Ducati Monster 696 - Service Manual - Reparation - Werkstatthandbuch - Manuale di Servizio - Taller

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DUCATI MONSTER 696 - SERVICE MANUAL - MANUALE DI SERVIZIO - MANUEL DE REPARATION - REPARATURANLEITUNG - MANUAL DE TALLER

- English, Italiano, French, Spanish, German, Portuguese and Japanese Service Manual, Owners Manual (only in english), Parts Catalogue and Wiring Diagrams, for motorcycles Ducati Monster 696.

 
INDEX:

- 0A - General
- 0B - Information about the model
- 0C - Technical data
- 0D - Use and maintenance
- 0E - Fairings
- 0F - Controls - Devices
- 0G - Wheels - Suspension - Brakes
- 0H - Frame
- 0L - Fuel/Exhaust System
- 0M - Fuel injection - ignition system
- 0N - Engine
- 0P - Electrical system
- 0GENERAL SUMMARY

Section A
- 0A - General
- 1 - How to use this manual 3
- Layout of the manual 4
- 2 - Symbols - Abbreviations - References 5
- Product specifications 6
- 3 - Hazardous Products - Warnings 8
- General safety rules 8
- General maintenance indications 9

Section B
- 0B - Information about the model
- 1 - Identification data 3
- Identification data for the Monster 696 i.e. 3

Section C
- 0C - Technical data
- Technical specifications 3
- General 3
- Colours 4
- Transmission 4
- Timing system/valves 4
- Cylinder/Piston 5
- Gearbox 5
- Cooling system 5
- Front wheel 5
- Front suspension 6
- Rear wheel 6
- Rear suspension 6
- Hydraulic brakes 7
- Charging system/alternator 7
- Ignition system 7
- Fuel system 8
- Injection system 8
- Lights/instrument panel 8
- 1.2 - Dimensions 9
- 2 - Fuel, lubricants and other fluids 10
- 3 - Torque settings 11
- Frame torque settings 11
- Engine torque settings 16
- 4 - Service tools 19
- Specific tools for the engine 19
- Specific tools for the frame 23

Section D
- 0D - Use and maintenance
- 1 - Preliminary checks 3
- Running-in precautions 3
- Pre-ride checks 4
- 2 - Starting - Engine warmup 5
- Starting the engine 5
- 3 - Routine maintenance table 7
- Programmed maintenance plan: operations to be carried out by the dealer 7
- Programmed maintenance plan: operations to be carried out by the customer 8
- 4 - Maintenance operations 9
- Checking the engine oil level 9
- Changing the engine oil and filter cartridge 9
- Checking valve clearances 12
- Adjusting the valve clearances 13
- Changing and cleaning the air filters 14
- Changing the brake fluid 15
- Draining the brake circuit 18
- Filling the brake system with fluid 20
- Changing the clutch fluid 23
- Draining the clutch hydraulic circuit 25
- Filling the clutch circuit 27
- Adjusting the steering head bearings 29
- Adjusting the chain tension 31
- Checking brake pad wear and changing brake pads 32
- Adjusting the throttle and choke cables 35
- Adjusting the position of the gearchange and rear brake pedals 37
- Adjusting the rear shock absorber 38
- 5 - Diagnostic instruments 40
- Description of the Ducati Diagnostic System tester 41
- Tester power supply 43
- DDS tester 46
- Checking and adjusting timing belt tension 46
- Adjusting the idle speed 51
- Check the engine oil pressure 56
- Cylinder compression test 61
- Fuel pressure test 64
- Immobilizer override procedure 67
- Guided diagnosis 71
- Testing the battery charging system 74
- Icons table 77

Section E
- 0E - Fairings
- 1 - Headlight fairing - rear-view mirrors 3
- Removal of the rear-view mirrors 4
- Refitting the rearview mirrors 4
- Removal of the headlight fairing (696+) 5
- Refitting the headlight fairing (696+) 6
- 2 - Fairings 7
- Removal of the fuel tank fairings 8
- Refittings the fuel tank fairings 9
- 3 - Seat 12
- Removal of the seat 13
- Refitting the seat 14
- Removal of the tool tray 14
- Refitting the tool tray 15
- 4 - Front mudguard 16
- Removal of the front mudguard 17
- Refitting the front mudguard 18

Section F
- 0F - Controls - Devices
- 1 - Throttle and choke controls 3
- Adjusting the throttle and choke cables 4
- Removal of the throttle twistgrip 4
- Refitting the throttle twistgrip 6
- Removal of the choke cable 7
- Refitting the choke control 8
- 2 - Hydraulic clutch control 12
- Removal of the clutch master cylinder assembly 13
- Refitting the clutch master cylinder assembly 14
- Removal of the clutch slave cylinder 16
- Refitting the clutch slave cylinder 17
- 3 - Front brake control 21
- Removal of the front brake master cylinder 22
- Refitting the front brake master cylinder 23
- 4 - Rear brake control 24
- Removal of the rear brake master cylinder 25
- Disassembly of the rear brake control 27
- Refitting the rear brake master cylinder 28
- 5 - Gearchange mechanism 33
- Removal of the gearchange mechanism 34
- Disassembly of the gearchange mechanism 35
- Refitting the gearchange mechanism 36

