Cylinder Head Area
Application | Torque (Nm) | Notes |
Camshaft cover to cylinder head | 10 | |
Camshaft drive chain tensioner to head | 9 | |
Camshaft bearing ladder to head | * | Refer to section 5 |
Camshaft sprocket to camshaft | 10 | Replace fixing(s) if removed |
Camshaft drive chain rubbing blade to crankcase | 9 | Replace fixing(s) if removed |
Camshaft drive chain top pad to cylinder head | * | Refer to section 5 |
Cylinder head to crankcase (M6 screws) | 10 | Replace fixing(s) if removed |
Cylinder head to crankcase bolts | * | Refer to section 3 |
Camshaft cap and ladder to head | * | Refer to section 3 |
Cylinder head dry seal plug | 22 | Replace fixing(s) if removed Apply ThreeBond 1305 to the threads |
Sound suppression bolt in head | 12 | |
Spark plugs | 12 | |
Cylinder head exhaust stud | 10 | Replace fixing(s) if removed |
Clutch
Application | Torque (Nm) | Notes |
Clutch cover to crankcase (28 mm bolts) | 9 | |
Clutch cover to crankcase (35 mm bolts) | 10 | |
Clutch centre nut | 98 | Replace fixing(s) if removed |
Clutch pressure plate to centre drum | 10 | |
Clutch lever clamp bolts | 12 | |
Clutch lever nut | 3.5 | |
Clutch cable adjuster bracket to crankcase | 12 | |
Switch cube screws (left) | 3 | |
Clutch cover protector | 6 |
Crankshaft, Crankcase and Sprag
Application | Torque (Nm) | Notes |
Crankcase upper to lower (M8 fixings) | * | Refer to section 5 |
Crankcase upper to lower (M6 fixings) | * | Refer to section 5 |
Crankcase dry seal plug | 22 | Replace fixing(s) if removed |
Breather cover to crankcase | 9 | Replace fixing(s) if removed |
Connecting rod big end nut | * | Refer to section 5 |
Camshaft drive sprocket gear to crankshaft | 27 | Replace fixing(s) if removed |
Sprag clutch to alternator rotor | Refer | to section 7 |
Engine Covers
Application | Torque (Nm) | Notes |
Clutch cover to crankcase | 9 | |
Sprocket cover to crankcase | 9 | |
Alternator cover (25 mm bolts) to crankcase | 8 | |
Alternator cover (35 mm bolts) to crankcase | 9 | |
Wire retainer on alternator cover | 6 | |
Crank cover (25 mm bolts) to crankcase | 8 | |
Crank cover (35 mm bolts) to crankcase | 9 | |
Balancer cover to crankcase | 8 |
Transmission
Application | Torque (Nm) | Notes |
Output sprocket to output shaft Detent wheel to selector drum | 85 | Use new tab washers Replace fixing(s) if removed |
Detent arm bolt | 12 | Replace fixing(s) if removed |
Input shaft bearing carrier/retainer | 12 | Replace fixing(s) if removed |
Selector shaft retainer | 12 | Replace fixing(s) if removed |
Spring abutment bolt | 20 | |
Gear position sensor | 5 | Replace fixing(s) if removed |
Gear selector arm pinch bolt | 9 | Replace fixing(s) if removed |
Gear pedal pivot bolt | 22 | |
Gear change rod adjuster nuts | 6 | |
Sprag housing to rotor | 16 |
Lubrication System
Application | Torque (Nm) | Notes |
Sump to crankcase | 12 | |
Sump drain plug to sump | 25 | Replace sealing washer(s) if removed |
Oil pressure relief valve to crankcase | 15 | Apply ThreeBond 1305 to the threads |
Low oil pressure warning light switch to crankcase | 13 | Replace sealing washer(s) if removed |
Oil filter to adapter | 10 | |
Heat exchanger to crankcase | 59 | Replace sealing washer(s) if removed |
Oil pump drive chain retainer plate | 9 | Replace fixing(s) if removed |
Oil pump to crankcase | 12 | Replace fixing(s) if removed |
Oil pump drive sprocket to pump shaft | 12 | Apply ThreeBond 1374 to the threads |
Oil pump rotor cover to pump body bolts | 12 | |
Oil pump pick up pipe | 12 | |
Oil transfer pipe | 12 | |
Water pump cover to oil pump body bolts | 12 | |
Transmission oil feed pipes to crankcase | 8 | Replace fixing(s) if removed |
Breather drain tube | 9 |
Final Drive
Application | Torque (Nm) | Notes |
Rear sprocket to cush drive | 55 | |
Chain guard bolts | 9 | |
