SHELL Advance Fork 7.5 Or DONAX TA

Recommended oil:

SHELL Advance Fork 7.5 or DONAX TA

Standard capacity:

0.480 cu.dm per leg.

Standard oil level:

104 mm.

3 - / Torque settings

Frame torque settings

Part / Thread (mm) / Nm tolerance ±10% / Note
Accessories and Outfit
Hand guard screw / 6x1 / 10
Hand guard clamp screw / 5x0.8 / 3
Screw securing front turn indicator to hand guard
Side stand
Side stand shaft / 10x1.25 / 20
Stand shaft safety nut / 10x1.25 / 25
Screws securing stand assembly to engine / 10x1.5 / 36 / LOCK 5
Side stand sensor retaining screw / 6x1 / 10
Chain, front sprocket
Sprocket nut / 25x1.5 / 186 * / GREASE B
Sprocket cover screw / 6x1 / 8
Sprocket cover screw (metal sheet) / 5x0.8 / 6
Light units
Screw securing number plate holder shell to bracket / 6x1 / 6 / LOCK 2
Number plate holder shells jointing screw / 4x0.7 / 3
Number plate holder-to-support screw / 6x1 / 6 / Screw with threadlocker
Number plate holder-to-support screw / Self-tapping / 3
Nut securing cat's eye support to number plate holder / 6x1 / 4 / Only for EU model
Rear turn indicator screw / 6x1 / 6
Nut securing number plate light to number plate holder / 6x1 / 1.5
Screw securing tail light to grab rail / 5x0.8 / 2
Screw securing vibration damper to tail light / Self-tapping
Screw securing tail light vibration damp.bracket to grab rail / 5x0.8 / 4
Screw securing grab rail to subframe / 8x1.25 / 20*
Screw securing seat fast.adj.slide to grab rail / 5x0.8 / 5
TPRT retaining screw / Self-tapping / 7
Screw securing headlight mount (cover) to steering head / 6x1 / 10
Screw securing headlight to headlight mount / Self-tapping / 3
Instrument panel
Instrument panel nut / 5x0.8 / 4
Front fork
Fork bottom end bolt / 6x1 / 8,5 * / GREASE B - sequence
1-2-1
Bottom yoke screw / 8x1.25 / 22 * / GREASE B
sequence 1-2-3-1-2
starting from the bottom
Steering head screw / 8x1.25 / 22 * / GREASE B
Steering bearings ring nut / 35x1 / 30 * / GREASE B
Steering lock nut / 8x1.25 / 16 / LOCK 2 (apply Loctite to nut thread only)
Headlight mount lower bracket screw / 6x1 / 10
Electric system
Screw securing voltage regulator and horn to frame / 6x1 / 10
Immobilizer antenna / LOCK 9 in-between antenna and switch cover
Speed sensor retaining screw / 6x1 / 10
RH-LH switch securing screw / 2.5
Nut securing battery cable and starter motor cable to solenoid starter / 6x1 / 4
ECU-to-support screw / 6x1 / 10
Screw retaining ground cable to crankcase / 6x1 / 10
Coil-to-airbox screw / 5x0.8 / 5
Nut securing solenoid starter-starter motor cable to starter motor / 6
Screw retaining grommet to crankcase / 6x1 / 10
Relay support plate to tank retaining screw / 5x0.8 / 5
Solenoid starter support plate to tank retaining screw / 5x0.8 / 5
ECU support-to-frame screw / 6x1 / 10
Relay to support plate retaining screw / 5x0.8 / 2
Ignition switch cover box nut / 6x1 / 7
Front brake
Front brake caliper retaining screw / 10x1.25 / 43 * / GREASE B
Screw securing front brake master cylinder to handlebar / 6x1 / 10 / Sequence 1-2-1
Brake bleed nipple / 6x1 / 10
Brake bleeding fitting / 10x1 / 23
Screw securing brake line guide bracket to bottom yoke / 6x10 / 10
Rear swingarm
Swingarm pivot shaft retaining screw / 18x1.5 / 75 * / GREASE B
Chain adjustment eccentric screw / 12x1.25 / 31 * / GREASE B - sequence
1-2-1
Calliper plate rotation locking pin / 12x1.25 / 33 * / LOCK 5
Chain slider screw (top and bottom) / 6x1 / 10 / LOCK 2
Chain guard screw (bottom and top) / 6x1 / 10 / LOCK 2
Screw securing mudguard to swingarm / 6x1 / 10 / LOCK 2
Rear brake
Brake bleed nipple / 6x1 / 10
Brake bleeding fitting / 10x1 / 23
Rear brake caliper retaining screw / 8x1.5 / 25 * / GREASE B
Nut on rear brake push-rod / 6x1 / 8
Brake pedal adjuster nut / 2.3
Rear brake pedal w.light switch nut / 5
Rear brake master cylinder retaining screw / 6x1 / 10 / LOCK 2
Rear brake oil tank screw / 6x1 / 2
Handlebar - Clutch control
Screw securing U-bolt to handlebar / 8x1.25 / 25 * / GREASE B
sequence 1-1-2-2-1-1
starting from the arrowed side
Screw securing stud bolt to steering head / 10x1.5 / 45 *
Clutch slave cylinder retaining screw / 6x1 / 10 / Sequence 1-2-3-1
Throttle control retaining screw / 6x1 / 6 / Sequence 1-2-1
Clutch master cylinder retaining screw / 6x1 / 10 / Sequence 1-2-1
Rear shock absorber
