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Engine
Fastening of engine to frame
Description Qty Screw/ Nut
Nm
ft-lb Note
Front connection 2+2 M10 40 29.5
Left-side upper and lower rear connection 2 M10 50 36.8
Adjusting bush right-side upper and lower rear connection 2 M20x1.5 12 8.8
Lock ring right-side upper and lower rear connection 2 M20x1.5 50 36.8
Screw right-side upper and lower rear connection 2 M10 50 36.8
Elements fastened to the engine
Description Qty Screw/ Nut Nm ft-lb Note
Engine oil inlet flange 2 M6 12 8.8
Engine oil drain plug 2 M6 12 8.8
Rear brake lever mount fastening 1 M6 10 7.4
Rear brake lever mount fastening 1 M8 17 12.5
Rear brake pump mount fastening 2 M8 17 12.5
Pinion fastening 1 M10 50 36.8
Clutch control cylinder fastening 3 M6 12 8.8
Pinion case fastening 3 M6 6 4.4
Fastening of fuel delivery pipe to throttle body 1 M12x1.5 22 16.2
Coolant drain screw 1 M6 10 7.4
Coolant thermistors 2 M14 30 22.1
Driving shaft, countershaft, gearshift
Description Qty Screw/ Nut Nm ft-lb Note
Positioning lever / positioning disc 2 Screw T.C.E.I. M6 x 20 11 8.1 L243
Differential shaft under KS 1 Nut M22 x 1.5 150 110.5
KS driving shaft 1 Nut M33 x 1.5 230 169.5 L243
Countershaft under MS 1 Screw T.C.E.I. M10 x 20 50 36.8 L648
Oil Pump
Description Qty Screw/ Nut Nm ft-lb Note
Oil pump 1 M12 x 1.5 L648
Oil pump casing 1 L574
Oil pump lid 4 Screw T.C.E.I. M6 x 45 11 8.1
Clutch
Description Qty Screw/ Nut Nm ft-lb Note
Secondary KS shaft 1 Nut M24 x 1.5 170 125.3 L648
Clutch spring 6 Screw T.E. M6 x 25 11 8.1
Disengagement rod 1 Locking nut M12 30 22.1
Complete diaphragm ring 8 Screw T.C.E.I. M5 x 20 5 3.7
Clutch gear / clutch housing 3 Screw T.E. M8 x 16 30 22.1 L648
Head, cylinders
Description Qty Screw/ Nut Nm ft-lb Note
Camshaft support / head "1" (front) 8 Screw T.C.E.I. M6 x 30 11 8.1
Head "1" (front) 2 Exhaust pipe M18 x 1.5 manual tightening L243
Head "2" (rear) 1 Exhaust pipe M18 x 1.5 manual tightening L243
Camshaft support / head "2" (rear) 4 Screw T.C.E.I. M6 x 30 11 8.1
Camshaft support / head "2" (rear) 2 Screw T.C.E.I. M6 x 45 11 8.1
Camshaft support / head "2" (rear) 2 Screw T.C.E.I. M6 x 55 11 8.1
Head "2" (rear) 1 Plug screw M18 x 1.5 manual tightening L243
Head / exhaust 6 Stud bolt M8 x 16/20 10 7.4 L648
Head "2" (rear) 1 Angular union L574
Head / case 8 Stud bolt M10 x 171 10 7.4 L243
Cylinder / head non varnished cylinder version 8 M8 x 45 28-30 20.6-22.1
Cylinder / head varnished cylinder version 8 M8 x 45 25-28 18.4-20.6
Head / stud bolt not varnished head version 8 Nut M10 58 42.7
Head / stud bolt varnished head version 8 Nut M10 50-55 36.8- 40.5
Head / stud bolt varnished version with nut on outer side 8 Nut M10 58 42.7
Head / chain compartment 4 Screw T.C.E.I. M6 x 100 12 8.8
Head "2" (rear) / bearing flange 2 Screw T.E. M6 x 35 11 8.1
Head "2" (rear) / bearing flange 2 Screw T.E. M6 x 20 11 8.1
Head "2" (rear) / differential transmission - exhaust camshaft 3 Screw T.E. M6 x 14 11 8.1 L243
Drive gear / induction camshaft 6 Screw T.C.E.I. M6 x 11.5 11 8.1 L243
Head "1" (front) / gear - exhaust camshaft 3 Screw T.C.E.I. M6 x 11.5 11 8.1 L243
