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Ducati Monster 696 2009, Manual

The Ducati Monster 696 2009 is a sleek and powerful motorcycle that promises an exhilarating ride. To ensure a seamless ownership experience, we provide a comprehensive user manual that can be easily downloaded for free from our website. Explore the thrilling world of Ducati with our detailed manual at manualshive.com.

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A

B

C

D

E

F

G

H

L

M

N

P

section

C 3

18

Monster 696/696+

 - M.Y. 2009 - edition 00

Technical data

Notes

For product specifications and symbols, see paragraph “Product specifications” (Sect. A 2).

Wet clutch centre nut

M25x1.5

190

180

200

GREASE B

Oil filler plug

M20x2.5 

5

5

6

Oil way blanking plug 

M10x1

15

13

17

LOCK 5 or 
THREE BOND 1375B

Oil pressure sensor 

M10x1

19

17

21

Dry clutch drum screws 

M8x1.25 

35

33

37

LOCK 4

Clutch cover screw 

M6x1

10

9

11

Clutch cover screw 

M6x1

10

9

11

Clutch cover screw with cable guide

M6x1

9.5

8.5

9

Wet clutch cover screw

M6x1

9.5

8.5

9

Wet clutch cover screw

M6x1

9.5

8.5

9

Wet clutch cover screw

M6x1

9.5

8.5

9

Wet clutch spring screw

M6x1

10

9

11

Alternator cover inspection plug

M15x1

20

18

22

THREE BOND 1215

Pick-up sensor inspection screw

M12x1

15

13

17

LOCK 2 or 
THREE BOND 1324

Spark plug 

M12x1.25

20

18

22

Alternator-side crankcase cover screw

M6x1

10

9

11

Alternator-side crankcase cover screw

M6x1

10

9

11

Alternator-side crankcase cover screw

M6x1

10

9

11

Inspection cover screw 

M6x1

4.5

4.5

6

Alternator stator retaining screw

M6x1

10

9

11

LOCK 2 or 
THREE BOND 1324

Alternator rotor/flywheel screw 

M6x1

13

11

15

LOCK 5

Stator wiring clamp bracket screw

M5x0.8 

5

5

7

By-pass pump cap 

M15x1

25

22

28

LOCK 5 or 
THREE BOND 1375B

Reducer bush

M10x1

-

-

-

LOCK 5 or 
THREE BOND 1375B

Oil pump retaining screw 

M8x1.25 

26

23

29

Oil pump retaining screw 

M6x1

10

9

11

Oil pump assembly screw

M6x1

10

9

11

Part

Thread (mm) Nm

Min.

Max.

Notes

Summary of Contents for Monster 696 2009

Page 1: ...tion about the model0 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 ...

Page 2: ...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...

Page 3: ...aning 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...

Page 4: ... 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 ...

Page 5: ... 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 suspen...

Page 6: ...oval 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 numb...

Page 7: ...ns 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 P...

Page 8: ... 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 assemb...

Page 9: ...lywheel 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 timin...

Page 10: ... 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 bea...

Page 11: ... 2009 edition 00 General summary 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 ...

Page 12: ......

Page 13: ...A B C D E F G H L M N P A General 0 ...

Page 14: ...ster 696 696 M Y 2009 edition 00 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 ...

Page 15: ... specialized technicians should have a basic technical background Additional information on how to install various components is provided in the parts catalogue Important This manual also describes the essential checks to be carried out prior to delivery of the motorcycle Ducati Motor Holding S p A declines all liability for any technical errors or omissions in this manual and reserves the right t...

Page 16: ... to its fully assembled starting condition Important Some of the sections of this manual are not present since the motorcycle in question is not equipped with the relevant parts Important The layout of the manual is designed in such a way as to be applicable to all the different models manufactured by Ducati Motor Holding To facilitate consultation of the manual the table of contents is identical ...

Page 17: ...g The terms right hand RH and left hand LH are used with reference to the motorcycle s direction of forward travel Warning Failure to comply with these instructions may put you at risk and could lead to severe injury or even death Important Failure to follow the instructions in text marked with this symbol can lead to serious damage to the motorcycle and its components Notes This symbol indicates ...

Page 18: ...int grease for parts subject to prolonged mechanical stress Temperature range 10 to 110 C SHELL Retinax LX2 GREASE D Protective grease with anti corrosive and waterproofing properties SHELL Retinax HD2 GREASE E PANKL grease PLB 05 GREASE F OPTIMOL grease PASTE WHITE T LOCK 1 Low strength threadlocker Loctite 222 LOCK 2 Medium strength threadlocker compatible with oil Loctite 243 LOCK 3 High streng...

Page 19: ...high temperature excellent resistance to solvents and chemical attack Loctite 128443 LOCK 11 Instant adhesive gel offering tensile shear strength Loctite 454 gel DUCATI liquid gasket 942470014 Exhaust pipe paste Self sealing paste hardens when heated resists temperatures exceeding 1000 C Holts Firegum Spray used to protect electrical systems Eliminates moisture and condensation and provides excell...

Page 20: ... has been stopped Wear heat resistant gloves before handling these components or allow the engine and exhaust system to cool down before proceeding Warning The exhaust system might be hot even after engine is switched off take special care not to touch the exhaust system with any part of your body and do not park the motorcycle next to inflammable material wood leaves etc Used engine oil Warning P...

Page 21: ...perations needed to access the part to be repaired Note that the disassembly procedures in this manual describe the most efficient way to reach the part to be repaired General advice on repair work Always use top quality tools When lifting the motorcycle only use devices that comply fully with the relevant European directives When working on the motorcycle always keep the tools within reach ideall...

Page 22: ......

Page 23: ...A B C D E F G H L M N P B Information about the model0 ...

Page 24: ...A B C D E F G H L M N P section B 2 Monster 696 696 M Y 2009 edition 00 Information about the model 1 Identification data 3 Identification data for the Monster 696 i e 3 ...

Page 25: ...cation data Identification data for the Monster 696 i e Each Ducati motorcycle has two identification numbers the frame number and the engine number and an EC nameplate A not present on the US version Notes Please quote these numbers which identify the motorcycle model when ordering spare parts dB A min 1 ZDM e A ...

Page 26: ...power 01 Power limited 4 Version 5 Year of manufacture 8 2008 6 Manufacturing facility 7 Progressive serial No Data stamped on the frame US version 1 Ducati 2 Motorcycle type 3 Variant Numeric or X Check digit 4 Model year 8 2008 5 Manufacturing facility 6 Progressive serial No ZDM M5 00 01 AA X B 000001 4 3 5 6 7 2 1 Data stamped on the frame Europe version 3 4 5 6 1 2 ZDM 1 R A DN X B 000001 Dat...

Page 27: ...amped on engine Europe version 1 Manufacturer Ducati Motor Holding 2 Engine type 3 Progressive production No Data stamped on engine US version 1 Engine type 2 Model year 3 Progressive production No ZDM 696A2 000001 2 1 3 Data stamped on engine Europe version RAD X 000001 1 3 2 Data stamped on engine US version ...

Page 28: ......

Page 29: ...A B C D E F G H L M N P C Technical data 0 ...

Page 30: ...ng 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 t...