Screw/nut securing shock absorber/linkage to swingarm / 10x1.25 / 45 * / GREASE B
Screw securing shock absorber to rocker / 10x1.25 / 45 * / GREASE B
Screw securing linkage to rocker arm / 10x1.25 / 45 * / GREASE B
Screw securing suspension rocker arm to frame / 10x1.25 / 45 * / GREASE B
Ball joints to linkage nut / 12x1.25 / 36 *
Front mudguard
Mudguard stud bolt / 6x1 / 12 / LOCK 2
Stud bolt-to-mudguard screw / 6x1 / 10 / Screw with threadlocker
Front fork leg guard screw / 6x1 / 3 / Screw with threadlocker
Footpegs and Levers
Nut securing UNIBALL for gear change rod and linkage / 6x1 / 10 / Hold the screw
Screw securing heel guard to rear footpeg mount / 5x0.8 / 6 *
Gearchange pedal shaft / 8x1.25 / 23 * / LOCK 2
Screws securing sprocket cover to LH footpeg mount / 5x0.8 / 8
Screw securing footpeg mount plate to crankcase / 10x1.5 / 36
Special screw securing footpeg plate to swingarm pivot shaft / 12x1.25 / 30 / GREASE B
Brake lever fixing screw / 6x1 / 10
Screws securing rear footpeg plates to front plate / 8x1.25 / 24 / LOCK 2
Screw securing gear change lever to pawl / 6x1 / 10 / LOCK 1
Rear mudguard
Rear sprocket splashguard nut / 6x1 / 4.5 / GREASE B
Splashguard bracket retaining screw / 5x0.8 / 5 / LOCK 2
Front wheel
Front wheel shaft nut / 25x1.25 / 63 * / GREASE B (grease nut thread and underside and wheel shaft)
Front brake disc retaining screw / 8x1.25 / 25 * / DRILOC 218 as first mount at BREMBO.
For spare parts: LOCK 2
Rear wheel
Lh rear wheel nut (rear sprocket) / 33x1.5 / 156 * / GREASE B
Rh rear wheel nut (wheel) / 38x1.5 / 177 * / GREASE B
Driving pins securing screw / 6x1 / 11 * / LOCK 2
Rear sprocket nuts / 10x1.25 / 48 * / GREASE B
Rear brake disc retaining screw / 8x1.25 / 25 * / LOCK 2
Fuel Tank
GAC flange screw / 5x0.8 / 5
GAC flange cover screw / 5x0.8 / 5
Screw securing wiring tab to tank / 4x0.7 / 2
Fuel tank filler fixing screw / 5x0.8 / 5
Screw securing tank to subframe / 8x1.25 / 12
Tank front buffer screw / 6x1 / 10
Screw securing fuel line clamp to tank / 4x0.7 / 2
Exhaust
Nut securing manifold to HOR/VERT head / 8x1.25 / 24
CO pick-up blanking plug / G1/8” / 25
Exhaust pipe clamp / 8x1.25 / 19
Screw securing exhaust butterfly valve actuator to subframe / 6x1 / 4 / LOCK 2
Lambda sensor fastener / 18x1.5 / 45
Screw securing collector box to bracket / 6x1 / 10
Silencers jointing clamp / 8x1.25 / 19
Silencers jointing bracket screw / 8x1.25 / 24
Screw securing silencers bracket to subframe / 8x1.25 / 24
Screw securing number plate holder bracket to silencers / 8x1.25 / 24
Seat
Screw securing seat to tank / 5x0.8 / 5
Screw securing seat to fast.adj.slide / 6x1 / 10
Screw securing seat side body panel to subframe / 5x0.8 / 3
Screw securing seat side body panel to silencer / 6x1 / 10
Frame
Engine to frame mounting bolt nut / 12x1.25 / 60 / GREASE B
Rear subframe retaining screw / 8x1.25 / 25
Special screw securing rear subframe to tank support / 8x1.25 / 25
Ignition switch special screw / 6x1 / shear it / Screw with threadlocker
Seat support-to-frame screw / 6x1 / 10
Oil cooler
Oil cooler nipple on cooler / 14x1.5 / 23 / Hold on cooler with LOCK 1
Oil cooler mounting bolt / 6x1 / 10
Oil pipe fitting on cooler with twin seal / 16x1.5 / 18 * / Smear with Engine Oil
Oil pipe fitting on casing with twin seal / 16x1.5 / 25 * / Smear with Engine Oil
Thermistor fastener / 10 / LOCK 4
Air intake/Oil breather
Fitting for stepper motor tube / 8 / LOCK 2
Center screw securing air box to frame / 6x1 / 10
Oil breather valve hose clip / 2
Clamp jointing coupling to airbox / 1.1
Clamp jointing coupling to throttle body / 1.1
Air box peg / 5x0.8 / 5 / LOCK 2
Filter box cover screw / 5x0.8 / 5
Fuel system, Canister
Clamp securing throttle body to intake manifold / 2
Nut securing canister support to bracket / 10
Canister support to engine retaining screw / 6x1 / 10
Fairing
Screw securing LH/RH fairing to frame / 5x0.8 / 5
Screw securing LH/RH fairing to tank / 5x0.8 / 3
Fuel tank cover fixing screw / 5x0.8 / 5
Screw securing cover to filler / 5x0.8 / 2
Rear grab rail cover retaining screw / 4x0.7 / 1
Screw securing headlight fairing to headlight mount (cover) / 5x0.8 / 3
Headlight fairing to headlight bracket mount retaining screw / 5x0.8 / 0.8 / Welnut
Screw securing inner mudguard shell to headlight fairing / 5x0.8 / 3

