c 3 abcdefghlmnp

LOCK 1. Front sprocket guard screw. M 6x1. 6. Chain sliding shoe retaining screw. M6x1. 6. LOCK 1 ... Nut retaining battery mount to cylinder head M 8x1.25. 13.
74KB taille 3 téléchargements 226 vues
sezione / section

Caratteristiche tecniche

C3

Technical specification

3 - TORQUE SETTINGS

A

Frame torque settings Part

Thread (mm)

Nm tolerance ±10%

Notes

LOCK 1

Chain, front sprocket Front sprocket retaining screw

M 5x0.8

6*

Front sprocket guard screw

M 6x1

6

Chain sliding shoe retaining screw

M6x1

6

B

LOCK 1

Light units Headlight retaining screw

M 8x1.25

C

12

Screw securing headlight holder to subframe on silent block

4

Tail light nuts

M 6x1

6

Number plate light nuts

M 5x0.8

2.5

Cat's eye mounting nut

M 4x0.7

2

Hose guide to headlight bracket screw

M 6x1

9

Turn indicators retaining screw

M 6x1

6

Headlight holder retaining screw

M 6x1

10

Headlight reflector retaining screw

M 4x0.7

2.3

D

E

Instrument panel Instrument panel silentblock fasteners

F

4

Screw retaining instrument panel to silentblock

M 5x0.8

5

Temperature/air pressure sensor retaining screw

M 5x0.8

3

G Front fork

Steering head retaining screw, center position

M 8x1.25

23 *

GREASE B

Steering head retaining screws

M 8x1.25

24 *

GREASE B

Bottom yoke screw

M 8x1.25

20 *

GREASE B Sequence 1-2-1

Fork bottom end bolt

M 8x1.25

20 *

GREASE B Sequence 1-2-1

Steering lock nut

M 8x1.25

18

LOCK 2 (apply Loctite to nut thread only)

Steering bearings ring nut

M 35x1

30 *

GREASE B

Front fork splashguard retaining screw

M 5x0.8

5.5

LOCK 2

H

L

M

Electrical system Relay mount retaining screw

M 5x0.8

1

LH and RH switch screw

M 5x0.8

3.5

Key cover blind nut

M 6x1

7

Key-operated switch bolt

M 6x1

Battery cable screw

M 6x1

6

Starter motor nut

M 6x1

5

Nut securing cable to contactor

M 6x1

4

N * Shear bolt LOCK 2

Monster S2R800/S2R800 Dark Aggiornamento/Update - M.Y. 2006 - edizione/edition 00

P 25

A

B

C

D

sezione / section

Caratteristiche tecniche

C3

Technical specification

Part

Thread (mm)

Nm tolerance ±10%

Speed sensor retaining screw

M 6x1

10

Screw retaining voltage regulator to oil breather tank and frame

M 6x1

6

Screw retaining regulator to oil breather tank M 6x1

6

Screw retaining battery mount to silentblocks M 6x1

6

Nut retaining battery mount to cylinder head

M 8x1.25

13

Control unit retaining screw

M 6x1

10

Screw retaining ground cable to engine

M 8x1.25

12

Horn bracket retaining screws

M 8x1.25

25

LOCK 2

Warning horn retaining screw

M 8x1.25

25

LOCK 2

Coil support retaining screw

M4x0.7

4

Coil-to-airbox nut

M6x1

7

Coil-to-frame screw, right side

M6x1

8

Immobilizer antenna

Notes

LOCK 2 LOCK 11 in-between antenna and switch cover

E Relay mount retaining screw

M5x0.8

1 Front brake

F

G

H

L

M

N

P

Front brake caliper retaining screw

M 10x1.25

43 *

GREASE B

Front brake master cylinder retaining screw

M 6x1

10

sequence 1 (UP) -2-1

Rear brake bleed valve

M 6x1

12

Front/Rear brake hose coupling

M 10x1

20

Brake and gearbox lever pin

M 8x1.25

24 *

LOCK 2

GREASE B

Rear brake Rear brake caliper retaining screw

M 8x1.25

24 *

Front/Rear brake hose coupling

M 10x1

20

Rear brake master cylinder retaining screw

M 6x1

10

Screw retaining rear brake hose clip to swingarm

M 5x0.8

6

Rear brake fluid reservoir retaining screw

M 6x1

2 Rear swingarm

Swingarm securing screw

M 8x1.25

18 *

GREASE B

Chain adjustment eccentric screw

M 12x1.25

33 *

GREASE B Sequence 1-2-1

Screw securing the rear brake line guide and M 5x0.8 speed sensor to swingarm

2.5

Chain guard screw

M 6x1

6

Caliper plate pin

M 12x1.25

33

LOCK 8

Handlebar Handlebar clamp screw

M 8x1.25

20 *

GREASE B Sequence 1-2-1

Clutch master cylinder retaining screw

M 6x1

10

sequence 1 (UP) -2-1

Clutch hose fitting

M 10x1

23

Clutch bleed nipple

M 6x1

4

26

Monster S2R800/S2R800 Dark Aggiornamento/Update - M.Y. 2006 - edizione/edition 00

sezione / section

Caratteristiche tecniche

C3

Technical specification

Part

Thread (mm)