Head "2" (rear) / differential transmission upper side 1 Nut M14 x 1 50 36.8 L243
Valve cover 10 Spacer screw M6 x 23 9 6.6
Head "1" (front) / chain guide shoe 2 Spacer screw M6 x 16 11 8.1
Head 4 Spark plug 18 13.3
Induction flange 4 Screw T.C.E.I. M8 x 25 19 14.0
Cylinder / chain tightener 2 Plug screw M16 x 1.5 30 22.1
Head "1" (front) 1 Coolant temp. thermistor 20 14.7
Head "2" (rear) 1 Coolant temp. thermistor 20 14.7
Cylinder bracket support shoe 2 Screw T.C.E.I. M10 x 40 40 29.5
Cylinder bracket support shoe 2 Nut M10 40 29.5 L243
Ignition system, starter motor
Description Qty Screw/ Nut Nm ft-lb Note
Driving shaft position sensor / flywheel cover 2 Taptite screw M6 x 16 11 8.1
Flywheel cover / generator 3 Screw T.C.E.I. M6 x 40 11 8.1 L243
Magnetic gear - unidirectional case L648
Free wheel flange 3 Screw T.C.E.I. M8 x 16 30 22.1 L648
Magnetic gear cone L648
Ignition / driving shaft 1 Screw T.C.E.I. M6 x 30 130 95.8 L648
Ignition device cover / MS casing 12 Screw T.C.E.I. M6 x 35 11 8.1
Ignition device cover 1 Plug screw M24 x 1.5 3 2.2
Camshaft position sensor / head "1" (front) 2 Taptite screw M5 x 12 4 2.9 L243
Starter motor 2 Screw T.C.E.I. M6 x 30 11 8.1
Clutch cover, coolant pump
Description Qty Screw/ Nut Nm ft-lb Note
Coolant pump 1 Impeller manual tightening
Clutch cover 1 Oil pressure switch M10 x 1 15 11.1 L243
Coolant pump casing 1 Screw T.C.E.I. M6 x 25 11 8.1
Coolant pump casing 3 Screw T.C.E.I. M6 x 55 11 8.1 L243
Clutch cover 11 Screw T.C.E.I. M6 x 35 11 8.1
Clutch cover 3 Screw T.C.E.I. M8 x 40 19 14.0
Clutch cover 1 Screw T.C.E.I. M8 x 65 19 14.0
Rear Fork
Description Qty Screw/ Nut Nm ft-lb Note
Fork pin metal ring 1 M30 x 1.5 12 8.8
Fork pin lock ring 1 M30 x 1.5 60 44.2
Fork pin nut 1 M20 x 1.5 90 66.3
Caliper mount locking pin 1 M12 50 36.8 L243
Chain tightener screw and nut 1+1 M8 manual tightening
Brake pipe grommet fastening 2 M5 4 2.9
Chain case fastening 2 M5 4 2.9
Chain tightener shoe fastening 2 M5 2 1.5
Rear mudguard fastening 2+2 M5 3 2.2
Side Stand
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of stand plate to frame 2 M10 40 29.5
Stand fastening pin 1 M10 x 1.25 10 7.4
Switch fastening screw 1 M6 10 7.4
Lock nut 1 M10 x 1.25 25 18.4
Front Suspension
Front fork
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of upper plate on fork tubes 1+1 M8 25 18.4
Fastening of upper plate on fork tubes 2+2 M8 25 18.4
Steering head metal ring 1 M35 x 1 40 29.5
Steering head lock ring 1 M35 x 1 manual tight plus 90 degrees
Upper plate fastening bush 1 M29 x 1 80 59.0
Lower plate travel-end bush fastening screw 1+1 M8 22 16.2
Closing of fork / wheel pin clamps 2+2 M8 22 16.2
Steering Shock Absorbers
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of shock absorb collar on dashboard/front fairing mount 1 M6 12 8.8
Tube end lock nut 1 M8 12 8.8
Screw fastening collar on shock absorber tube on lower plate 1 M5 5 3.7
Fastening of shock absorber tube on lower plate 1 M6 12 8.8
Rear Suspension
Shock absorber
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of shock absorber to frame 1 M10 50 36.8
Linkage
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of single connecting rod to frame 1 M10 50 36.8