Section G
- 0G - Wheels - Suspension - Brakes
- 1 - Front wheel 3
- Removal of the front wheel 4
- Overhauling the front wheel 6
- Refitting the front wheel 8
- 2 - Front fork 11
- Removal of the front forks 12
- Overhauling the front forks 13
- Refitting the front forks 26
- 3 - Hydraulic front brake 27
- Maintenance operations 28
- Removal of the front brake system 28
- Removal of the brake discs 30
- Overhauling the front brake components 30
- Refitting the front brake system 31
- 4 - Rear wheel 34
- Removal of the rear wheel 35
- Overhauling the rear wheel 37
- Refitting the rear wheel 38
- 5 - Rear swingarm 41
- Removal of the swingarm 42
- Inspecting the swingarm pivot shaft 44
- Checking swingarm endfloat 45
- Refitting the swingarm 46
- 6 - Hydraulic rear brake 48
- Removal of the rear brake system 49
- Refitting the rear brake system 51
- 7 - Rear suspension 53
- Rear suspension system 54
- Removal of the rear shock absorber 54
- Overhauling the rear shock absorber 55
- Refitting the rear suspension 57
- 8 - Final drive 58
- Inspecting the final drive 59
- Removal of the front sprocket 60
- Refitting the front sprocket 61
- Removal of the rear sprocket 62
- Refitting the rear sprocket 63

Section H
- 0H - Frame
- 1 - Handlebar 3
- Removal of the handlebar 4
- Refitting the handlebar 5
- 2 - Steering 6
- Adjusting the steering head bearings 7
- Steering angle adjustment 8
- Removal of the steering head components 9
- Refitting the steering head components 13
- 4 - Footrest brackets 16
- Removal of the footrest brackets 17
- Refitting the footrest brackets 20
- 5 - Stands 24
- Removal of the sidestand 25
- Refitting the sidestand 27
- 6 - Frame inspection 28
- Disassembly of structural components and the frame 29
- Removal of the frame 31
- Removal of the rear subframe 34
- Checking the frame 36
- Reassembly of the rear subframe 37
- Refitting the rear subframe 39
- 7 - Tail light-number plate holder and locks 40
- Removal of the tail light-protection-number plate holder assembly 41
- Refitting the tail light-protection-number plate holder assembly 44
- Removal of the seat release mechanism 46
- Refitting the seat release mechanism 48
- Removal of the number plate holder 50
- Refitting the number plate holder 50

Section L
- 0L - Fuel/Exhaust System
- 2 - Fuel tank 3
- Removal of the fuel tank 4
- Removal of the fuel tank filler cap 7
- Refitting the filler cap 7
- Removal of the fuel tank flange 8
- Refitting the fuel tank flange 9
- Refitting the fuel tank 10
- 6 - Throttle body for pivoting fuel tank 19
- Removal of the throttle body 20
- Refitting the throttle body 23
- 7 - Air intake 28
- Removal of the airbox 29
- Removal of the oil breather valve 33
- Refitting the oil breather valve 33
- Refitting the airbox 34
- 8 - Exhaust system 41
- Operating principle of the catalytic converter 42
- Removal of the exhaust system 43
- Refitting the exhaust system 47

Section M
- 0M - Fuel injection - ignition system
- 1 - Description of the system 3
- General information on the fuel injection-ignition system 3
- Fuel circuit 6
- Air circuit 7
- Operating phases 9
- 2 - Fuel injection-ignition system 10
- 3 - System components 11
- Electronic Control Unit (ECU) 11
- Fuel injectors 13
- Lambda sensor 15
- Air pressure sensor 17
- Temperature sensor 18
- Spark plug 19
- Coil 20
- Throttle Position Sensor (TPS) 22
- Rpm/timing sensor 23
- Main and injection relays 24