Nm tolerance ±10%

Clutch transmission unit screw

M 6x1

10

Throttle control securing screw

M 6x1

8

Throttle control cover securing screw

M 4x0.7

1.8

Counterweight retaining screw

M 6x1

9

Notes

A

B

Rear shock absorber Rear shock absorber upper screw

M 10x1.25

42 *

GREASE B

Rear shock absorber lower screw

M 10x1.25

42 *

GREASE B

Suspension linkage upper screw

M 10x1.25

42 *

GREASE B

Suspension rocker arm to frame fixing screw M 12x1.5

75 *

GREASE B

Ball joints to actuating rod nut

36 *

M 12x1.5

C

Front and Rear mudguards Front mudguard retaining screw

M 6x1

3

LOCK 2

Rear mudguard retaining screw

M 6x1

3

LOCK 2

Number plate holder protection screw

M 6x1

5.5

Splashguard to underseat retaining screw

M 6x1

1.8

Number plate holder to splashguard nut

M 6x1

1.9

D

E

Footpegs and Levers Lever and gearbox pin

M 8x1.25

24

LOCK 2

Gear change lever fixing screw

M 6x1

10

LOCK 1

Actuating rod ball joints screw on gear change M 6x1 lever

10

Front footpeg holders to engine retaining screws

M 10x1,5

36

Screws securing the front footpegs to swingarm shaft

M 12x1.25

55 *

GREASE B

Rear footpeg holders to frame retaining screws

M 8x1.25

24

LOCK 2

Screw securing heel guards to footpegs

M 5x0.8

5

LOCK 2

F

G

H

Front and Rear wheel Front wheel nut

M 25x1.25

63 *

GREASE B

Rear wheel nut -left side

M 33x1.5

156 *

GREASE B

Rear wheel nut -right side

M 38x1.5

176 *

GREASE B

Front and rear brake discs securing screw

M 8x1.25

24 *

LOCK 2

Rear chain sprocket nut

M 10x1.25

48 *

LOCK 2

Driving pins securing screw

M 6x1

11 *

LOCK 2

L

M

Fuel Tank Retaining screw of plastic fuel tank flange

M6x1

10

Fuel hose clamp

1.5

Fuel filler plug fixing screw

M 5x0.8

6

Fuel tank hinge bracket retaining screw

M 6x1

10

Fuel tank pads retaining screw

M 6x1

10

N

Exhaust Screw for tie on exhaust pipes

M 8x1.25

P

19

Monster S2R800/S2R800 Dark Aggiornamento/Update - M.Y. 2006 - edizione/edition 00

27

sezione / section

Caratteristiche tecniche

C3

Technical specification

Part

A

B

C

Thread (mm)

Nm tolerance ±10%

Notes

Special screw securing exhaust manifolds to M 12x1.5 crankcase

25

LOCK 1

Exhaust pipe to casing retaining screw

M 6x1

9

Stainless steel 1/8 gas thread plugs to exhaust pipes

M 10x1.25

25

Silencers-to-frame retaining screw

M 8x1.25

24

Heat guard-to-silencer screw

M 6x1

10

LOCK 2

Heat guard-to-exhaust pipes screw

M 6x1

2,4

LOCK 2

Nuts securing exhaust pipes to horizontal and M 6x1 vertical head

24 Seat

D

E

Seat lock ring nut

M 22x1.5

1

Seat lock holder retaining screw

M 5x0.8

6

Seat cover holder retaining screw

M 5x0.8

3

Seat pulley screw

Self-tapping

Screw retaining seat cover and tool box compartment cover to seat

M 6x1

2

Seat lock retaining screw

M 5x0.8

6

LOCK 3

LOCK 2

Oil inlet/breather

F

G

Airbox hose clip

......