Page 31: ...Subframe Type Cast aluminium Steering head angle 22 8 Steering angle 32 Trail 87 mm Front wheel Light alloy with three spokes Front wheel size MT 3 50x17 Front tyre size 120 60 ZR 17 Rear wheel Light alloy three spokes with cush drive dampers Rear wheel size MT 4 50x17 Rear tyre size 160 60 ZR 17 Type of tyre Radial tubeless tyres Front brake Hydraulic with 2 calipers Rear brake Hydraulic with 1 c...

Page 32: ... gears operated by a lever on the left side of the motorcycle Gear ratios 1st 2nd 3rd 4th 5th 6th 13 32 18 30 21 28 23 26 22 22 26 24 Reference Adjusting clearance Checking clearance Timing diagram With 1 mm valve clearance Intake Opening 18 B T D C Closing 60 A B D C Exhaust system Opening 53 B B D C Closing 23 A T D C Intake valve diameter 44 mm Exhaust valve diameter 38 5 mm Valve lift With 0 m...

Page 33: ... clearance 0 015 to 0 058 mm Nominal diameters Ø 18 mm Piston Ø 18 mm 0 020 to 0 015 Gudgeon pin Ø 18 mm 0 to 0 004 Gudgeon pin to connecting rod clearance 0 006 to 0 028 mm Cylinder compression Standard Minimum Max permissible difference 11 to 13 bar min 10 bar max 2 bar Reference Standard value Service limit Gearbox shafts Endfloat 0 05 to 0 020 mm Selector drum Endfloat 0 10 to 0 040 mm Gear se...

Page 34: ...most worn part 2 mm Tyre pressure Cold 2 2 2 4 bar Swingarm pivot shaft runout On 100 mm 0 2 mm Wheel rim runout Radial 1 mm 0 04 inc Lateral 0 5 mm 0 02 inc Chain Make Type D I D 520 V6 Dimensions 5 8 x 1 4 No of links 107 1 open Reference Technical specifications Type SACHS progressive monoshock with adjustable rebound compression and spring preload Shock absorber Stroke 59 5 mm Hydraulic dampin...

Page 35: ...ylinder Type PS 15 Master cylinder diameter 15 mm REAR Brake disc Type Drilled disc Shim 5 mm 4 5 mm min Material Steel Diameter 245 mm Braking surface 25 cm2 Brake caliper Make Brembo Type P34C 2 pistons Caliper cylinder diameter 34 mm Pad friction material FERIT I D 450 FF Brake master cylinder Type PS11 Master cylinder diameter 11 mm Reference Technical specifications Battery Voltage 12 V Charg...

Page 36: ...er injector 8 Make Type Electronic Control Unit Siemens M3C Reference Technical specifications Bulbs Front headlight low beam high beam H7 12 V 55 W Number plate light C5W 12 V 5 W Side light H6 12 V 6 W Turn signal light RY10W 12 V 10 W Tail light and brake light LED Fuses Regulator 30 A Instrument panel 5 A Injection 20 A Key ON 10 A ECU 5 A Devices 15 A High beam and low beam headlights parking...

Page 37: ...A B C D E F G H L M N P section C 1 2 9 Monster 696 696 M Y 2009 edition 00 Technical data 1 2 Dimensions 1452 2058 117 770 784 960 1012 ...

Page 38: ...ecified in the table can be used where the average ambient temperatures are within the limits shown Fuel lubricants and other fluids Type dm litres Fuel tank including a reserve of 3 5 dm3 litres Unleaded fuel with an octane rating of at least 95 98 RON 15 Sump and filter SHELL Advance Ultra 4 3 1 Front rear brake and clutch circuits SHELL Advance Brake DOT 4 Protection for electrical contacts SHE...

Page 39: ...ghts and reflectors Screw securing headlight to support M5x0 8 5 Screw securing headlight support to bottom yoke M6x1 10 Screw securing front turn indicator to headlight support M5x0 8 3 LOCK 2 Nut securing hole cover to support M5x0 8 3 Instruments Screw securing instrument panel to support 3 Instrument panel cover retaining screw M4x0 7 1 5 Front Fork Steering stem nut M35x1 30 GREASE B Screw se...

Page 40: ...iper screw M10x1 25 45 GREASE B Initial tightening for front brake caliper screws to seat caliper 2 GREASE B Swingarm Chain tensioner shoe retaining screw M5x0 8 5 Screw with threadlocker Chain tensioner slide adjuster screw M8x1 25 8 GREASE B unscrewing torque Swingarm pivot shaft nut M8x1 25 18 GREASE B Caliper mounting bracket pin M12x1 25 33 Drive chain slider retaining screw 2 Australia versi...

Page 41: ...c screw M8x1 25 24 LOCK 2 Rear sprocket nut M10x1 25 46 LOCK 2 Pin on sprocket flange M14x1 5 46 LOCK 8 Rear wheel axle nut M25x1 25 83 GREASE B Footrests and Levers Brake side Brake lever pivot screw on RH footrest bracket M8x1 25 24 LOCK 2 Rear brake light switch M6x1 5 Master cylinder pushrod retaining nut M6x1 7 5 Screw securing footrest bracket to engine RH side M10x1 5 36 Screws securing fro...

Page 42: ...ontal vertical cylinder head Nut 1 initial tightening Nut 2 final tightening Nut 1 final tightening M8x1 25 6 24 24 1 8 gas stainless steel plugs to exhaust pipes M10x1 25 25 Rear screw securing heat shield to silencer M6x1 10 Screw securing silencer to silencer support on subframe M8x 1 25 22 Lambda sensor fixing 45 Front screw securing heat shield to silencer M6x1 10 Screw securing heat shield t...

Page 43: ...rews securing filter support cover to airbox M5x0 8 5 Air filter retaining nut M6x1 6 Screws securing airbox to frame M6x1 10 Clamp securing oil breather valve hose to blow by valve 1 5 Clamp securing blow by valve hose to airbox 1 5 Screws securing ECU to airbox M5x0 8 5 Screw securing cable guide to LH side of crankcase M6x1 10 Clamp securing hoses to airbox 1 1 Temperature sensor fixing to inta...

Page 44: ...1 Valve cover screws M6x1 10 9 11 Timing belt cover screw M6x1 10 9 11 LOCK 2 or THREE BOND 1324 Timing belt cover screw M6x1 10 9 11 Pulley flange retaining screw M6 10 9 11 Canister plug screw M6x1 3 2 7 3 2 LOCK 2 or THREE BOND 1324 Canister nipple USA version M6x1 3 2 7 3 2 LOCK 2 or THREE BOND 1324 CAMOZZI union screw M5x0 8 3 2 7 3 2 LOCK 2 or THREE BOND 1324 Blow by valve M40x1 5 34 30 38 P...

Page 45: ...ft blanking cap M20x1 15 13 5 16 5 THREE BOND 1375B Connecting rod screw Tighten at 50 rpm 2 second pause then back off through 360 at 30 rpm Tighten at 30 rpm Tighten at 10 rpm Tighten through 65 1 at 14 rpm Torque check M10x1 35 20 35 70 to 103 Apply GREASE B to thread Crankshaft grub screw M8x1 25 13 11 15 LOCK 5 or THREE BOND 1375B Drilled crankshaft grub screw M8x1 25 13 11 15 LOCK 5 or THREE...