Chain rubbing strip to swinging arm | 9 |
Cooling System
Application | Torque (Nm) | Notes |
Radiator to frame | 6 | |
Coolant bypass to head | 15 | |
Thermostat housing to head | 9 | |
Water elbow to crankcase (left hand) | 9 | |
Water elbow to crankcase (right hand and upper fixing only) | 12 | |
Fan shroud to radiator | 2.5 | |
Water temperature sensor | 18 | |
Radiator lower bracket to radiator | 6 | |
Radiator lower bracket to water outlet bracket | 6 | |
Expansion tank to frame | 3 | |
Expansion tank cover to frame | 3 | |
Radiator bleed screw | 1.5 | |
Top hose bleed screw | 1 | |
Water pump outlet pipe | 12 | Replace fixing(s) if removed |
Water pump inlet pipe | 12 | Replace fixing(s) if removed |
Coolant hose clips | 2 |
Fuel System, Exhaust System and Airbox
Application | Torque (Nm) | Notes |
Fuel tank to frame (rear fixing) | 12 | |
Fuel cap to fuel tank | 4 | |
Fuel pump mounting plate to fuel tank | 9 | |
Throttle body transition piece to cylinder head | 12 | |
Throttle body adaptor clip | 1.5 | |
Fuel rail to throttle body | 3.5 | |
Throttle position sensor | 2 | |
Idle speed control stepper motor | 3.5 | |
Throttle cable bracket to throttle body | 3.5 | |
Throttle cable guide screws | 3 | |
Exhaust downpipe to cylinder head | * | Refer to section 10 |
Exhaust downpipe to frame | 19 | |
Silencer heat shield | 5 | Torque every service |
Silencer to frame | 15 | |
Silencer rear finisher | 5 | Apply ThreeBond 1305 to the threads |
Silencer front finisher | 5 | |
Silencer clamp to intermediate pipe | 10 | |
Oxygen sensor | 25 | |
Catalytic converter heat shield | 5 | |
Air filter cover to housing | 1.5 | |
Airbox to breather housing | 9 | |
Air filter to housing | 1 | |
Air intake trumpet to airbox | 6 | |
Air temperature sensor | 1.5 | |
Manifold air pressure (MAP) sensor | 1.5 | |
Barometric pressure sensor | 1.5 | |
Fall detection switch | 3 | Replace fixing(s) if removed |
Crankshaft sensor | 4 | Replace fixing(s) if removed |
Road speed sensor | 9 | Replace fixing(s) if removed |
Evaporative canister to bracket | 8 | |
Evaporative bracket to frame | 9 |
Rear Suspension
Application | Torque (Nm) | Notes |
Swinging arm spindle nut | 110 | Replace fixing(s) if removed (locknut) |
Chain rubbing strip to swinging arm | 9 | |
Rear suspension unit upper mounting bolt | 48 | |
Rear suspension unit lower mounting bolt to drop link | 80 | |
Rear suspension reservoir | 3 | |
Drag link pivot at frame | 80 | |
Drop links to swinging arm | 80 | |
Chain guard (upper and lower) | 9 |
Front Suspension
Application | Torque (Nm) | Notes |
Upper yoke pinch bolt | 20 | |
Lower yoke pinch bolt | 20 | |
Upper yoke centre nut | 90 | |
Fork top cap | 35 | |
Damping cylinder bolt | 20 | Replace sealing washer if removed |
Damping rod to top cap | 20 | |
Handlebar clamp riser to top yoke (10 mm bolt) | 35 | |
Handlebar upper clamp to lower clamp (8 mm bolt) | 26 | Lubricate threads with engine oil |
Handlebar end weights | 5 | |
Switch cube screws | 3 | |
Mirror | 25 |
Wheels
Application | Torque (Nm) | Notes |
Front wheel spindle/axle bolt | 65 | |
Front wheel spindle pinch bolts | 22 | |
Rear wheel spindle | 110 | |
Chain adjuster locknut | 15 | |
Rear sprocket to cush drive | 55 | Replace fixing(s) if removed |
Front Brakes
Application | Torque (Nm) | Notes |
Front brake caliper to fork | 28 | |
Front brake pad retaining pin | 18 | |
Front brake pad retaining pin plug | 3 | |
Front brake caliper bleed screw | 6 | |
Front brake hose to caliper | 25 | Replace sealing washer(s) if removed |
Front brake master cylinder to handlebar | 12 | |
Front brake hose to master cylinder | 25 | Replace sealing washer(s) if removed |
Front brake disc to wheel | 22 | Replace fixing(s) if removed |
Brake lever pivot bolt | 1 | |
Brake lever pivot bolt locknut | 6 | |