* critical point for dynamic safety. Tightening torque tolerance must be: ± 5% Nm.

Note

For product specifications and symbols, refer to "Product specifications" (Sect. A 2).

Engine torque settings

Part / Thread (mm) / Nm / Min. / Max. / Note
Blow-by valve / M40x1.5 / 34 / 30 / 38
Mesh filter duct plug / M32x1.5 / 42 / 38 / 46
Oil temperature sensor ring nut / M30x1.5 / 38 / 34 / 42 / LOCK 4
Crankshaft gear fixing nut / M25x1.5 / 190 / 171 / 209 / GREASE B
Generator rotor nut / M24x1 / 270 / 256 / 284 / LOCK 5
Crankshaft gear fixing nut / M22x1 / 190 / 171 / 209 / GREASE B
Oil drain plug / M22x1.5 / 42 / 38 / 46
Oil mesh filter / M22x1.5 / 42 / 38 / 46
Oil filler plug / M22x1.5 / 5 / 5 / 6
Fixed/mobile tensioner pin / M20x1 / 50 / 45 / 55 / LOCK 2
or THREE BOND 1324
Steel/aluminium crankshaft blanking plug / M20x1 / 15 / 13.5 / 16.5
Timing belt roller ring nut on head / M10x1 / 71 / 64 / 78 / GREASE A
Gearbox drum locating screw / M16x1.5 / 30 / 27 / 33
Oil filter nipple / M16x1.5 / 42 / 38 / 46 / LOCK 2
or THREE BOND 1324
Oil cartridge filter / M16x1.5 / 11 / 10 / 12 / Engine oil on seal
Mesh filter duct plug / M15x1 / 20 / 18 / 22 / LOCK 5
or THREE BOND 1375B
By-pass pump plug / M15x1 / 25 / 22 / 28 / LOCK 5
or THREE BOND 1375B
Ring nut for belt rollers on lay shaft / M15x1 / 71 / 64 / 78 / GREASE A
Ring nuts for belt rollers on heads / M15x1 / 71 / 64 / 78 / GREASE A
Generator cover inspection plug / M15x1 / 20 / 18 / 22 / THREE BOND 1215
Fixed tensioner bearing stop screw / M14x2 / 50 / 45 / 55 / GREASE C
Nut for timing lay shaft gear / M14x1 / 55 / 50 / 60 / GREASE A
Radiator preset blanking plug / M14x1.5 / 27 / 24 / 30 / LOCK 5
or THREE BOND 1375B
Oil cooler nipple / M14x1.5 / 27 / 24 / 30 / LOCK 5
or THREE BOND 1375B
Pick-up inspection screw / M12x1 / 15 / 13 / 17 / LOCK 2
or THREE BOND 1324
Earth screw / M12x1 / 15 / 30 / 17 / LOCK 2
or THREE BOND 1324
Oil temperature sensor / M12x1.5 / 18 / 16 / 19 / LOCK 4
Spark plugs / M12x1.25 / 20 / 18 / 22
Head nuts: 1st snug torque
2nd snug torque
final torque / M10x1.5 / 15
25
40 / 23
38 / 27
42 / GREASE C
Grease under head and thread of stud bolt
Con-rod bolts: 1st snug torque
stop for 2sec. and unscrew by 360°
1st snug torque
2nd snug torque
2nd TIGHTENING
check angle > 30° / M10x1 / 35
20
35
70.5 / 66 / 73 / GREASE B
apply grease on thread
Oil pump duct plug / M10x1.5 / Fully home with tool
15 13 17 / LOCK 5
or THREE BOND 1375B
Head stud bolts / M10x1.5 / 25 / 23 / 26 / LOCK 2
or THREE BOND 1324