Page 46: ... 5 8 5 9 Wet clutch spring screw M6x1 10 9 11 Alternator cover inspection plug M15x1 20 18 22 THREE BOND 1215 Pick up sensor inspection screw M12x1 15 13 17 LOCK 2 or THREE BOND 1324 Spark plug M12x1 25 20 18 22 Alternator side crankcase cover screw M6x1 10 9 11 Alternator side crankcase cover screw M6x1 10 9 11 Alternator side crankcase cover screw M6x1 10 9 11 Inspection cover screw M6x1 4 5 4 5...

Page 47: ... for the engine WORKSHOP SERVICE TOOLS Code no Description 88700 5644 Socket wrench for camshaft pulley nut 88713 2423 Torque wrench for tightening front sprocket nut 88713 2676 Wrench for tightening cylinder head nuts 88713 2103 Stand for cylinder head assembly 98112 0002 Timing degree wheel 88713 0123 Timing check tool 1 1 2 3 1 1 2 3 ...

Page 48: ...Ducati Diagnosis System cylinder vacuum meter kit 88765 1581 Valve lift gauge 88765 2878 Spacer and fork feeler gauge 0 2 0 3 mm 88713 2783 Tool for fitting spring and closing rocker 88713 2009 Belt pulley timing tool 88713 2011 Crankshaft holding tool 88700 5749 Crankcase assembly cap Code no Description ...

Page 49: ... data 88713 1091 Plate for gear selector fork positioning 88713 1749 Puller for drive pulley and cover 88765 1297 TDC gauge 88713 2837 Rocker pin puller 88713 2556 Clutch drum holding tool 88713 2591 Clutch screw 88713 2036 Alternator holding tool for tightening nut Code no Description ...

Page 50: ...0 Technical data 88713 2092 Primary drive gears puller 88713 3152 Tool for tightening timing belt roller nut 88713 2442 Oil seal installation tool 88713 2906 Oil filter cartridge wrench 88713 2282 Pulley holding tool 88713 1411 Oil seal installation tool Code no Description ...

Page 51: ...ts catalogue Specific tools for the frame WORKSHOP SERVICE TOOLS Code no Description 677 4 003 1A Chain joining link 88713 1072 Drift to install half bearing in bottom yoke 88713 1344 Chain assembly tool 8000 70139 Front wheel axle wrench 88713 1096 Tool for forks overhaul oil seal installation ...

Page 52: ... 696 696 M Y 2009 edition 00 Technical data 88713 1058 Wrench for steering stem nut 88713 1062 Tool for installing steering head bearings 88713 1010 Exhaust gases pick up connector 88713 3166 Wrench for tightening frame ring nut Code no Description ...

Page 53: ...A B C D E F G H L M N P D Use and maintenance 0 ...

Page 54: ...5 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 3...

Page 55: ... brake pads against brake discs To allow all the mechanical moving parts of the motorcycle to adapt to one another and above all to avoid adversely affecting the life of basic engine parts it is advisable to avoid harsh acceleration and not to run the engine at high rpm for too long especially uphill It is also advisable to check the drive chain frequently and ensure that it is lubricated as requi...

Page 56: ...cessary Sect C 2 Fuel lubricants and other fluids Brake and clutch fluid Check the fluid levels in the respective reservoirs Tyres Check tyre pressure and condition Sect C 1 1 Front wheel Rear wheel Controls Operate the brake clutch throttle and gear change controls levers pedals and twistgrip to check that they function correctly Lights and indicators Make sure the lights indicators and horn work...

Page 57: ...3 is in the RUN position then press the starter button 4 Allow the engine to start on its own without turning the throttle twistgrip Wait until the oil temperature reaches 75 C Shift the cold start lever to the vertical position A Important The oil pressure warning light should go out a few seconds after the engine has started If the light stays on stop the engine and check the oil level Sect P 7 ...

Page 58: ...sition as the engine warms up Once the engine is at normal running speed it should idle smoothly with the cold start lever completely closed High engine temperature over 35 C 95 F ambient temperature Follow the same procedure but without using the cold start control 2 Notes Follow the High ambient temperature procedure to start the engine when it is already warm Cold ambient temperature below 10 C...

Page 59: ...Check and clean the air filter 1 Change the air filter Check throttle body synchronisation and idle speed setting 1 Check the brake and clutch fluid levels Change the clutch and brake fluid Check and adjust the brake and clutch control cables Check lubricate the throttle choke cables Check tyre pressure and wear Check the brake pads Renew if necessary Check the steering head bearings Check the dri...

Page 60: ...n accordance with the specified distance or time intervals km miles or months whichever occurs first List of operations with frequency distance or time interval km x1000 1 miles x1000 0 6 Months 6 Check the engine oil level Check the brake and clutch fluid levels Check tyre pressure and wear Check the drive chain tension and lubrication Check the brake pads If necessary contact your dealer to rene...

Page 61: ...ow top it up Remove the filler cap 2 and top up with the recommended oil Replace the filler cap Changing the engine oil and filter cartridge Notes Change the oil when the engine is warm but with the engine stopped In these conditions the oil is more fluid and will drain more rapidly and completely Remove the drain plug 3 on the oil sump and allow the used oil to drain off Warning Dispose of oil an...

Page 62: ...dge 2 with engine oil before installing it this enables the recommended oil level to be maintained without topping up Screw the cartridge into place and tighten to the specified torque Sect C 3 Engine torque settings Every two oil changes clean the oil pickup gauze filter Remove the outer plug 5 Unscrew the filter 7 and withdraw it from the crankcase Clean the filter with petrol and compressed air...

Page 63: ... up to the MAX line in the sight glass Refit the filler cap 2 Run the engine at idle speed for a few minutes Check for oil leaks Check that the oil pressure light on the instrument panel switches off a few seconds after the engine starts If not switch off the engine and trace the fault After a few minutes check the oil level again and top up to the MAX level line if necessary Refit all parts remov...

Page 64: ... valve clearances With the valve in the rest position slide a feeler gauge between the opening rocker and the opening shim to measure the clearance The clearances must be within the specified limits Opening rocker arm Intake A Adjusting clearance 0 10 to 0 15 mm Checking clearance 0 05 to 0 15 mm Exhaust A Adjusting clearance 0 10 to 0 15 mm Checking clearance 0 05 to 0 15 mm A ...

Page 65: ...e If the clearances measured are outside the specified limits measure the value and adjust as required Sect N 4 1 Checking and adjusting valve clearances Adjusting the valve clearances Proceed as described in Sect N 4 1 Checking and adjusting valve clearances Closing rocker arm Intake B Adjusting clearance 0 to 0 05 mm Checking clearance 0 to 0 20 mm Exhaust B Adjusting clearance 0 to 0 05 mm Chec...

Page 66: ...he filter cartridge can be cleaned with a jet of compressed air or renewed as necessary Important A clogged air filter will reduce air intake and engine power increase fuel consumption and cause a build up of deposits on the spark plugs Do not run the engine without the air filter This will draw foreign material present in the air into the engine and may damage the engine Install the cartridge in ...

Page 67: ...ash the affected area thoroughly with plenty of running water Filling the front brake circuit Undo the screws 3 and remove the cover and membrane 1 from the front brake fluid reservoir 2 Attach a length of transparent plastic tubing to the bleed valve 4 and insert the other end of the tubing in a container placed on the floor Siphon off the fluid from the reservoir 2 Fill the reservoir 2 with new ...

