Ducati Monster 696 2009 Manuale utente

A - General 0

B - Information about the model 0

C - Technical data 0

D - Use and maintenance 0

E - Fairings 0

F - Controls - Devices 0

G - Wheels - Suspension - Brakes 0

H - Frame 0

L - Fuel/Exhaust System 0

M - Fuel injection - ignition system 0

N - Engine 0

P - Electrical system 0

GENERAL SUMMARY 0

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2Monster 696/696+ - M.Y. 2009 - edition 00
General summary
Section A 
A - General 0
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 
B - Information about the model 0
1 - Identification data 3
Identification data for the Monster 696 i.e. 3
Section C 
C - Technical data 0
1.1 - 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

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3Monster 696/696+ - M.Y. 2009 - edition 00
General summary
4 - Service tools 19
Specific tools for the engine 19
Specific tools for the frame 23
Section D 
Use and maintenance 0
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

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4Monster 696/696+ - M.Y. 2009 - edition 00
General summary
Section E 
E - Fairings 0
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 
F - Controls - Devices 0
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

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5Monster 696/696+ - M.Y. 2009 - edition 00
General summary
Section G 
G - Wheels - Suspension - Brakes 0
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

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6Monster 696/696+ - M.Y. 2009 - edition 00
General summary
Section H 
H - Frame 0
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 
L - Fuel/Exhaust System 0
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

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7Monster 696/696+ - M.Y. 2009 - edition 00
General summary
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
10 - Evaporative emissions canister 51
Evaporative emissions canister system (USA versions only) 52
Removal of the evaporative emissions canister 53
Refitting the evaporative emissions canister 55
Section M 
M - Fuel injection - ignition system 0
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 
N - Engine 0
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

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8Monster 696/696+ - M.Y. 2009 - edition 00
General summary
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

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9Monster 696/696+ - M.Y. 2009 - edition 00
General summary
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

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10 Monster 696/696+ - M.Y. 2009 - edition 00
General summary
Section P 
P - Electrical system 0
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