ENGLISH
25
Hexagon nut at primary gear
M20x1,5
Loctite 243 + 220 Nm
(162 ft.lb)
Collar nut flywheel
M12x1 left
60 Nm
(44 ft.lb)
Hexagon nut for inner clutch hub
M18x1,5
Loctite 243 + 80 Nm
(59ft.lb)
Kickstarter stop screw
M12x1,5
50 Nm
(37ft.lb)
Allan head screw oil pumps
M6
Loctite 243 + 8 Nm
(6ft.lb)
Hexagon screw camshaft gear
M10
Loctite 243 + 35 Nm
(25ft.lb)
Allan head screw cylinder head top sect.
M6x25/m6x35/M6x65/M6x70 (8.8)
8 Nm
(6ft.lb)
Allan head screw cylinder head top sect.
M7x50/M7x55 (12.9)
20 Nm
(15ft.lb)
Cylinder head screws
M10
60 Nm
(44ft.lb)
Collar nuts at cylinder base
M10
50 Nm
(37ft.lb)
Hexagon screw chain sprocket
M10
Loctite 243 + 40 Nm
(30ft.lb)
Oil drain plug
M22x1,5
30 Nm
(22ft.lb)
Magnetic plug
M12x1,5
20 Nm
(15ft.lb)
Plug bypass valve
M12x1,5
20 Nm
(15ft.lb)
Hollow screws oil lines
M8x1
10 Nm
(7ft.lb)
Hollow screws oil lines
M10x1
15 Nm
(11ft.lb)
Jet screw clutch cover
M8
10 Nm
(7ft.lb)
Screw plug timing-chain tensioner
M12x1,5
20 Nm
(15ft.lb)
Counternuts valve adjusting screws
M7x0,75
20 Nm
(15ft.lb)
Crankshaft locking bolt
M8
25 Nm
(19ft.lb)
Spark plug
M12x1,25
20 Nm
(15ft.lb)
Engine mounting bolt
M8
40 Nm
(30ft.lb)
Engine mounting bolt
M10
70 Nm
(52ft.lb)
TIGHTENING TORQUES - ENGINE 660 SUPERMOTO FACTORY REPLICA 2002
ASSEMBLY CLEARANCE, WEAR LIMIT
Crank shaft
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.15 - 0.25 mm
run out of crank stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.04 mm
Connecting rod bearing
radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.00 mm
Cylinder 400
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 89.04 mm
Cylinder 640
bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 101.04 mm
Piston forged
assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.12 mm
Piston rings end gap
compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.60 mm
oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.80 mm
Valves
seat sealing intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.50 mm
seat sealing exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 2.00 mm
run out of valve heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.03 mm
valve guides diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 7.05 mm
Oil pumps
clearance outer rotor - housing . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
clearance outer rotor - inner rotor . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm
Bypaß valve
minimum spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.00 mm
Clutch
Length of springs . . . . . . . . . . . . . . . . . . . . . . . . .min. 30.5 mm (new 33.00 mm)
wear limit organic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.50 mm
Camshaft
diameter of bearing bolt (needle bearing) . . . . . . . . . . . . . . . . . . .min. 19.97 mm
Transmission shafts
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.40 mm