Page 68: ...ape Warning While filling the system always keep the fluid level above the MIN mark to prevent the formation of air bubbles in the circuit Allow the fluid to flow from the bleed valve 4 until it changes colour Tighten the bleed valve to the specified torque Sect C 3 Frame torque settings and top up the reservoir fluid level Notes Repeat this operation on each brake caliper Filling the rear brake c...

Page 69: ... reservoir 5 with new brake fluid up to the MAX mark Operate the brake pedal two or three times to pressurize the circuit Hold the pedal pressed down Warning While filling the system always keep the fluid level above the MIN mark to prevent the formation of air bubbles in the circuit Allow the fluid to flow from the bleed valve 7 until it changes colour Tighten the bleed valve 7 to the specified t...

Page 70: ...ase of accidental contact wash the affected area thoroughly with plenty of running water Remove the cover 1 and membrane from the front brake fluid reservoir 2 and the cover 5 from the rear brake fluid reservoir 6 Connect a commercial brake bleeder to the front brake caliper bleed valve 4 or rear brake caliper bleed valve 7 Notes Follow the manufacturer s instructions when using a commercial brake...

Page 71: ...e a brake bleeding tool available attach a length of transparent plastic tubing to the front caliper bleed valve 4 or rear caliper bleed valve 7 and immerse the other end of the tubing in a container on the floor containing old brake fluid Unscrew the bleed valve by a 1 4 turn Operate the brake lever or pedal until all the fluid has drained out Repeat this operation for each brake caliper 4 7 ...

Page 72: ...ghly with plenty of running water Fill the reservoirs 2 and 5 with the recommended fluid Sect C 2 Fuel lubricants and other fluids from an unopened container Important During the following operation the fluid level must remain topped up at all times The end of the transparent plastic tubing must remain immersed in the discharged fluid at all times Operate the brake lever or pedal several times to ...

Page 73: ...ame torque settings If you do not have a brake bleeder available connect a length of transparent plastic tubing to the bleed valve as outlined in the draining procedure Open the bleed valve a 1 4 turn and operate the brake lever or pedal several times until fluid emerges from the bleed valve Pull the lever fully in and open the bleed valve by at least a 1 4 of a turn Wait a few seconds then releas...

Page 74: ...edition 00 Use and maintenance Tighten the bleed valve 4 or 7 to the specified torque Sect C 3 Frame torque settings Replace the dust cap Top the fluid up to the correct level and refit cover 1 to reservoir 2 and tighten screws 3 and fit cap 5 to reservoir 6 6 5 6 5 ...

Page 75: ...from the clutch fluid reservoir 2 Attach a length of transparent plastic tubing to the bleed valve 4 and insert the other end of the tubing in a container placed on the floor Siphon off the fluid from the reservoir 2 Fill the reservoir 2 with new clutch fluid up to the MAX mark Operate the clutch lever two or three times until the circuit is pressurized Hold the lever pulled in towards the handgri...

Page 76: ...ster 696 696 M Y 2009 edition 00 Use and maintenance Allow the fluid to flow from the bleed valve 4 until it changes colour Tighten the bleed valve 4 to the specified torque Sect C 3 Frame torque settings and top up the reservoir fluid level 4 ...

Page 77: ...e 4 Notes Follow the manufacturer s instructions when using a commercial clutch bleeding tool Open the bleed valve and pump with the bleeding tool until no more fluid emerges If you do not have a bleeding tool available attach a length of transparent plastic tubing to the bleed valve 4 and insert the other end of the tubing in a container of old clutch fluid placed on the floor Unscrew the bleed v...

Page 78: ...clutch slave cylinder assembly 6 Push in the internal piston to force out all the fluid from inside the cap Refit the slave cylinder cap and tighten retaining screws 5 to the specified torque Sect C 3 Frame torque settings Tighten the bleed valve to the specified torque Sect C 3 Frame torque settings 6 5 6 5 ...

Page 79: ... a commercial clutch bleeding tool Open the bleed valve 4 and pump with the bleeding tool Make sure that the reservoir level does not fall below the MIN mark Repeat the bleeding operation until the fluid emerging from the plastic tube connected to the bleed valve 4 is free of air bubbles If you do not have a bleeding tool available connect a length of transparent plastic tubing to the bleed valve ...

Page 80: ... N P section D 4 28 Monster 696 696 M Y 2009 edition 00 Use and maintenance Fill up to 3 mm above the MIN level mark on the reservoir Replace the membrane and the cover 1 on the reservoir 2 and tighten the screws 3 2 3 2 ...

Page 81: ...ews 1 remove the two clamps 2 and remove the handlebar 3 from the steering head positioning it out of the way so it does not hinder subsequent operations Slacken the clamp screws 4 securing the top yoke to both fork legs Loosen the clamp screw 5 that holds the steering tube to the top yoke Using service tool no 88713 1058 turn the nut 6 to the specified torque Sect C 3 Frame torque settings Tighte...

Page 82: ... M N P section D 4 30 Monster 696 696 M Y 2009 edition 00 Use and maintenance Reposition the handlebar 3 fit the clamp 2 and tighten the four clamp screws 1 to the specified torque Sect C 3 Frame torque settings 1 1 3 2 ...

Page 83: ...unterclockwise to decrease it In the latter case you will need to push the wheel forward Important An incorrectly tensioned chain will lead to accelerated wear of the transmission components Check that the reference marks on both sides of the swingarm are lined up This indicates perfect wheel alignment Tighten the axle nuts 1 to the specified torque Sect C 3 Frame torque settings Tighten the tensi...

Page 84: ...w the pads to bed in completely Checking front brake pad wear Look through the slot in the caliper clip 1 to make sure the groove in the brake pad friction material 2 is still visible Important If either of the pads is worn both pads must be renewed as a set Change the brake pads as follows Remove the calipers Sect G 3 Removal of the front brake system Remove the cotter pin 3 from the pad retainin...

Page 85: ... necessary top up as follows Turn the handlebar so that the reservoir is level Unscrew the two crosshead screws 6 and remove the reservoir cover 5 Remove the inner membrane from the reservoir Top up to maximum level with the specified brake fluid Sect C 2 Fuel lubricants and other fluids Refit all previously removed components Checking rear brake pad wear Check through the slot between the two cal...

Page 86: ... MAX marks If not unscrew the reservoir cover 4 and top up with the recommended brake fluid Notes If it proves difficult to change the brake pads first remove the caliper from the motorcycle Sect G 6 Removal of the rear brake system Warning As the brake calipers are components of vital importance to the safety of the motorcycle refer to the instructions in Sect G 3 Removal of the front brake syste...

Page 87: ...ed free travel Tighten the lock nut and replace the cap Adjust travel of the cold start control cable by turning the control lever on the handlebar to its maximum position and checking that plate 4 is located against the travel limit stop Check that engine speed in this condition is 2000 rpm To adjust the rpm turn the adjuster screw 7 Proceed in the same way to adjust the freeplay of the throttle ...

Page 88: ... cable if you feel excessive resistance or stiffness renew the cable To lubricate throttle cable undo the two screws 9 and remove the upper half of the twistgrip housing 8 Grease the end of the cable 10 and the race Carefully close the throttle assembly inserting the cable 10 in the guide A on the upper twistgrip housing 8 Replace and tighten the two screws 9 9 8 9 10 10 A 8 A ...

