5GS 461
2.4 Tightening torques
P and DG screws are fitted in plastic and light alloy metal parts. These screws form a permanent thread when
they are installed for the first time. The material is permanently deformed. Screws can be removed and installed
as often as necessary without impairing the strength of the screwed assembly, provided that the specified
tightening torque is observed.
For this reason it is essential to use a torque wrench.
When inserting DG and P screws into an existing screw thread:
Insert the DG or P screw in the hole and turn counterclockwise until it gently drops into the hole in axial direction
and engages the existing threads. Tighten the screw clockwise to the specified torque.
This procedure ensures that the screw engages properly in the existing thread and does not form a new thread
and weaken the assembly.
For the microencapsulated screw, before renewed assembly, clean both threads (insert tap in the internal thread
by hand and then blow out the threaded hole, brush off the exterior thread), coat the cleaned screw with
medium-strength Loctite 242 or 243.
Screwdriver speed with: P and DG screws max. 500 rpm.
Do not use an impact wrench to release or tighten screw connections.
Screws with and without locking serration must not be confused.
Fastener Thread size For component Tightening
torques
Nm
Comment
Screw M 4x12 Cover for chain tensioner / crankcase 3.0
Stud M 8 Stud / crankcase for bar 23.0 2)
M 10x1 Decompression valve 14.0
Screw D 4x12 Spring housing / fan housing 3.0
Collar nut M 5 Filter cover / slotted nut 1.0
Collar nut M 5 Flange / filter base / carburetor 3.5
Screw M 4x10 Flange / crankcase 2.5 5)
Screw M 4x12 Crank drive flange / crankcase 3.5 4), 6)
Screw P 6x21.5 Handlebar at top / tank housing 8.0 3)
Screw P 6x32.5 Handlebar at bottom / tank housing 8.0 3)
Screw P 4x19 Handle molding 1.6
Screw D 4x16 Hand guard clutch side 4.0 4), 6)
Screw M 5x35x22 Hand guard ignition side 7.0 4), 6)
Screw M 5x23 Shroud / crankcase 6.0
Nut M 5 Shroud / cylinder 3.5
Screw M 5x25 Crankcase drive side / fan side 10.0 4), 6)
Screw M 5x20 Fan housing 7.0 4)
Carrier M 12x1 L Carrier 50.0
Screw M 4x16 Ring buffer / crankcase 4.5 5)
Screw P 6x19 Ring buffer / tank housing rear 5.5
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