2

Airbox stud to airbox fixing

M 6x1

6

Peg to airbox stud fixing

M 6x1

4

Oil breather valve hose clip

M 6x1

1.2

Oil breather tank hose clip

2

Oil breather tank to frame retaining screw

M 6x1

6

Fuel system, Canister

H

Throttle body mounting clip

2

Pressure regulator to throttle body retaining screw

M 6x1

5

Canister support to engine retaining screw

......

10 Fairing

L

Side body panel retaining screw

M 5x0.8

0.8

Headlight fairing to bracket retaining screw

M 6x1

8 Stand

M

Side stand plate retaining screw

M 10x1,5

36

Side stand sensor wire retainer screw

M 6x1

10

Side stand pivot nut

M 8x1.25

24

Side stand sensor retaining screw

M 6x1

10

N

LOCK 5

Frame Engine to frame mounting bolt nut

M 12x1.5

60 *

Oil pipe fitting on casing

M 9/16"UNF"

19

Fitting for oil delivery pipe to heads

M 8x1.25

15

GREASE B

P 28

Monster S2R800/S2R800 Dark Aggiornamento/Update - M.Y. 2006 - edizione/edition 00

sezione / section

Caratteristiche tecniche

C3

Technical specification

Part

Thread (mm)

Nm tolerance ±10%

Notes

A

Oil cooler Oil pipe fitting on cooler with twin seal

M 16x1.5

25 *

Engine oil

Oil pipe fitting on casing with twin seal

M 16x1.5

25 *

Engine oil

Oil cooler nipple on cooler

M 14x1.5

27

LOCK 1

B

* critical point for dynamic safety. Tightening torque tolerance must be: ± 5% Nm. Note For product specifications and symbols, refer to “Product specifications” (Section A2).

C

D

E

F

G

H

L

M

N

P Monster S2R800/S2R800 Dark Aggiornamento/Update - M.Y. 2006 - edizione/edition 00

29

sezione / section

Caratteristiche tecniche

C3

Technical specification

Engine torque settings

A

B

C

D

E

Part

Thread (mm)

Nm

Min.

Max.

Blow-by valve

M 40x1.5

40

36

44

Mesh filter duct plug

M 32x1.5

42

38

46

Oil temperature sensor ring nut

M 30x1.5

38

34

42

LOCK 4

Wet clutch drum nut

M 25x1.5

190

180

200

GREASE B

Generator rotor nut

M 24x1

270

256

284

Engine oil

Crankshaft gear fixing nut

M 22x1

190

171

209

GREASE B

Oil drain plug

M 22x1.5

42

38

46

Oil mesh filter

M 22x1.5

42

38

46

Oil filler plug

M 22x1.5

5

5

6

Steel/aluminium crankshaft blanking plug

M 20x1

15

13.5

16.5

Gearbox drum locating screw

M 16x1.5

30

27

33

Oil filter nipple

M 16x1.5

42

38

46

LOCK 2 or THREE BOND 1324

Oil cartridge filter

M 16x1.5

11

10

12

Engine oil on seal

Mesh filter duct plug

M 15x1

20

18

22

LOCK 5 or THREE BOND 1375B

By-pass pump plug

M 15x1

25

22

28

LOCK 5 or THREE BOND 1375B

Ring nut for belt rollers on lay shaft

M 15x1

71

64

78

GREASE A

Ring nuts for belt rollers on heads

M 15x1

71

64

78

GREASE A

Generator cover inspection plug

M 15x1

20

18

22

THREE BOND 1215

Nut for timing lay shaft gear

M 14x1

55

50

60

GREASE A

Radiator preset plug

M 14x1.5

24

21

27

LOCK 5 or THREE BOND 1375B

Radiator preset blanking plug

M 14x1.5

27

24

30

LOCK 5 or THREE BOND 1375B

Oil cooler nipple

M 14x1.5

27

24

30

LOCK 5 or THREE BOND 1375B

Pick-up inspection screw

M 12x1

15

13

17

LOCK 2 or THREE BOND 1324

Earth screw

M 12x1

18

16

19

LOCK 2 or THREE BOND 1324

Oil temperature sensor

M 12x1.5

18

16

19

LOCK 4

Spark plugs

M 12x1.25

20

18

22

Head nuts:

M 10x1,5

F

G

H

L

M

N

1st snug torque 2nd snug torque final torque

P 30

Notes

THREE BOND 1375B

Grease under head and thread of stud bolt with GREASE C 15 25 40

23 38

27 42

Monster S2R800/S2R800 Dark Aggiornamento/Update - M.Y. 2006 - edizione/edition 00

sezione / section

Caratteristiche tecniche

C3

Technical specification

Part

Thread (mm)

Con-rod bolts:

M 10x1

1st tight. at 50 rpm 2nd Stop for 2 sec. and loosen by 360° at 30 rpm 3rd snug at 30 rpm 4th snug at 10 rpm Tight. at 10 rpm check angle > 30° Oil pump duct plug

Nm

Min.