Fastening of single/double connecting rod to frame 1 M10 50 36.8
Fastening of double connecting rod fork 1 M10 50 36.8
Fastening of double connecting rod / shock absorber 1 M10 50 36.8
Electrical System
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of battery clamping bracket 1 M6 12 8.8
Fastening of horn mount 1 M8 x 1.25 25 18.4
Fastening of speed sensor on rear brake caliper mount 1 M6 12 8.8
Fastening of rear indicators 2 M6 2-3 1.5-2.2
Fastening of electronic unit protection case 3 SWP3.9 1 0.7
Fastening of voltage regulator 2 M6 12 8.8
Fastening of front indicators 2 M6 2-3 1.5-2.2
Fastening of coil to mount 8 M5 5 3.7
Fastening of rear light to rear fairing end 2 SWP3.9 1.5 1.1
Fastening of headlight to front fairing 3 SWP3.9 1.5 1.1
Fastening of headlight to front fairing 1 M6 4 2.9
Fastening of relay box to dashboard/front fairing mount 2 M6 4 2.9
Fastening of fuse box to dashboard/front fairing 2 M6 3 2.2
Fastening of earth to frame 1 M6 12 8.8
Air Filter Casing
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of air filter casing cover 7 M5 4 2.9
Fastening of air filter casing to throttle body 6 M6 8 5.9
Fastening of intake conveyors 4 SWP3.9 1 0.7
Fastening of air sensor support plate 1 SWP3.9 1.5 1.1
Front Wheel
Description Qty Screw/ Nut Nm ft-lb Note
Wheel pin nut 1 M25 x 1.5 80 59.0
Rear Wheel
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of sprocket on sprocket holder 5 M10 50 36.8
Wheel pin nut 1 M25 x 1.5 120 88.4
Cooling System
Description Qty Screw/ Nut Nm ft-lb Note
Thermal switch on 3-way manifold 1 M14 x 1.5 30 22.1 L572
Fastening of electrofan mount 2+2 M6 6 4.4
Fastening of electrofan motor to mount 3+3 M4 2 1.5 L243
Radiator coolant drain screws 1+1 M6 10 7.4 L572
Fastening of expansive tank to coils mount 2 M6 10 7.4
Fastening of expansion tank cap 1 M28 x 3 manual tightening
Fastening of coolant filler neck 1 M6 10 7.4
Braking Systems
Front system
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of right and left brake caliper 2+2 M10 x 1.25 50 36.8
Fastening of brake fluid tank 1 M6 5 3.7
Fastening of brake fluid tank bracket 1 M6 12 8.8
Fastening of brake discs 6+6 M8 30 22.1 L243
Fastening of front brake pipe 1 M10 x 1 20 14.7
Fastening of brake fluid bleeder 3 M10 x 1 10 7.4
Rear system
Description Qty Screw/ Nut Nm ft-lb Note
Brake caliper fastening 2 M8 25 18.4
Brake lever pin 1 M8 15 11.1 L243
Fastening of brake fluid tank 1 M5 1 0.7
Brake pump fastening 2 M6 12 8.8
Brake rod lock nut 1 M6 manual tightening
Brake disc fastening 5 M8 30 22.1 L243
Brake pipe fastening 1 M10 x 1 20 14.7
Clutch Control
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of clutch fluid pipe 1 M10 x 1 20 14.7
Fastening of fluid tank bracket 1 M6 12 8.8
Fastening of clutch fluid tank on mount 1 M5 3 2.2
Clutch fluid bleeder 1 M10 x 1 10 7.4
Exhaust System
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of exhaust pipes to engine 3+3 M8 25 18.4
Exhaust silencer fastening 1 M8 25 18.4
Fuel Tank
Fuel pump flange
Description Qty Screw/ Nut Nm ft-lb Note
Fuel return fitting 1 M6 6 4.4 L243
Fastening of pump mount to flange 3 M5 4 2.9