Master cylinder brake hose clamp to fork leg | 6 | |
Brake hose wire guide | 7 |
Rear Brakes
Application | Torque (Nm) | Notes |
Rear brake caliper to carrier | 22 | |
Rear brake caliper sliding bolt | 27 | |
Rear brake pad retaining pin | 18 | |
Rear brake pad retaining pin plug | 3 | |
Rear brake caliper bleed screw | 6 | |
Rear brake hose to caliper | 25 | Replace removed sealing washer(s) if removed |
Rear brake master cylinder to frame | 16 | |
Rear brake master cylinder reservoir to mounting | 7 | |
Rear brake master cylinder pushrod locknut | 18 | |
Rear brake light switch | 15 | Replace removed sealing washer(s) if removed |
Brake pedal pivot bolt | 22 | |
Brake hose P-clip bolt | 6 | |
Rear brake disc to wheel | 22 | Replace fixing(s) if removed |
ABS System
Application | Torque | Notes |
ABS module to bracket | 9 | |
ABS bracket to frame | 9 | |
ABS pulser ring to brake disc | 5 | Replace fixing(s) if removed |
ABS sensor to bracket | 9 | Replace fixing(s) if removed |
ABS lines to modulator | 25 | |
ABS hard line to front brake hose | 17 |
Frame, Footrests, Control Plates and Engine Mountings
Application | Torque (Nm) | Notes |
Lower crankcase to frame | 48 | Refer to section 9 |
Cylinder head to frame | 48 | Refer to section 9 |
Heel guard to frame | 12 | |
Side stand mounting bracket | 45 | |
Side stand pivot bolt | 20 | |
Side stand pivot bolt | 45 | |
Side stand switch | 7 | Replace fixing(s) if removed |
Seat lock to frame | 5 | |
Front subframe | 15 | |
Lower rear engine mounting frame adjuster | 3 |
Electrical
Application | Torque (Nm) | Notes |
Alternator rotor to crankshaft | 120 | |
Alternator stator to cover | 12 | Replace fixing(s) if removed |
Alternator regulator to bracket | 9 | |
Starter motor to crankcase | 10 | |
Starter motor power lead connection | 3 | |
Starter motor solenoid lead connection | 5 | |
Spark plug to cylinder head | 12 | |
Horn | 18 | |
Immobiliser ECU | 9 | |
Ignition switch | 12 | Replace fixing(s) if removed |
Instrument assembly | 2 | |
Headlight | 3.5 | |
Headlight bezel | 3 | |
Rear light | 4 | |
Front and rear indicator | 3 | |
Negative battery lead to upper crankcase | 9 |
Bodywork
Application | Torque (Nm) | Notes |
Mudguard extension bracket | 9 | Replace fixing(s) if removed |
Front mudguard to forks - Tiger 800 | 6 | Replace fixing(s) if removed |
Front mudguard to forks - lower - Tiger 800XC | 6 | Replace fixing(s) if removed |
Front mudguard to forks - upper - Tiger 800XC | 6 | Replace fixing(s) if removed |
Handguard bracket to lever pivot bolt | 1 | |
Handguard to bracket | 9 | |
Handguard to handlebar spacer | 6 | Replace fixing(s) if removed |
Sumpguard nuts | 10 | |
Sumpguard rubber to sump | 3 | |
Sumpguard Bracket | 15 | |
Sumpguard front bolts | 15 | Replace fixing(s) if removed |
Screen fixings to brackets | 3 | |
Screen bracket (pressed, at side) | 5 | |
Screen bracket (cast at fron) | 5 | |
Centre panel (Tiger 800) or Beak support moulding (Tiger 800XC) to subframe (nut and screw) | 5 | |
Beak to beak support moulding | 3 | |
Beak support moulding to subframe | 5 | |
Cockpit infill panels to cockpit moulding | 3 | |
Ignition switch cover | 5 | |
Fuel tank panel, front | 5 | |
Lower radiator panel | 3 | |
Upper radiator panel | 5 | |
Radiator infill panel lower fixing | 6 | Replace fixing(s) if removed |
Radiator infill panel upper fixing | 3 | Replace fixing(s) if removed |
Battery tray | 6 | Apply ThreeBond 1360 to the threads |
Rear mudguard upper fixing | 3 | |
Rear mudguard lower fixing | 5 | Replace fixing(s) if removed |
Rear mudguard splash cover | 3 | |
Rear panel M6 bolts | 5 | |
Rear panel M8 bolts | 20 | |
Grab rail to subframe bolts | 20 | |
Rear rack | 3 | |
Front seat bridge | 5 | |
Fuel tank infill | 3 | |
Rear seat bracket lower fixing | 5 | |
Rear seat bracket upper fixing | 5 |