Max.

Notes GREASE B on thread

35

20 35 70.5 M 10x1,5 15

66

B

73

Fully home with tool 13 17

A

LOCK 5 or THREE BOND 1375B

C

Head stud bolts

M 10x1,5

25

23

26

LOCK 2 or THREE BOND 1324

Pressure switch

M 10x1

19

17

21

Reduction bushing

M 10x1

Spark plug

M 10x1

15

13

17

Neutral light switch

M 10x1.25

10

9

11

Clutch-side casing service plug

M 10x1,5

15

13

17

LOCK 5 or THREE BOND 1375B

Oil circuit plug on exhaust side

M10x1

15

13

17

LOCK 2 or THREE BOND 1324

Crankshaft dowels

M 8x1.25

13

11

15

THREE BOND 1375B

Gearbox pawl screw

M 8x1.25

25

22

28

Gear stopper screw

M 8x1.25

18

16

20

LOCK 2 or THREE BOND 1324

Intake and exhaust flange stud bolts

M8x1.25

15

13

17

LOCK 2 or THREE BOND 1324

Intake manifold nuts

M8x1.25

23

20

26

Oil pump screws

M 8x1.25

26

23

29

Casing jointing screws: 1st snug torque final torque

M 8x1.25 19 25

17 22

21 28

Casing drilled screw

M 8x1.25

20

18

22

GREASE B

Fixed tensioner

M 8x1

20

18

22

LOCK 2 or THREE BOND 1324

Mobile tensioner

M 8x1.25

26

23

29

Ground screw

M 8x1.5

13

11

15

Clutch springs screws

M 6x1

6

5

7

Stator cable guide screws

M 6x1

10

9

11

LOCK 2 or THREE BOND 1324

Starter motor screws

M 6x1

10

9

11

LOCK 2 or THREE BOND 1324

Starter idle gear pin screw

M 6x1

10

9

11

LOCK 2 or THREE BOND 1324

D LOCK 5 or THREE BOND 1375B

E

F

G

H GREASE B

Monster S2R800/S2R800 Dark Aggiornamento/Update - M.Y. 2006 - edizione/edition 00

L

M

N

P 31

A

sezione / section

Caratteristiche tecniche

C3

Technical specification

Part

Thread (mm)

Nm

Min.

Max.

Notes

Generator stator retaining screws

M 6x1

10

9

11

LOCK 2 or THREE BOND 1324

Flywheel / rotor screws

M 6x1

13

11

15

LOCK 2 or THREE BOND 1324

Gearbox bearing stop plate screws

M 6x1

10

9

11

LOCK 2 or THREE BOND 1324

Head service screws (aluminium)

M6x1

3

2

3

LOCK 5 or THREE BOND 1375B

Intake manifold fuel pump fitting

M 6x1

2.5

2

3

LOCK 2 or THREE BOND 1324

Bosch pick-up retaining screws

M 6x1

10

9

11

Battery mount lower stud bolt

M 6x1

10

9

11

LOCK 2 or THREE BOND 1324

Gearbox pawl screw

M 6x1

9

8.5

9.5

LOCK 2 or THREE BOND 1324

Inspection cover screws

M 6x1

4.5

4.5

6

Rocker arm shaft cover screws

M 6x1

10

9

11

Intake / exhaust valve cover screws

M 6x1

10

9

11

Casing jointing screws

M 6x1

9

8.5

9.5

Clutch cover screws

M 6x1

9

8.5

9.5

Generator cover screws

M 6x1

10

9

11

Clutch spring screws

M 5x0.8

5

5

7

Driven belt roller flange retaining screws

M5x0.8

5

5

7

Manifold nipple

M 5x0.8

3

2

3

Split belt roller flange retaining screws

M5x0.8

5

5

7

Head cover plug

M5x0.8

2.5

2.5

3

Screws

M 10x1,5

45

40

50

Screws

M 8x1.25

25

22

28

Screws

M 6x1

10

9

11

Screws

M 5x1

5

5

7

B

C

D

E

F

G

H

L

M

GREASE A

LOCK 2 or THREE BOND 1324

Note For product specifications and symbols, refer to “Product specifications” (Section A2).

N

P 32

Monster S2R800/S2R800 Dark Aggiornamento/Update - M.Y. 2006 - edizione/edition 00