Pressure switch / M10x1 / 19 / 17 / 21
Reduction bushing / M10x1 / LOCK 5
or THREE BOND 1375B
Spark plug / M10x1 / 15 / 13 / 17
Neutral light switch / M10x1.25 / 10 / 9 / 11
Clutch-side casing service plug / M10x1.5 / 15 / 13 / 17 / LOCK 5
or THREE BOND 1375B
Oil circuit plug on exhaust side / M10x1 / 15 / 13 / 17 / LOCK 2
or THREE BOND 1325
Crankshaft dowels / M8x1.25 / 13 / 11 / 15 / THREE BOND 1375B
Gearbox pawl screw / M8x1.25 / 25 / 22 / 28
Gear stopper screw / M8x1.25 / 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 / M8x1.25 / 26 / 23 / 29
Crankcase jointing bolt: 1st snug torque
final torque / M8x1.25 / 19
25 / 17
22 / 21
28
Casing drilled screw / M8x1.25 / 20 / 18 / 22
Fixed tensioner / M8x1 / 20 / 18 / 22 / LOCK 2
or THREE BOND 1324
Mobile tensioner / M8x1.25 / 26 / 23 / 29
Ground screw / M8x1.5 / 13 / 11 / 15
Clutch springs screws / M6x2 / 6 / 5 / 7
Stator cable guide screw / M6x1 / 10 / 9 / 11 / LOCK 2
or THREE BOND 1324
Starter motor screws / M6x1 / 10 / 9 / 11 / LOCK 2
or THREE BOND 1324
Starter idle gear pin screw / M6x1 / 10 / 9 / 11 / LOCK 2
or THREE BOND 1324
Generator stator retaining screws / M6x1 / 10 / 9 / 11 / LOCK 2
or THREE BOND 1324
Flywheel / rotor screws / M6x1 / 13 / 11 / 15 / LOCK 2
or THREE BOND 1324
Gearbox bearing stop plate screws / M6x1 / 10 / 9 / 11 / LOCK 2
or THREE BOND 1324
Head service screws (aluminium) / M6x1 / 3 / 2 / 3 / LOCK 2
or THREE BOND 1324
Intake manifold fuel pump fitting / M6x1 / 2.5 / 2 / 3 / LOCK 2
or THREE BOND 1324
Bosch pick-up retaining screws / M6x1 / 10 / 9 / 11
Battery mount lower stud bolt / M6x1 / 10 / 9 / 11 / LOCK 2
or THREE BOND 1324
Gearbox pawl screw / M6x1 / 9 / 8.5 / 9.5 / LOCK 2
or THREE BOND 1324
Inspection cover screws / M6x1 / 4.5 / 4.5 / 6
Rocker arm shaft cover screws / M6x1 / 10 / 9 / 11
Intake / exhaust valve cover screws / M6x1 / 10 / 9 / 11
Casing jointing screws / M6x1 / 9 / 8.5 / 9.5
Clutch cover screws / M6x1 / 10 / 8.5 / 9.5
Generator cover screws / M6x1 / 10 / 9 / 11
Clutch spring screws / M5x0.8 / 5 / 5 / 7
Driven belt roller flange retaining screws / M5x0.8 / 5 / 5 / 7
Manifold nipple / M5x0.8 / 3 / 2 / 3 / LOCK 2
or THREE BOND 1324
Head cover plug / M5x0.8 / 2.5 / 2.5 / 3
Screws securing oil pipe to heads / M5x0.8 / 5 / 5 / 7 / LOCK 2
or THREE BOND 1325
Screws / M10x1.5 / 45 / 40 / 50
Screws / M8x1.25 / 25 / 22 / 28
Screws / M6x1 / 10 / 9 / 11
Screws / M5x0.8 / 5 / 5 / 7

Note

For product specifications and symbols, refer to "Product specifications" (Sect. A 2).