Page 89: ... using an open ended wrench on the flats to move the gearchange pedal to the required position Tighten both lock nuts onto the rod To adjust the position of the rear brake pedal proceed as follows Loosen the locknut 4 Turn the pedal travel adjustment screw 5 until the pedal is in the desired position Tighten the locknut 4 Operate the pedal by hand to make sure it has 1 5 to 2 mm of free play befor...

Page 90: ... it anti clockwise 8 clicks To adjust the spring preload unscrew the lower adjuster nut 3 using a pin wrench Screw the lower nut 3 in or out to increase or reduce the preload Warning To turn the preload adjuster nuts use only a specific tool and take care otherwise the wrench pins may slip off the nut This could injure your hands Never use a wrench with a too small pin or with a too short handle I...

Page 91: ...ance Important If the motorcycle is to be ridden with a pillion rider and luggage we recommend setting the rear shock absorber spring preload to the maximum to ensure the best handling and proper ground clearance at all times It may also be necessary to adjust the rebound damping accordingly ...

Page 92: ...ector 10 514 1 032 1A Auxiliary test cable 11 552 1 037 1A Cylinder compression cable with M12 connection 12 875 1 065 1A Oil pressure pipe 13 97900 0230 Mains power adapter 14 97900 0224 Mains power adapter 15 88765 1371 Belt tensioning sensor 16 88765 1374 Bracket for belt tensioning sensor 17 590 1 189 1A Fuel pressure test pipe 18 97900 0234 Ammeter clamp 19 514 1 033 1A Cigar lighter socket a...

Page 93: ...on any electrical device to perform tests on individual components and to measure pressure and temperature values The DDS tester 1 is comprised of a palmtop display unit A a BBAD self diagnosis module B and a display memory card C The touch screen display unit A serves for both data display and input using the stylus housed on the side of the unit The self diagnosis module B enables communication ...

Page 94: ...tom connection panel has 3 connection sockets with the following functions one USB port M one power connection socket N one diagnostics connection socket P You can connect a printer to the DDS tester 1 to print test reports connect the printer to the serial port COM1 G located on the top connection panel of the tester 1 Technical data Power supply from the mains 220 V from the motorcycle battery 1...

Page 95: ...e mains adapter 14 to the power connection socket N from the motorcycle by connecting the specific cables see paragraph Connection to the motorcycle from the tester s internal battery the battery Q is housed in the top part of the tester To operate the tester 1 using the internal battery and to recharge the battery refer to the User Manual supplied with the DDS tester To switch on the display pres...

Page 96: ...gine starting and idling on motorcycles in which the battery is not in perfect working order If the tester detects a power supply voltage of less than 9 Volt the current procedure will be aborted when the voltage returns to within the acceptable tolerance limits the procedure must initiated again from the beginning The DDS tester 1 may be powered from the motorcycle in any one of the following way...

Page 97: ...the diagnostic connection socket P on the tester then connect the battery socket adapter 8 to the connection socket R on the power and diagnostics cable 2 and to the motorcycle battery Notes For connection of the various devices required for self diagnostic procedures consult the instruction handbook supplied with the tester N 1 P 2 R 8 2 ...

Page 98: ... tester can read electrical voltages current temperature timing belt tension and pressure values lubrication and fuel supply circuits for example Checking and adjusting timing belt tension Notes The on screen icons used during this procedure are explained in a table at the end of this section Notes This operation which is performed using the DDS tester has the advantage that it can be carried out ...

Page 99: ...ension on section 22 of the vertical cylinder timing belt Remove the belt tension sensor and disconnect the DDS tester from the motorcycle Measuring timing belt tension Switch on the DDS tester 1 see paragraph Tester power supply Connect the power and diagnostics cable Measurement Module 3 to the measurement module connector F on the DDS tester 1 Connect the belt tension sensor 15 to the connector...

Page 100: ... point of the belt run with the reader parallel to the belt and at a distance of about 1 to 1 5 cm from it On the DDS tester 1 select the Measurement module function by pressing the corresponding icon then press the Belt Tension icon followed by the Start icon to access the Mechanical belt tension screen The socket to which the cable Measurement Module 3 is to be connected is indicated on the scre...

Page 101: ...w belt and the reset values when belt tension reaches 70 Hz Warning The timing belts can become slack during normal operation When checking belt tension if the reading is less than 70 Hz retension the belt to restore the specified nominal values Sect C 1 1 Timing system valves If the tension value is incorrect tighten or slacken the belt by loosening the bolts 24 and 25 and moving the tensioner pu...

Page 102: ...tate the contact point U anti clockwise to increase belt tension or clockwise to reduce it Re check the timing belt tension Repeat the above procedure until the correct belt tension is obtained Then tighten the screws 24 and 25 to the specified torque Sect C 3 Engine torque settings U 88713 1215 27 25 24 26 ...

Page 103: ...he engine temperature to reach 100 C When the engine temperature reading reaches 100 C carry out the adjustment operations described below The idle speed must be between 1250 1350 rpm 1300 50 if the idle speed is lower or higher than the specified range open or close the bypass screws 21 of both cylinders by a 1 4 turn and once the correct idle speed has been obtained check that the CO level in bo...

Page 104: ...e vacuum pressures downstream of the butterfly valve Differences in pressure between the horizontal and vertical cylinder are therefore acceptable provided that the idle speed is adjusted correctly If you are unable to reach the desired idle speed setting try reducing the vacuum differential downstream of the butterfly valve as described in the following paragraph Throttle body balancing repeat th...

Page 105: ...nect the vacuum pressure pipes 6 to the connectors A and C of cable 3 and connect the fittings 7 to the pipes Switch on the DDS tester see the paragraph Tester power supply Enter the Measurement module function Press the Cylinder synchronisation icon The socket to which the Measurement Module cable 3 is to be connected is indicated on the screen with a capital letter A B or C Remove the screws 25 ...

Page 106: ...d C of the cable 3 and to the vacuum pressure pipes 6 Press the Start icon to begin the cylinder pressure measurement procedure The onscreen indicator light E will turn red when the function is active Start the engine The values may be displayed in two different ways in numerical form or in graphic form to select the desired display type press the Value display icon F The values can be reset by pr...

Page 107: ...the balance turn the bypass screws 21 until the two lines on the graph coincide if in graphic mode or until identical numerical values are displayed if in numerical mode Correct balancing is obtained when the two lines of the graph are superimposed or when the two numerical values indicated are equal 21 21 ...

Page 108: ...ne oil pressure test point 21 as described below Disconnect the wiring connector A and remove the pressure switch 21 taking care to recover the seal Insert the fitting 9 into the connection on the hose 12 interposing the two copper sealing washers 20 Insert the fitting 9 of the pipe 12 in the threaded hole M10x1 mm of the right hand crankcase cover and screw it fully home Refit the pressure switch...

Page 109: ...pe 12 to transform the pressure signal into an electrical signal Switch on the DDS tester 1 see paragraph Tester power supply Connect the power and diagnostics cable Measurement Module 3 to the measurement module connector B on the DDS tester 1 Connect the pressure sensor 5 to socket A of the cable 3 12 5 B 1 3 A 5 552 1 039 1A 3 A 3 ...

Page 110: ... maintenance On the DDS tester 1 select the Measurement module function by pressing the corresponding icon then press the PressureTest icon D followed by the Start icon E The letter A is displayed on the screen to indicate the connection socket of the Measurement Module cable 3 F D E ...

