Ducati Monster 1200 - Service Manual - Repair Manual

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DUCATI MONSTER 1200 - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycles Ducati Monster 1200.

 
CONTENTS:

M.01 - General
How to use this manual
- Layout of the manual
Symbols - Abbreviations - References
- Product specifications
Hazardous Products - Warnings
- General maintenance instructions
- General safety rules
M.02 - Information about the model
Model identification data
- Identification data
M.03 - Technical data
Technical specifications
- Lights/instrument panel
- Lights/instrument panel
- Injection system
- Fuel system
- Injection-ignition system
- Charging system/generator
- Hydraulic brakes
- Rear suspension
- Rear wheel
- Front suspension
- Front wheel
- Cooling system
- Gearbox
- Cylinder/Piston
- Crankshaft
- Timing system/valves
- Transmission
- Colours
- General
Dimensions
- Dimensions
- Dimensions
Fuel, lubricants and other fluids
- Fuel, lubricants and other fluids
Torque settings
- Engine tightening torque values
- Frame tightening torque values
Service tools
- Special diagnosis equipment
- Special tools for the frame
- Specific tools for the engine
M.04 - Maintenance operations
Scheduled maintenance chart
- Operations to be carried out by the customer
- Operations to be carried out by the dealer
Maintenance operations
- Adjusting the rear shock absorber
- Adjusting the front fork
- Adjusting the position of the gear change and rear brake pedals
- Adjusting the clutch lever and front brake lever
- Checking the rear brake pad wear and changing the brake pads
- Checking the front brake pad wear and changing the brake pads
- Adjusting the chain tension
- Adjusting the steering head bearing play
- Filling the clutch circuit
- Draining the clutch hydraulic circuit
- Changing the clutch fluid
- Changing the fluid in the rear brake system
- Changing the fluid in the front brake system
- Changing the coolant
- Checking the coolant level
- Changing and cleaning the air filters
- Spark plugs replacement
- Changing the timing belts
- Checking valve clearance
- Changing the engine oil and filter cartridge
- Check engine oil level
M.05 - Fairings
Panel - headlight fairing
- Refitting the panel
- Removing the panel
Gruppo cruscotto
- Rimontaggio gruppo cruscotto
- Smontaggio gruppo cruscotto
Seat - side panels
- Rimontaggio cover fondo sella
- Smontaggio cover fondo sella
- Rimontaggio maniglie posteriori
- Smontaggio maniglie posteriori
- Refitting the seat release mechanism
- Removal of the seat release mechanism
- Refitting the seat
- Removing the seat
Front and rear mudguard
- Refitting the rear mudguard
- Removing the rear mudguard
- Refitting the front mudguard
- Removing the front mudguard
M.07 - Chassis
Front wheel
- Refitting the front wheel
- Overhauling the front wheel
- Removing the front wheel
Rear wheel
- Refitting the rear wheel
- Overhauling the rear wheel
- Removing the rear wheel
Front brake control
- Refitting the front brake system
- Refitting the brake discs
- Overhauling the front brake components
- Removing the brake discs
- Removing the front brake system
- Maintenance operations
- Refitting the front brake master cylinder
- Removing the front brake master cylinder
Rear brake
- Refitting the rear brake calliper
- Removing the rear brake disc
- Removing the rear brake calliper
- Refitting the rear brake control
- Disassembling the rear brake control
- Removing the rear brake control
ABS information
- Disabling the ABS
- ABS operating information
- Operating principle
ABS components
- Wiring/hose routing
- Refitting the ABS control unit
- Removing the ABS control unit
- Changing the rear phonic wheel sensor
- Changing the front phonic wheel sensor
ABS component maintenance
- Bleeding the ABS hydraulic system
- Adjusting the phonic wheel sensor AIR-GAP
Handlebar unit: Throttle twistgrip
- Refitting the throttle twistgrip
- Removal of the throttle twistgrip
- Refitting the handlebar
- Removing the handlebar
Handlebar unit: hydraulic clutch control
- Refitting the clutch transmission unit
- Removal of the clutch transmission unit
- Refitting the clutch master cylinder assembly
- Removal of the clutch master cylinder assembly
Gearchange mechanism
- Refitting the gearchange mechanism
- Disassembling the gearchange control
- Removing the gearchange mechanism
Fork - steering head: front fork
- Refitting the front forks
- Removal of the front forks
Fork - steering head: steering
- Refitting the steering tube components
- Removing the steering head components
- Steering angle adjustment
- Adjusting the steering head bearing clearance
Rear shock absorber unit
- Refitting the rear suspension
- Overhauling the rear shock absorber
- Removing the rear shock absorber
- Rear suspension system
Swinging arm
- Refitting the rear swinging arm
- Inspecting the swinging arm shaft
- Removing the swinging arm
- Refitting the rear wheel eccentric hub and rear wheel shaft
- Removing the rear wheel eccentric hub and the rear wheel shaft
Final drive
- Washing the chain
- Refitting the rear sprocket
- Replacing the rear sprocket
- Refitting the front sprocket
- Removing the front sprocket
- Inspecting the final drive
Footpeg brackets
