2009 te,txc,tc,sm
TIGHTENING TORQUES (+/- 5%)
ENGINE
Camshaft cap fastening screw M6x1 12 Nm 1,2 Kgm 8.7 ft/lb
Rocker arm axle plug M14x1,5 (+LOCTITE 243) 25 Nm 2,55 Kgm 18.4 ft/lb
Cylinder head cover fastening screw M6x1 8Nm 0,8 Kgm 5.8ft/lb
Cylinder head fastening nut M8x1,25 15 Nm 1,5 Kgm 10.8 ft/lb
Cylinder head and cylinder fastening nut M10x1,5 (+MOLIKOTE HSC) 37 Nm+90° 3.8 Kgm+90° 27.5 ft/lb+90°
Oil hose fastening screw (cylinder head-transmission cover) M10x1 15 Nm 1,5 Kgm 10.8 ft/lb
Cooling pipe connection on cylinder M14x1,5 (+LOCTITE 542) 25 Nm 2,55 Kgm 18.4 ft/lb
Water temperature sensor (TE-SMR) M10x1,25 5 Nm 0,5 Kgm 3.6 ft/lb
Plug for water temperature sensor hole (TC-TXC) M8x1,25 8 Nm 0,8 Kgm 5.8 ft/lb
Rear screw, left cylinder side (USA excluded) M5x0,8 (+LOCTITE 243) 5 Nm 0,5 Kgm 3.6 ft/lb
Gear selector stopping pin M10x1,25 (+LOCTITE 601) 15 Nm 1,5 Kgm 10.8 ft/lb
Oil hole plug on conrod pin M14x1 (+LOCTITE 243) 20 Nm 2 Kgm 14.5 ft/lb
Primary drive driving gear fastening nut M18x1,25 (+LOCTITE 243) 180 Nm 18 Kgm 130 ft/lb
Centrifugal disc on INTAKE CAMSHAFT fastening screw M6x1 (+LOCTITE 243) 8 Nm 0,8 Kgm 5.8 ft/lb
Timing chain slider fastening screw M8x1,25 12 Nm 1,23 Kgm 8.9 ft/lb
Crankcase bearings plates fastening screw M6x1 (+LOCTITE 272) 11 Nm 1,1 Kgm 7.9 ft/lb
Engine oil drain plug M16x1,5 25Nm 2,55 Kgm 18.4 ft/lb
Engine oil filter plug M14x1,5 25Nm 2,55 Kgm 18.4 ft/lb
Engine oil filter cartridge cover fastening screw M5x0,8 (+LOCTITE 243) 6 Nm 0,6 Kgm 4.3 ft/lb
Oil filling cap M18x1,5 3 Nm 0,3 Kgm 2.1 ft/lb
Carburetor union fastening screw (TC-TXC) M4x0,7 (+LOCTITE 272) 3 Nm 0,3 Kgm 2.2 ft/lb
Alternator fastening nut M12x1 75Nm 7,65 Kgm 55.3 ft/lb
Stator plate fastening screw (TC-TXC) M6x1 (+LOCTITE 272) 8 Nm 0,8 Kgm 5.8 ft/lb
Stator plate fastening screw (TE-SMR) M5x0,8 (+LOCTITE 272) 6 Nm 0,6 Kgm 4.3 ft/lb
Starter lever fastening screw M6x1 (+LOCTITE 272) 8 Nm 0,8 Kgm 5.8 ft/lb
Spark plug M10x1 (*)
Pick-up fastening screw M5x0,8 (+LOCTITE 272) 6 Nm 0,6 Kgm 4.3 ft/lb
Clutch hub and disc housing fastening nut M18x1 75Nm 7,6 Kgm 55 ft/lb
Starting gears stop plate fastening screw M6x1 (+LOCTITE 243) 8 Nm 0,8 Kgm 5.8 ft/lb
Gearbox forks driving shaft fastening screw M8x1,25 (+LOCTITE 243) 20 Nm 2 Kgm 14.5 ft/lb
Gear control click and plate fastening screw M6x1 (+LOCTITE 243) 8 Nm 0,8 Kgm 5.8 ft/lb
Gear shift position sensor fastening screw M5x0,8 (+LOCTITE 243) 6Nm 0,6 Kgm 4.3 ft/lb
Water pump rotor fastening nut M5x0,8 (+LOCTITE 243) 3,9 Nm 0,4 Kgm 2.9 ft/lb
Water pump body fastening screw M6x1(+LOCTITE 542) 8 Nm 0,8 Kgm 5.8 ft/l
Drive sprocket seal ring plate fastening screw M5x0,8 (+LOCTITE 243) 6Nm 0,6 Kgm 4.3 ft/lb
Timing chain slider pin fastening screw M4x0,7 3 Nm 0,3 Kgm 2.2 ft/lb
(*): Apply a little graphite grease to the spark plug thread; fit and screw the spark plug by hand then tighten to the torque of 10÷12 Nm- 7.4÷8.9
ft/lb. Loosen the spark plug then tighten it again to the torque of 10÷12 Nm- 7.4÷8.9 ft/lb.