Page 111: ...ector A of the cable 3 the value measured will displayed next to the letter A on the screen Oil pressure test values Warm engine Minimum oil temperature 80 C 1100 to 1300 rpm greater than 0 8 bar 3500 to 4000 rpm greater than 4 bar Important The maximum pressure must never exceed 6 0 bar Excessively high pressure may indicate that the relief valve is stuck Excessively low pressure on the other han...

Page 112: ...00 Use and maintenance Remove the tool and refit the pressure switch 21 along with its seal Tighten the pressure switch to the specified torque Sect C 3 Engine torque settings Reconnect the electrical system connector A to the pressure switch Disconnect the DDS tester 21 A ...

Page 113: ... will result in a reduction in engine performance and can lead to component failure Run the engine and allow it to warm up to the point at which fan operation starts at least once Remove the HT leads 20 from both spark plugs Remove the spark plug from the cylinder to be tested Position the HT lead carefully to avoid sparking Screw the cylinder compression fitting 11 into the spark plug bore Connec...

Page 114: ...ance Connect the pressure sensor 5 to socket A of the cable 3 Notes Measure the compression on one cylinder at a time On the DDS tester 1 select the Measurement module function by pressing the corresponding icon then press the Cylinder Compression icon D followed by the Start icon E A 3 D E ...

Page 115: ...rising Check the pressure in each cylinder standard value 11 to 12 bar minimum value 10 bar maximum permissible difference between cylinders 2 bar An excessively high pressure value can be caused by build up of deposits in the combustion chamber An excessively low pressure value can be caused by gas escaping between the cylinder head and the barrel worn valve seats bent valve stems incorrect valve...

Page 116: ...fuel tank Sect L 2 Removal of the fuel tank Remove the fuel feed hose 20 Take the fuel pressure pipe test 17 and connect one end D to the outlet fitting on the tank and the other end E to the fuel feed hose 20 in this way the fuel pressure can be measured at the test outlet F Connect the pressure sensor 5 to the test outlet F of the pipe 17 to transform the pressure signal into an electrical signa...

Page 117: ... Connect the power and diagnostics cable Measurement Module 3 to the measurement module connector E on the DDS tester 1 Connect the pressure sensor 5 to socket A or C of the cable 3 On the DDS tester 1 select the Measurement module function by pressing the corresponding icon then press the Pressure Test icon F followed by the Start icon G E 1 3 A C 3 G F ...

Page 118: ...n two graphic forms to select the desired display type press the Value display icon H The measured value is indicated alongside the letter A or C identifying the cable used for the measurement i e if you used connector A of the cable 3 the measured value will be displayed next to the letter A on the screen The maximum pressure must be 3 bar nominal On completion of the test remove all the componen...

Page 119: ...obilizer system it is possible to start the engine using the emergency procedure described in Sect P 8 Immobilizer and transponder which requires a secret code which may be entered using the DDS tester Switch on the DDS tester 1 see paragraph Tester power supply Connect the power and diagnostics cable 2 to the diagnostics connector H on the tester and to the diagnostics socket L on the motorcycle ...

Page 120: ...ersion and confirm Press the icon Select system to display a list of the bike s systems that can be analysed Select Engine electronics and press the Confirm icon B Next press the Self diagnosis icon to access the corresponding function The DDS tester will interrogate the electronic control unit and display the parameters analysed with their relative values Notes Make all connections with the motor...

Page 121: ... D 5 69 Monster 696 696 M Y 2009 edition 00 Use and maintenance Press the Actuators icon C to display the actuators and other components connected to the ECU Select the option Immobilizer Override and then press the icon Apply D C D ...

Page 122: ...press the Confirm icon B One the entire code has been entered press the Confirm icon B again On completion of the operation the message Was the operation completed successfully will appear press Confirm If any problems were encountered during the operation the tester will display the relative error messages each message must be confirmed by pressing the Confirm icon or rejected by pressing the Exi...

Page 123: ...h the various diagnostic procedures providing descriptions and documentation for motorcycle components wiring diagrams for the electronic systems and information on the locations of specific components Switch on the DDS tester 1 see paragraph Tester power supply Connect the power and diagnostics cable 2 to the diagnostics connector F on the tester and to the diagnostics socket G on the motorcycle ...

Page 124: ...ext screen press the Select motorcycle icon select the motorcycle model and confirm then select the version and confirm Press the icon Select system to display a list of the bike s systems that can be analysed Select Engine electronics and press the Confirm icon B Press the Guided diagnosis icon C to access the corresponding function B C ...

Page 125: ...n access the Self diagnosis function by pressing the corresponding icon If any errors are present the symbol D will be displayed To determine the type of errors present press the Errors icon E Once errors have been detected you can then resolve them through the guided diagnosis procedure press the Guided Diagnosis icon C The DDS tester will interrogate the electronic control unit and display the p...

Page 126: ...lamp 18 detects the magnetic field generated by the current passing through that cable Remove the fuel tank Sect L 2 Removal of the fuel tank Switch on the DDS tester 1 see heading Tester Power Supply Connect the power and diagnostics cable Measurement Module 3 to the measurement module connector D on the DDS tester 1 Connect the ammeter clamp to the connector E of the power and diagnostics cable ...

Page 127: ...ce On the DDS tester 1 select the Measurement module function by pressing the corresponding icon then press the Ammeter icon F followed by the Start icon The socket to which the cable Measurement Module 3 is to be connected is indicated on the screen with a capital letter A B or C 1 F A B C 3 ...

Page 128: ...arging the battery at the same time If the current has a negative sign this means that the charging system is not able to power the electrical loads and a significant amount of the current required must be supplied by the battery which is therefore discharging Important If polarity is reversed when clamping the ammeter onto the cable the sign of the readings will also be reversed giving rise to in...

Page 129: ...n 00 Use and maintenance Icons table Symbol Description Confirm Exit Measurement module Belt tension Start stop Menu 1 Select vehicle Select motorcycle Self diagnosis Settings Apply Cylinder synchronisation Value display Reset Pressure test Cylinder compression Actuators ...

Page 130: ...A B C D E F G H L M N P section D 5 78 Monster 696 696 M Y 2009 edition 00 Use and maintenance Guided diagnosis Select system Errors Ammeter clamp Symbol Description ...

Page 131: ...A B C D E F G H L M N P E Fairings 0 ...

Page 132: ...arview 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 ...

Page 133: ...6 Nut 7 Screw 8 Headlight fairing 9 Screw 10 Windshield 11 Nut 12 Quick release fastener 13 Screw 14 Washer Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram INSTRUMENT PANEL HEADLIGHT FAIRING HANDLEBAR AND CONTROLS 2 4 3 4 1 2 1 5 9 11 12 8 7 696 13 14 10 6 9 5 ...

Page 134: ... the rear view mirrors Undo the screws 2 remove the rearview mirrors 1 and recover the washers 4 Refitting the rearview mirrors Insert the mirror 1 in the clamp 3 and fit the screw 2 with the washer 4 Tighten the screw 2 to the specified torque Sect C 3 Frame torque settings 2 1 1 2 2 1 3 1 2 3 ...

Page 135: ... support and remove the headligt fairing 8 complete with the brackets 5 To remove the brackets 5 undo the screws 7 taking care not to lose the quick release fasteners 12 Disassembly of the headlight fairing If the windshield 10 needs replacing unscrew the screws 13 taking care to recover the washers 14 and the nuts 11 Remove the windshield 10 9 5 6 7 5 5 10 14 13 12 8 11 10 13 8 11 14 ...