- Rimontaggio piastra porta pedane
- Smontaggio piastra porta pedane
- Refitting the footpegs
- Removing the footpegs
Stands
- Refitting the side stand
- Removing the side stand
Frame inspection
- Refitting the headlight assembly
- Reassembling structural components and frame
- Removal of the rear subframe
- Removing of the headlight assembly
- Disassembling structural components and frame
Tail light - number plate holder
- Rimontaggio fanale posteriore
- Smontaggio fanale posteriore
- Refitting the number plate holder
- Removing the number plate holder
Electrical component tray
- Refitting the electrical component tray
- Removing the electrical component tray
M.08 - Fuel system / Exhaust system
Fuel tank
- Refitting the fuel tank
- Refitting the fuel tank flange
- Removing the tank flange
- Refitting the filler cap
- Removing the filler cap
- Removing the fuel tank
Airbox - Throttle Body
- Refitting airbox and throttle body
- Removing the airbox and throttle body
Air intake
- Refitting the secondary air system
- Removing the secondary air system
- Refitting the air filters
- Removing the air filters
Exhaust system
- Refitting the silencer
- Refitting the exhaust system
- Removing the exhaust system
- Removing the silencer
Canister filter
- Refitting the Canister filter
- Removing the Canister filter
- Canister filter system
M.09 - Engine
Removing-refitting the engine assembly
- Refitting the engine
- Removing the engine
Lubrication system: oil pump
- Refitting the oil pump
- Reassembling the oil pump
- Disassembling the oil pump
- Removing the oil pump
Lubrication system: oil cooler
- Refitting the lubrication system
- Oil cooler inspection
- Removing the lubrication system
Cooling system: water tank
- Refitting the water tank
- Removing the water tank
Cooling system: water radiator
- Refitting the cooling system hoses and unions
- Removing the cooling system hoses and unions
- Refitting the water radiator
- Replacing the cooling fan
- Removing the water radiator
Cooling system: water pump
- Refitting the water pump
- Removing the water pump
Cylinder head assembly: checks and adjustments
- Checking the engine timing
- Checking valve lift
- Checking and adjusting the valve clearance
Cylinder head assembly: timing system
- Refitting the timing outer covers
- Refitting the timing belts
- Refitting the cylinder heads pulleys/idler pulleys
- Reassembling the timing pulleys
- Refitting the idler and tensioner pulley mounting pins
- Refitting the timing layshaft pulley
- Removing the timing layshaft pulleys
- Disassembling the camshaft pulleys
- Removing the tensioner pins
- Removing the cylinder head pulley/idler pulley
- Removing the tensioner pulley/timing belt
- Removing the timing belt covers
Cylinder head assembly: camshafts
- Refitting the intake manifold and water union
- Removing the intake manifold and water union
- Refitting the camshafts
- Checking the camshafts and supports
- Removing the camshafts
Cylinder head assemblies: valves - rocker arms
- Refitting the cylinder head assemblies
- Reassembling the cylinder head
- Overhauling the cylinder head components
- Removing the valve rocker arms
- Removing the valves
- Removing the cylinder heads
Cylinder/piston assembly
- Refitting the cylinder/piston assembly
- Overhauling the cylinder/piston components
- Removing the cylinder/piston assembly
Clutch assembly: clutch
- Reassembling the clutch
- Checking and overhauling the components
- Removing the clutch
- Description of the clutch assembly
Clutch assembly: clutch cover
- Refitting the clutch cover
- Reassembling the clutch cover
- Disassembling the clutch cover
- Removing the clutch cover
Clutch assembly: primary drive gears
- Refitting the primary drive gears and checking backlash
- Removing the primary drive gears
Gearbox assembly: gearchange mechanism
- Refitting the gearchange mechanism
- Refitting the gear interlock plunger and ratchet
- Disassembling gear interlock plunger and ratchet
- Removing the gearchange mechanism
Gearbox assembly: gearbox shafts
- Reassembling the gearbox assembly
- Reassembling the gearbox shafts
- Inspecting the fork selector drum
- Inspecting the gear selector forks
- Overhauling the gearbox
- Disassembling the gearbox shafts
- Removing the gearbox assembly
Flywheel - generator
- Refitting the generator cover
- Refitting the flywheel-generator assembly
- Overhauling the flywheel-generator assembly
- Removing the flywheel - generator assembly
- Disassembling the generator cover
- Removing the generator cover
Crankcase assembly: outer components
- Refitting the starter motor
- Removing the starter motor
- Refitting the starter motor gear
- Removing the starter motor idler gear
- Refitting the timing gears
- Removing the timing gears
- Refitting the external components
- Removing outer components
Crankcase assembly: crankcase halves
- Reassembling the crankcase halves
- Shimming the shafts
- Reassembling the crankcase halves
- Main bearings
- Overhauling the crankcase halves
- Separating the crankcase halves
Crankcase assembly: connecting rods
- Refitting the connecting rod assembly
- Reassembling the connecting rod assembly
- Overhauling the connecting rods
- Disassembling the connecting rod assembly
- Removing the connecting rod assembly