Does Anyone know if an old fashioned paper workshop manual is available..i did get a manual on disc but when I opened it up it took me online and internet explorer went bananas and basically knackered my hard drive :Arghh:…I had to get a new hard drive installed :Inpain: I’ve since thrown the offending cd in the bin! I’d really like to know the torque settings of all the major nuts and bolts and all the other tips that you get from a workshop manual,if a paper one isn’t available it might be an idea for someone to list torque settings and other maintenance help somewhere on the site
I think that was probably a coincidence...shame! Well, I just erm borrowed works industrial sized printer for my last workshop manual. And stored it in a folder. Perfect I mean, if you have a pdf it's easy..but is the manual a pdf or something else?
Something like this? Hypermotard Torque Settings Settings in Nm. Bolt size, pitch then the three settings (min, normal, max) Torque settings Frame torque settings 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 holdershell 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 steeringhead 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 holderbracket 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 Editor note: vacuum caps needed to replace this ugly mofo: 1/8 size 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. Engine torque settings 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 15 2nd snug torque 25 final torque M10x1.5 40 GREASE C Grease under head and thread of stud bolt Con-rod bolts: 1st snug torque 35 stop for 2 sec. and unscrew by 360° 1st snug torque 20 2nd snug torque 35 2nd TIGHTENING 30.5 check angle > 30° M10x1 GREASE B apply grease on thread Oil pump duct plug M10x1.5 Fully home with tool 15 LOCK 5 or THREE BOND 1375B Head stud bolts M10x1.5 25 LOCK 2 or THREE BOND 1324 Pressure switch M10x1 19 Reduction bushing M10x1 LOCK 5 or THREE BOND 1375B Spark plug M10x1 15 Neutral light switch M10x1.25 10 Clutch-side casing service plug M10x1.5 15 LOCK 5 or THREE BOND 1375B Oil circuit plug on exhaust side M10x1 15 LOCK 2 or THREE BOND 1325 Crankshaft dowels M8x1.25 13 THREE BOND 1375B Gearbox pawl screw M8x1.25 25 Gear stopper screw M8x1.25 18 LOCK 2 or THREE BOND 1324 Intake and exhaust flange stud bolts M8x1.25 15 LOCK 2 or THREE BOND 1324 Intake manifold nuts M8x1.25 23 Oil pump screws M8x1.25 26 Crankcase jointing bolt: 1st snug torque 19 final torque M8x1.25 25 Casing drilled screw M8x1.25 20 Fixed tensioner M8x1 20 18 22 LOCK 2 or THREE BOND 1324 Mobile tensioner M8x1.25 26 Ground screw M8x1.5 13 Clutch springs screws M6x2 6 Stator cable guide screw M6x1 10 LOCK 2 or THREE BOND 1324 Starter motor screws M6x1 10 LOCK 2 or THREE BOND 1324 Starter idle gear pin screw M6x1 10 LOCK 2 or THREE BOND 1324 Generator stator retaining screws M6x1 10 LOCK 2 or THREE BOND 1324 Flywheel / rotor screws M6x1 13 LOCK 2 or THREE BOND 1324 Gearbox bearing stop plate screws M6x1 10 LOCK 2 or THREE BOND 1324 Head service screws (aluminium) M6x1 3 LOCK 2 or THREE BOND 1324 Intake manifold fuel pump fitting M6x1 2.5 LOCK 2 or THREE BOND 1324 Bosch pick-up retaining screws M6x1 10 Battery mount lower stud bolt M6x1 10 LOCK 2 or THREE BOND 1324 Gearbox pawl screw M6x1 9 LOCK 2 or THREE BOND 1324 Inspection cover screws M6x1 4.5 Rocker arm shaft cover screws M6x1 10 Intake / exhaust valve cover screws M6x1 10 Casing jointing screws M6x1 9 Clutch cover screws M6x1 10 Generator cover screws M6x1 10 Clutch spring screws M5x0.8 5 Driven belt roller flange retaining screws M5x0.8 5 Manifold nipple M5x0.8 3 LOCK 2 or THREE BOND 1324 Head cover plug M5x0.8 2.5 Screws securing oil pipe to heads M5x0.8 5 LOCK 2 or THREE BOND 1325 Screws M10x1.5 45 Screws M8x1.25 25 Screws M6x1 10 Screws M5x0.8 5
It's for the air cooled hypers. I grabbed the list from online somewhere and think it's for the 1100 but can't imagine why it would differ greatly for the 796. I have the workshop manual and when I get the time plan to produce something from that as the format for this is not great but.....