Page 136: ...itting the headlight fairing 696 Fit the brackets 5 to the headlight support fitting the screws 9 and nuts 6 Counterhold the nuts 6 and tighten the screws 9 to the specified torque Sect C 3 Frame torque settings Refit the brackets 5 insert the screws 7 and tighten them to the specified torque Sect C 3 Frame torque settings Check that the quick release fasteners 12 are inserted in the brackets on t...

Page 137: ...k cover 4 Screw 5 Rear fuel tank cover 6 Spacer 7 Screw 8 Quick release fastener 9 Special screw 10 Nylon washer 11 Screw 12 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram FUEL TANK COVER 6 7 8 12 2 9 5 11 10 4 1 4 3 1 ...

Page 138: ...Remove the seat Sect E 3 Removal of the seat Unscrew the screws 7 and 12 securing the front tank cover 3 but do not remove the cover Undo the screws 4 and 11 eand remove the RH tank cover 1 and LH tank cover 2 releasing the tabs A from the slots B in the rear cover 5 recover the nylon washers 10 3 7 12 7 12 2 4 1 4 11 ...

Page 139: ...recover the spacers 6 Unscrew the special screws 9 and remove the rear tank cover 5 Refittings the fuel tank fairings Locate the rear cover 5 on the fuel tank and secure it in place with the special screws 9 Tighten the two upper special screws 9 to the specified torque Sect C 3 Frame torque settings 5 B A 3 9 5 9 9 9 ...

Page 140: ...3 with the larger diameter side facing upwards as shown in the photo Locate the front tank cover 3 on the fuel tank Refit the right hand tank cover 1 inserting the tabs A in the corresponding slots B in the rear cover 5 Insert the screws 11 complete with the nylon washers 10 and screws 11 in the RH tank cover 1 and LH tank cover 2 6 6 3 6 3 5 B A 2 4 ...

Page 141: ...Fairings Insert the screws 7 and 12 in the front tank cover 3 Tighten the screws 12 and 7 to the specified torque Sect C 3 Frame torque settings starting with the front screw Tighten the screws 4 and 11 to the specified torque Sect C 3 Frame torque settings 1 4 11 3 7 12 7 12 ...

Page 142: ...le 3 Screw 4 Tool tray 5 Rubber 6 Special screw 7 Spacer 8 Rubber mounting 9 Elastic strap 10 Seat cover Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram SEAT A A 3 9 4 8 1 7 6 5 2 10 696 6 ...

Page 143: ...e area of the catch to release the pin Pull the seat backwards to release it from the front catches and remove it from the frame Disassembly of the seat On the 696 version unscrew the two special screws 6 and slide off the seat cover 10 Reassembly of the seat Refit the seat cover 10 and tighten the special screws 6 to the specified torque Sect C 3 Frame torque settings 10 6 10 6 ...

Page 144: ...eat engage the front end of the seat base in the lugs B on the fuel tank then push down on the rear end of the seat until you hear the latch click into place Removal of the tool tray Remove the seat as described in the paragraph Removal of the seat in this section Uncsrew thew screws 3 and remove the tool tray 4 B 4 3 ...

Page 145: ...6 696 M Y 2009 edition 00 Fairings Refitting the tool tray Refit the tool tray 4 insert the screws 3 and tighten to the specified torque Sect C 3 Frame torque settings Refit the seat as described in this section in the paragraph Refitting the seat 4 3 ...

Page 146: ... 4 Front mudguard 1 Front mudguard 2 Washer 3 Rivet 4 Clip 5 Screw 6 Nylon washer Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram FUEL TANK COVER 5 6 1 3 2 4 ...

Page 147: ...nect the front brake hose A from the clip 4 Remove the retaining screws 5 and recover the nylon washers 6 Remove the front mudguard 1 Notes On USA versions a reflector is mounted on the front mudguard 1 Notes The clip 4 is secured to the front mudguard by means of a shear rivet 3 with two washers 2 A 4 6 2 LOCK 5 6 3 4 2 ...

Page 148: ...ont mudguard fitted to avoid the risk of the brake pipes fouling the wheel on braking Apply threadlocker to the screws 5 Position the front mudguard 1 and refit the retaining screws 5 with the washers 6 Locate the front brake hose grommet A in the mudguard clip 4 Tighten the screws 5 to the specified torque Sect C 3 Frame torque settings 6 2 LOCK 5 6 3 4 2 A 1 ...

Page 149: ...A B C D E F G H L M N P F Controls Devices 0 ...

Page 150: ...der 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 maste...

Page 151: ...ster on handlebar 9 Plug 10 Throttle cable adjuster on throttle body 11 Choke cable adjuster on throttle body 12 Choke cable adjuster on handlebar 13 Cover 14 Left hand handlebar switch with choke control Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram HANDLEBAR AND CONTR...

Page 152: ...s Removal of the throttle twistgrip Rotate the race on the throttle body linkage to free the end D of the inner cable from the race Peel back the rubber sleeve A unscrew the lock nut B and unscrew the adjuster 10 from the race on the throttle body Remove the screws 4 and the cover 13 and disconnect the throttle cable from the twistgrip freeing the cable end C from the race and fully unscrewing and...

Page 153: ...96 M Y 2009 edition 00 Controls Devices Remove the throttle cable 6 from the motorcycle Remove the end plug 9 from the handlebar Loosen the two screws 3 fixing the throttle twistgrip to handlebar Remove the throttle twistgrip 5 from the handlebar 3 6 5 ...

Page 154: ...t the throttle control components proceed in inverse order to the removal procedure making sure that the twistgrip housings locate in the reference hole in the handlebar Apply the recommended grease to the throttle cable 6 Notes Refer to the figures at the end of the chapter for the correct routing of the starter control cable A 6 ...

Page 155: ... the lock nut G and screw the adjuster 11 completely out of the bracket Withdraw the choke cable 2 from the throttle body and recover the spring 7 Remove the left hand handlebar switch 14 with the choke control by unscrewing the screws H Open the handlebar switch housing and withdraw the end fitting L of the choke inner cable from the switch Remove the choke control cable 2 G 2 E 7 11 F H 14 2 L ...

Page 156: ...oute of the original cable Tighten the adjuster 11 on throttle body support Insert the inner cable 2 in the hole of the rocker in spring 7 and in the throttle body linkage Pull the end of the inner cable to keep the cable taut and tighten the screw E Loosen the lock nut and turn the adjuster 11 to obtain a little freeplay of the outer cable Rotate the lever fully downwards and make sure that throt...

Page 157: ...A B C D E F G H L M N P section F 1 9 Monster 696 696 M Y 2009 edition 00 Controls Devices Notes Refer to the figures on the next page for correct routing of the choke cable M N ...

Page 158: ...A B C D E F G H L M N P section F 1 10 Monster 696 696 M Y 2009 edition 00 Controls Devices Positioning of the throttle choke cables ...

Page 159: ...A B C D E F G H L M N P section F 1 11 Monster 696 696 M Y 2009 edition 00 Controls Devices ...

