|
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 |
|
|