CHASSIS
Rear frame lower fastening screw M8x1,25 25,5 Nm 2,6 Kgm 18.8 ft/lb
Engine guard fastening screw M6x1 14,7 Nm 1,5 Kgm 10.8 ft/lb
Rear chain roller fastening screw M8x1,25 26,95 Nm 2,75 Kgm 19.9 ft/lb
Side stand fastening screw M8x1,25 (+LOCTITE 243) 11,75 Nm 1,2 Kgm 8.7 ft/lb
Rear frame upper fastening screw M8x1,25 25,5 Nm 2,6 Kgm 18.8 ft/lb
Frame to engine plate fastening screw M8x1,25 (+LOCTITE 270) 35,3 Nm 3,6 Kgm 26 ft/lb
Engine lower fastening screw M8x1,25 35,3 Nm 3,6 Kgm 26 ft/lb
Clutch and front brake controls clamp fastening screw M6x1 4,9 Nm 0,5 Kgm 3.6 ft/lb
Throttle control holders fastening screw M6x1 4,9 Nm 0,5 Kgm 3.6 ft/lb
Front brake hose upper fastening screw (TE, SMR) M10x1 19 Nm 1,95 Kgm 14 ft/lb
Front brake hose upper fastening screw (TC, TXC) M10x1 24,7 Nm 2,5 Kgm 18.2 ft/lb
Rear brake control pedal fastening screw M10x1,25 (+LOCTITE 243) 41,65 Nm 4,25 Kgm 30.7 ft/lb
Rear brake pump fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb
Front brake pump plate fastening screw (SMR) M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb
Rear brake fluid tank fastening screw M6x1 2,45 Nm 0,25 Kgm 1.8 ft/lb
Rear stop control switch (TE, SMR) M10x1 19 Nm 1,95 Kgm 14 ft/lb
Front control switch connector fastening screw (SMR) M2x0,4 0,8 Nm 0,1 Kgm 0,6 ft/lb
Rear brake pedal adjusting cam fastening screw M6x1 14,7 Nm 1,4 Kgm 10.8 ft/lb
Front brake hose guide plate fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb
Front brake tank cap fastening screw (SMR) M6x1 4,9 Nm 0,5 Kgm 3.6 ft/lb
Front fork legs fastening screw M8x1,25 25 Nm 2,5 Kgm 18.4 ft/lb
Front wheel axle fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb
Steering bearings adjusting ring nut M25x1 3,45 Nm 0,35 Kgm 2.5 ft/lb
Steering pivot fastening nut M24x1 83,3 Nm 8,5 Kgm 61.4 ft/lb
Handlebar upper clamp M8x1,25 28,4 Nm 2,9 Kgm 20.9 ft/lb
Handlebar holder fastening screw M10x1,5 21,1 Nm 2,15 Kgm 15.6 ft/lb
Front fork legs guard fastening screw M5x0,8 7,85 Nm 0,8 Kgm 5.8 ft/lb
Front fork legs ring guard fastening screw M5x0,8 2,45 Nm 0,25 Kgm 1.8 ft/lb
Rear swing arm axle fastening nut M16x1,5 (+LOCTITE 243) 122,5 Nm 12,5 Kgm 90.3 ft/lb
Rear swing arm to rocker arm fastening nut M12x1,25 80 Nm 8,2 Kgm 59 ft/lb
Tie rod to rocker arm fastening nut M12x1,25 80 Nm 8,2 Kgm 59 ft/lb
NOTE: If not otherwise specified, standard tightening torques for the following thread M5x0,8 5,6÷6,2 Nm 0,57÷0,63 Kgm 4.1÷4.5 ft/lb
M6x1 7,6÷8,4 Nm 0,80÷0,85 Kgm 5.8÷6.1 ft/lb
M8x1,25 24÷26 Nm 2,4÷2,6 Kgm 17.3÷18.8 ft/lb
Frame to tie rod fastening nut M12x1,25 80 Nm 8,2 Kgm 59 ft/lb
Rocker arm to tie rod lubricator M6x1 2,95 Nm 0,3 Kgm 2,2 ft/lb
Rear shock absorber to frame fastening pivot M10x1,25 52,4 Nm 5,35 Kgm 38,6 ft/lb
Rocker arm to frame fastening pivot M10x1,25 52,4 Nm 5,35 Kgm 38,6 ft/lb
Chain guide to rear swing arm fastening screw (TE-SMR) M8x1,25 25 Nm 2,5 Kgm 18.4 ft/lb
Chain guide to rear swing arm front fastening screw (TC) M8x1,25 (+LOCTITE 243)\ 10,4 Nm 1,05 Kgm 7.7 ft/lb
Chain guide to rear swing arm rear fastening screw (TC) M6x1 (+LOCTITE 243) 10,4 Nm 1,05 Kgm 7.7 ft/lb