Fastening of electric terminals on flange 2 M5 5 3.7
Closing of fuel return 1 M6 10 7.4 L243
Fastening of fuel delivery pipe on flange 1 M12 x 1.5 22 16.2
Petrol level sensor on pump mount 2 SWP 2.9 x 12 1.5 1.1
Fastening of fuel pump cables on flange 2 M6 10 7.4
Tank
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of cap on tank 3 M5 5 3.7
Fastening of fuel pump flange on tank 8 M5 7 5.2
Fastening of tank front on frame 2 M6 12 8.8
Fastening of tank rear on mount 1 M6 12 8.8
Engine Oil Tank and Radiator
Description Qty Screw/ Nut Nm ft-lb Note
Tank upper fastenings screw 1 M6 10 7.4
Tank fastening nuts 2 M6 10 7.4
Oil filter 1 M20 x 1.5 30 22.1
Oil drain plug 1 M8 15 11.1
Oil level pipe fittings 2 M10 x 1 20 14.7
Radiator astening screws 3 M6 12 8.8
Frame / Fairings
Description Qty Screw/ Nut Nm ft-lb Note
Radiator spoiler fastening 3 M6 5 3.7
Fastening of number plate holder to rear mudguard extension 2 M5 2 1.5
Fastening of reflector holder to number plate holder 2 M5 6 4.4
Front mudguard fastening 4 M5 5 3.7
Rearview mirror fastening screws 1+1 M6 8 5.9
Fastening of rearview mirror mounts and front fairing to mount 4 M6 5 3.7
Lower fastening of front fairing to conveyors 2 M5 4 2.9
Lower fastening of front fairing (on upper part) 2 M5 4 2.9
Fastening of conveyor covers 14 SWP 3.9 2 1.5
Fastening of conveyors to frame and mount 6 M6 5 3.7
Fastening of side fairing upper panel 2+2 M5 fr1 0.7
Fastening of side fairing upper panel 2+2 M5 rear2 1.4
Fastening of dashboards upper protection moulding 4 M5 2 1.5
Fastening of lower fairing to frame 4 M6 5 3.7
Fastening of silencer protection to lower fairing 2 M6 5 3.7
Fastening of sides 4 M6 5 3.7
Fastening of saddle support bush and lower moulded cover 2 M6 5 3.7
Fastening of saddle support lower moulded cover 4 M6 4 2.9
Fastening of rear fairing to saddle support lower molded cover 6 M5 2 1.5
Fastening of rear fairing end to rear fairing 2+2 M5 upper 5 3.7
Fastening of rear fairing end to rear fairing 2+2 M5 lower 3 2.2
Fastening of rear fairing / passenger grab strap 2 M6 12 8.8
Fastening of internal fairing and side fairing 8 SWP 2.9 x 12 1 0.7
Fastening of dashboard to mount 3 M6 5 3.7
Fastening of rider's saddle 2 M6 12 8.8
Fastening of rider's saddle front mount 4 M6 12 8.8
Fastening of passenger seat lock 2 M6 10 7.4
Fastening of passenger seat lock key-operated control 2 M6
12
8.8
Fastening of passenger footrest supports 4 M8 25 18.4
Fastening of rider's footrest supports 4 M8 25 18.4
Fastening of rider's footrest protection 4 M5 6 4.4
Fastening of rear mudguard 4 M5 6 4.4
Fastening of saddle support 4 M10 50 36.8
Fastening of coil mounts 4 M6 12 8.8
Right/Left Handlebars and Controls
Description Qty Screw/ Nut Nm ft-lb Note
Fastening of anti-vibration weights 2 M6 12 8.8
Anti-vibration weights metal ring 2 M18 x 1 35 25.8
Fastening of right/left handlebars to the fork 2 M8 25 18.4
Handlebars lock screw 2 M6 12 8.8
Fastening of left dimmer switch 1 M5 1.5 1.1
Fastening of right dimmer switch 1 M4 1 0.7
Fastening of front brake lever 2 M5 8 5.9
Fastening of clutch lever 2 M5 8 5.9
Note: L stands for Loctite Threadlocker. Use the appropriate type listed.