastener with O-ring (TWIN SEAL)	M16x1.5	25 *	Engine oil
Thermistor fixing		10	LOCK 4
Air intake oil breather
Screws securing filter cover to airbox	M5x0.8	5
Air filter retaining nut	M6x1	6
Screws securing airbox to frame	M6x1	10
Clamp securing oil breather valve hose to blow-by valve		1.5
Clamp securing blow-by valve hose to airbox		1.5
screw securing coil to airbox	M5x0.8	5
Screw securing cable guide to LH side of crankcase	M6x1	10
Clamp securing hoses to airbox		1.1
Cable guide to LH side of crankcase fastener	M5x0.8	5
EVAP system canister filter
Screws securing temperature sensor to intake hose	M3x0.5	0.4	LOCK 9
Clamp securing hose to throttle body		1.5
Clamp securing throttle body to intake manifold		1.5
Stepper tube clamp tightening		10
Canister fixing to LH air cowling	M6x1	8	For USA version only.
Fairings
Lower screw fixing RH and LH deflector to frame	M5x0.8	5
Screw fixing RH and LH deflector to central air cowling	M5x0.8	5
Upper screw fixing RH and LH deflector to frame	M5x0.8	5
Screw securing voltage regulator to RH air cowling	M6x1	8
Generator cover retaining screw	M5x0.8	5

* dynamic safety-critical point; tightening torque must be within Nm ±5%.

Note

For product specifications and symbols, refer to “Product specifications” (Sect. 1 - 2).

Engine torque settings


Part	Thread/pitch (mm)	Nm	Min.	Max.	Note
Camshaft timing belt pulley nut	M15x1	71	64	78	GREASE A
Cylinder head nut: Snug torque Preload torque Tightening torque	M10x1.5	15 30 48	13 28 46	17 32 50	Apply GREASE C to the underside and the thread of the stud screw
Intake flange stud	M8x1.25	15	13	17	LOCK 2 or TB1324
Intake manifold nut	M8x1.25	23	20	26
Exhaust flange stud	M8x1.25	15	13	17	LOCK 2 or TB1324
Timing hole cover	M8x1.25	10	9	11
Vertical cylinder oil temperature sensor	M8x1.5	9	8.5	9.5
Cylinder head service screw (aluminium)	M6x1	3	2	3	LOCK 5
Intake/exhaust valve cover screws	M6x1	10	9	11
Valve cover screws	M6x1	10	9	11	LOCK 2
Timing belt cover screw	M6x1	10	9	11	LOCK 2 or TB1324
Timing belt cover screw	M6x1	10	9	11	LOCK 2 or TB1324
Pulley flange retaining screw	M6x1	10	9	11
Canister plug screw	M6x1	5	4	6
Pick-up filter housing plug	M32x1.5	42	38	46
Oil pick-up filter	M22x1.5	42	38	46
Canister nipple (USA version)	M6x1	5	4	6
MAP sensor coupling screw	M5x0.8	5	4	6
Oil cartridge nipple	M16x1.5	42	38	46	LOCK 2 or TB1324
Oil cartridge	M16x1.5	11	10	12	Engine oil on the gasket
Oil pump intake service hole plug	M15x1	25	22	28	LOCK 5
Oil cooler nipple	M14x1.5	32	29	35	LOCK 5
Oil drain plug with magnet	M12x1.5	20	18	22	TB1215
Blow-by hole service plug	M12x1	15	13	17	LOCK 5
Main oil way plug	M10x1.5	15	13	17	LOCK 5 or TB1375B
Clutch cover inner oilway screw	M10x1.5	15	13	17	LOCK 5
Cylinder barrel/head stud	M10x1.5	30	28	32	LOCK 2 or TB1324
Neutral warning light switch	M10x1.5	10	9	11
Taper blanking plug for service hole	M10x1	20	18	22	LOCK 5
Oil pump adapter screw	M10x1				LOCK 5
Crankcase screw Initial tightening Final tightening	M8x1.25	19 25	17 22	21 28	Apply GREASE B to thread
Gear stop lever screw	M8x1.25	18	16	20	LOCK 2 or TB1324
Crankcase screw	M6x1	10	9	11
Blow-by valve screw	M6x1	10	9	11
Radial pick-up screw	M6x1	10	9	11
Clutch side primary bearing retaining plate screw	M6x1	10	9	11	LOCK 2 or TB1324
Chain side secondary bearing plate retaining screw	M6x1	10	9	11	LOCK 2 or TB1324
Idler gear shaft retaining screw	M6x1	10	9	11	LOCK 2 or TB1324
Adler clutch oil calibration screw	M6	6	5	7
Starter motor mounting screw	M6x1	10	9	11	LOCK 2
Outer starter motor mounting screw	M6x1	10	9	11	LOCK 2
Flywheel nut	M24x1	270	256	284	LOCK 5
Primary drive gear nut	M22x1	190	171	209	GREASE B
Steel/aluminium crankshaft blanking cap	M20x1	15	13.5	16.5	LOCK 5
Connecting rod screw Tighten at 50 rpm 2 second pause, then back off through 360° at 30 rpm Tighten at 30 rpm Tighten at 10 rpm Tighten at 14 rpm Torque check	M10x1	35 20 35 65º ±1º 70÷103			Apply GREASE B to thread
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
Timing belt driveshaft pulley retaining nut	M15x1	71	64	78	GREASE A
Timing belt driveshaft gear nut	M14x1	55	50	60	GREASE A
Tensioner pulley retaining screw	M8x1.25	26	23	29
Idler pulley retaining screw	M8x1	20	18	22	LOCK 2 or TB1324
Plastic cover screw	M6x1	10	9	11
Wet clutch centre nut	M25x1.5	190	180	200	GREASE B
Oil filler plug	M20x2.5				FULLY HOME
Soundproofing gasket fixing screw	M14x1.5	24	22	26	LOCK 5
Pick-up sensor inspection screw	M12x1	15	13	17	LOCK 2 or TB1324
Oil way blanking plug	M10x1	20	18	22	LOCK 5
Oil pressure sensor	M10x1	19	17	21
Wet clutch cover screw	M6x1	10	9	11
Wet clutch spring screw	M6x1	10	9	11
Spark plug	M12x1.25	20	18	22
Generator cover screw	M6x1	13.5	12.5	14.5
Generator stator retaining screw	M6x1	10	9	11	LOCK 2 or TB1324
Alternator rotor/flywheel screw	M6x1	13	11	15	LOCK 5
Stator wiring clamp bracket screw	M5x0.8	5	4.5	5.5	LOCK 2 or TB1324
By-pass pump cap	M15x1	17	15	19	LOCK 5 or TB1375B
Oil pump retaining screw	M8x1.25	26	23	29
Oil pump retaining screw	M6x1	10	9	11
Oil pump assembly screw	M6x1	10	9	11
Special generator cover to stud screw retaining screw	M6x1	13.5	12.5	14.5
Timing inspection cover screw	M6x1	5	4.5	5.5

Note

For product specifications and symbols, refer to paragraph “Product specifications” (sect. 1 - 2).