Bracket to chain guide fastening screw (TE-SMR) M6x1 (+LOCTITE 243) 2 Nm 0,2 Kgm 1.5 ft/lb
Chain slider and rear brake hose clamp lower fastening screw M5x0,8 4,4 Nm 0,45 Kgm 3.2 ft/lb
Chain slider and rear brake hose clamp reear fastening screw (TC-TXC) M5x0,8 4,4 Nm 0,45 Kgm 3.2 ft/lb
Chain guard fastening screw (TE-SMR) M5x0,8 4,4 Nm 0,45 Kgm 3.2 ft/lb
Chain adjuster fastening nut M8x1,25 4,4 Nm 0,45 Kgm 3.2 ft/lb
Spoiler to fuel tank fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb
Front number holder upper fastening screw (TC-TXC) M6x1 6 Nm 0,6 Kgm 4.4 ft/lb
Front number holder lower fastening screw (TC-TXC) M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb
Rear shock absorber guard fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb
Rear fender front fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb
Rear fender rear fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb
Front fender fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb
Radiator guard fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb
Side panel fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb
License plate fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb
Rear reflector fastening nut M4x0,7 1,9 Nm 0,2 Kgm 1.4 ft/lb
Brake hose ring to front fairing fastening screw ø 3,5 1,9 Nm 0,2 Kgm 1.4 ft/lb
Turn signals fastening screw M6x1 6 Nm 0,6 Kgm 4.4 ft/lb
Front headlamp fastening screw ø 3,9 1,45 Nm 0,15 Kgm 1 ft/lb
Electric start remote control switch cables fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb
Fuel tank front rubber pad fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb
Fuel cock fastening screw ø5,5 2,45 Nm 0,25 Kgm 1.8 ft/lb
Fuel tank rear fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb
Air filter box front fastening screw M6x1 10,4 Nm 1,05 Kgm 7.7 ft/lb
Air filter box flange fastening nut M5x0,8 3,45 Nm 0,35 Kgm 2.5 ft/lb
Front brake caliper fastening screw (TE- TC) M8x1,25 25,5 Nm 2,6 Kgm 18.8 ft/lb
Brake hoses lower fastening screw M10x1 19 Nm 1,95 Kgm 14 ft/lb
Front wheel axle fastening screw (SMR) M10x1,5 51,45 Nm 5,25 Kgm 38 ft/lb
Front brake caliper fastening screw (SMR) M10x1,5 25,5 Nm 2,6 Kgm 18.8 ft/lb
Brake caliper holding plate to front fork (SMR) M10x1,5 25,5 Nm 2,6 Kgm 18.8 ft/lb
Front wheel axle fastening screw (TE-TC-TXC) M20x1,5 51,45 Nm 5,25 Kgm 38 ft/lb
Front brake disc fastening screw (TE-TC-TXC) M6x1 (LOCTITE 243) 14,7 Nm 1,5 Kgm 1 0.8 ft/lb
Front brake disc fastening screw (SMR) M8x1,25 34,7 Nm 3,54 Kgm 25.6 ft/lb
Rear brake disc fastening screw M6x1 (LOCTITE 243) 14,7 Nm 1,5 Kgm 10.8 ft/lb
Front wheel nipple M4,07x0,75 4,4 Nm 0,45 Kgm 3.2 ft/lb
Rear wheel nipple M4,5x0,75 4,4 Nm 0,45 Kgm 3.2 ft/lb
Rear wheel sprocket fastening nut M8x1,25 (+LOCTITE 243) 34,3 Nm 3,5 Kgm 25.3 ft/lb
Rear wheel axle fastening nut M20x1,5 142,1 Nm 14,5 Kgm 104.8 ft/lb
Drive sprocket cover fastening screw M6x1 10,4 Nm 1 Kgm 7.7 ft/lb
Exhaust silencer fastening screw M6x1 10,4 Nm 1 Kgm 7.7 ft/lb
Exhaust pipes to cylinder head fastening screw M6x1 10,4 Nm 1 Kgm 7.7 ft/lb
Instrument fastening screw ø4,8 3,45 Nm 0,35 Kgm 2.5 ft/lb
Radiator fastening screw M6x1 7 Nm 0,72 Kgm 5.2 ft/lb