Section N
- 0N - Engine
- 1 - Removal–refitting of the engine assembly 4
- Removal of the engine 5
- Refitting the engine 7
- 2.1 - Lubrication system: oil pump 8
- Removal of the oil pump 9
- Disassembly of the oil pump 10
- Reassembly of the oil pump 10
- Refitting the oil pump 11
- 4.1 - Cylinder head assemblies: checks and adjustments 12
- Checking and adjusting valve clearances 13
- Checking the engine timing 17
- 4.2 - Cylinder head assemblies: timing belt covers/timing system 19
- Removal of the timing belt covers 20
- Removal of the timing system assembly 21
- Disassembly and reassembly of the timing belt pulleys 25
- Refitting the timing system assembly 26
- Refitting the timing belt covers 36
- 4.3 - Cylinder head assemblies: camshafts 37
- Removal of the intake manifolds 38
- Refitting the intake manifolds 39
- Removal of the inner timing belt covers 40
- Removal of the valve covers 42
- Refitting the valve covers 43
- Removal of the camshafts 44
- Inspecting the camshafts 46
- Checking the oil seals 46
- Refitting the camshafts 47
- Refitting the camshaft end caps 50
- 4.4 - Cylinder head assemblies: valves - rocker arms 52
- Removal of the cylinder head assembly 53
- Removal of the rocker arms, shims and valves 54
- Overhaul of cylinder head components 58
- Refitting the cylinder head assembly 67
- Refitting the rocker arms, shims and valves 68
- Refitting the cylinder heads 72
- 5 - Cylinder/piston assemblies 74
- Removal of the cylinder/piston assembly 75
- Overhaul of the cylinder barrel/piston components 78
- Refitting the cylinder/piston assembly 84
- 6.1 - Clutch assembly: APTC wet clutch 88
- Description of the APTC clutch assembly 89
- Removal of the APTC clutch 90
- Disassembly of the clutch hub-plates-centre assembly 92
- Overhaul and inspection of the APTC clutch components 93
- Reassembly of the clutch hub-plates-centre assembly 95
- Refitting the APTC clutch 97
- 6.2 - Clutch assembly: clutch-side crankcase cover 100
- Removal of the clutch-side crankcase cover 101
- Disassembly of the clutch-side crankcase cover 102
- Reassembly of the clutch-side crankcase cover 103
- Refitting the clutch-side crankcase cover 104
- 6.3 - Clutch assembly: primary drive gears 106
- Removal of the primary drive gears 107
- Refitting the primary drive gears and checking backlash 109
- 7.1 - Gearbox assembly: gearchange mechanism 112
- Removal of the gearchange mechanism 113
- Disassembly of the gear selector mechanism 114
- Disassembly of the gear interlock plunger and pawl assembly 115
- Refitting the gear interlock plunger and pawl assembly 116
- Reassembly of the gearchange mechanism 118
- Refitting the gearchange mechanism 121
- 7.2 - Gearbox assembly: gearbox shafts 123
- Removal of the gearbox assembly 124
- Disassembly of the gearbox shafts 126
- Overhaul of the gearbox 134
- Inspection of the gear selector forks 135
- Inspection of the gear selector drum 136
- Reassembly of the gearbox shafts 137
- Reassembly of the gearbox 141
- 8 - Flywheel - alternator 142
- Removal of the alternator-side crankcase cover 143
- Disassembly of the alternator-side crankcase cover 145
- Removal of the flywheel/alternator assembly 146
- Checking the flywheel/alternator assembly 148
- Refitting the flywheel-alternator assembly 153
- Reassembly of the alternator-side crankcase cover 155
- Refitting the alternator-side crankcase cover 155
- 9.1 - Crankcase assembly: external components 162
- Removal of external components 163
- Refitting the external components 167
- Removal of the timing gears 172
- Refitting the timing gears 174
- Removal of the starter motor idler gear 175
- Refitting the starter motor idler gear 176
- 9.2 - Crankcase assembly: crankcase halves 177
- Separation of the crankcase halves 178
- Overhaul of the crankcase halves 181
- Overhaul of the main bearings 184
- Reassembly of the crankcase halves 185
- Shimming the shafts 187
- Reassembly of the crankcase halves 192
- 9.3 - Crankcase assembly: crankshaft/connecting rods assembly 197
- Removal of the crankshaft/connecting rods assembly 198
- Disassembly of the crankshaft/connecting rods assembly 198
- Overhaul of the connecting rods 199
- Reassembly of the connecting rods 205
- Refitting the crankshaft/connecting rod assembly 207

Section P
- 0P - Electrical system
- 1 - Wiring diagram 4
- Key to wiring diagram 5
- Wiring colour codes 5
- Key to fusebox 6
- Routing of wiring on frame 7
- Plate A 9
- Plate B 9
- Plate C 11
- Plate D 12
- Plate E 13
- Plate F 15
- Plate G 16
- Plate H 16
- Plate J 18
- Plate K 18
- Plate L 19
- Plate M 21
- Plate N 21
- Plate O 23
- Plate P 25
- Plate Q 27
- Plate R 28
- Plate S 29
- Plate T 31
- Plate U 32
- Plate V 34
- 2 - Battery charging system 36
- Checking the battery charging system 36
- Recharging the battery 37
- Topping up the electrolyte 38
- Battery 41
- Battery support 43
- Alternator 44
- Rectifier-regulator 45
- 3 - Electric starting system 50
- Electric starting system 50
- Starter motor 51
- Starter contactor 53
- 4 - Lights and indicating devices 56
- Renewal of the headlight 56
- Changing bulbs 60
- High beam headlights relay 64
- Headlight aim 65
- 5 - Indicating devices 66
- Checking the indicating devices 66
- Changing light bulbs 71
- 6 - Protection and safety devices 72
- Checking protection and safety device components 72
- Checking the fuses 74
- 7 - Instruments 75
- Instrument panel 75
- Instrument panel system 75
- Display settings and functions 78
- 8 - Immobilizer and transponder 102
- 9 - Diagnostic instruments 105
- Using a multimeter to check the electrical systems 105