Page 160: ...unting clamp 8 Sealing washer 9 Banjo bolt 10 Fitting 11 Bleed valve 12 Dust cap 13 O ring 14 Clutch slave cylinder 15 Screw 16 Clutch pushrod 17 O ring 18 Microswitch 19 Washer 20 Rubber 21 Guide 22 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 7 3 4 1 9 8 10 6 1...

Page 161: ...o replacing the following parts control lever reservoir unit and master cylinder fasteners Unscrew the banjo bolt 9 recovering the sealing washers 8 to release the clutch master cylinder assembly 1 from the clutch control hose 6 Unscrew the two clamp screws 7 securing the clutch master cylinder assembly to the handlebar Remove the clutch master cylinder assembly 1 to dismantle the assembly refer t...

Page 162: ...cylinder is aligned with the punch mark B on the handlebar Tighten the retaining screws 7 to the specified torque Sect C 3 Frame torque settings in the sequence 1 2 1 starting with the uppermost screw Locate the hose 6 and sealing washers 8 on the master cylinder 1 and secure with the banjo bolt 9 but do not tighten at this stage Warning An incorrectly positioned hose can cause clutch faults and i...

Page 163: ...ing clips see the illustration at the end of this section Locate the hose 6 as shown in the figure then tighten down the banjo bolt 9 to the specified torque Sect C 3 Frame torque settings Operation Section reference Fill the clutch system with fluid D 4 Filling the clutch circuit Refit the LH mirror E 1 Refitting the rearview mirrors 27 2 9 6 ...

Page 164: ...leed valve the seals and the complete clutch pushrod assembly Undo the three screws 15 securing the clutch slave cylinder 14 to the engine and withdraw the unit from the crankcase Remove the dust cap 12 and the bleed valve 11 and unscrew the banjo bolt 10 taking care to recover the sealing washers 8 the unit 14 is now disconnected from hose 6 Push in the piston to force out all the fluid from insi...

Page 165: ... 17 Locate the slave cylinder unit 14 in the crankcase and tighten the screws 15 to the specified torque Sect C 3 Frame torque settings Locate the hose 6 on the slave cylinder 14 ensuring that the hose end fitting is correctly positioned relative to the slave cylinder 14 Warning An incorrectly positioned hose can cause clutch faults and interfere with moving parts 16 17 B 14 15 15 14 6 ...

Page 166: ...tighten the banjo bolt 10 to the specified torque Sect C 3 Frame torque settings Refit the bleed valve 11 and the dust cap 12 Refer to the diagram on the following page for correct positioning of the hose retaining clips 6 Operation Section reference Fill the clutch system with fluid D 4 Filling the clutch circuit 12 6 11 8 10 14 ...

Page 167: ...A B C D E F G H L M N P section F 2 19 Monster 696 696 M Y 2009 edition 00 Controls Devices Positioning of the clutch hose ...

Page 168: ...A B C D E F G H L M N P section F 2 20 Monster 696 696 M Y 2009 edition 00 Controls Devices ...

Page 169: ... pin 7 Caliper master cylinder hose 8 Fluid reservoir cover 9 Inspection plug replacement part 10 Mounting clamp 11 Banjo bolt 12 Sealing washer 13 Screw 14 Washer 15 Guide 16 Rubber Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram FRONT BRAKE 18 16 13 7 5 2 6 10 1 9 8 11 ...

Page 170: ... units are limited to replacing the following parts control lever reservoir unit reservoir fasteners and master cylinder fasteners Unscrew the mounting clamp screws 10 and then remove the front brake master cylinder assembly 1 from the handlebar For disassembly of components of the master cylinder unit 1 refer to the exploded view at the beginning of this chapter Operation Section reference Drain ...

Page 171: ...ebar Tighten the two screws of the master cylinder mounting clamp 10 Tighten the screws of the mounting clamp 10 to the specified torque Sect C 3 Frame torque settings starting with the uppermost screw indicated by the arrow and then proceed in the sequence 1 2 1 If the front brake hose c was disturbed follow the instructions given in Sect G 3 Refitting the front brake system Operation Section ref...

Page 172: ... release fastener 12 Washer 13 Switch 14 Bush 15 Fork 16 Hose 17 Rear brake master cylinder 18 Screw 19 Pushrod 20 Rubber boot 21 Screw 22 Plug 23 Fluid reservoir assembly 24 O ring 25 Nut Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 2 1 23 20 4 16 22 12 10 14 15 24 7 ...

Page 173: ...ons on these units are limited to replacing the following parts control lever reservoir unit reservoir fasteners and master cylinder fasteners Undo the screw 21 and remove the reservoir 23 complete with the hose 16 Remove the footrest bracket Sect H 4 Removal of the footrest brackets Unscrew the screws 18 securing the rear brake master cylinder 17 to the footrest bracket A Unscrew the banjo bolt 1...

Page 174: ... section F 4 26 Monster 696 696 M Y 2009 edition 00 Controls Devices Unscrew the pin 5 securing the rear brake pedal lever to the footrest bracket and remove the spring 6 the complete pedal lever 9 and the O ring 24 9 6 24 5 ...

Page 175: ...iew at the beginning of this section If the brake pedal 9 inner bushing 14 needs to be renewed fit the new bushing using a suitable press and position it so that it is set in 2 mm from the outer face of the pedal To disassemble the various parts of the system refer to the exploded view at the beginning of this chapter Warning After working on the rear brake control check the operation of the brake...

Page 176: ...racket pushing the pivot pin fully home and positioning the spring 6 as shown in the figure Apply threadlocker to the threads of the pivot pin 5 Refitting is the reverse of removal in particular tighten the screws 18 to the specified torque Sect C 3 Frame torque settings Notes If the case of renewal of the master cylinder caliper pipe 3 and the master cylinder reservoir pipe 16 take care to ensure...

Page 177: ...to the clevis 15 to obtain the measurement indicated in the figure Restrain the pushrod and tighten the nut 25 against clevis 15 to the specified torque Sect C 3 Frame torque settings Fit the rear brake control rod on the pivot bolt 9 securing it with the clip 11 Now lubricate the other end of the pushrod 19 with the recommended grease and insert it in the master cylinder 1 Refit the footrest brac...

Page 178: ...A B C D E F G H L M N P section F 4 30 Monster 696 696 M Y 2009 edition 00 Controls Devices Positioning of rear brake hose ...

Page 179: ...A B C D E F G H L M N P section F 4 31 Monster 696 696 M Y 2009 edition 00 Controls Devices ...

Page 180: ...A B C D E F G H L M N P section F 4 32 Monster 696 696 M Y 2009 edition 00 Controls Devices ...

Page 181: ...r 7 Nut 8 Ball joint 9 Nut 10 Gearchange lever tie rod 11 Nut 12 Nut 13 Ball joint 14 Gearchange lever 15 Screw 16 Screw 17 O ring Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram GEARCHANGE LEVER FOOTREST 6 17 5 1 17 4 2 7 8 9 10 11 12 13 14 16 15 3 18 ...

Page 182: ...hange pedal 2 and recover the washer 6 and the O ring seals 17 Unscrew and remove the clamp screw 16 securing the gearchange lever 14 to the gear selector shaft Withdraw the lever 14 complete with the gearchange control assembly Notes Mark the position of lever 14 relative to the gear selector shaft To remove the lever 14 from the gearchange assembly remove the bolt 15 2 1 14 15 16 ...

Page 183: ...al of gearchange components If the bush 5 inside the pedal 2 needs replacing drive the new bush into place using a press The bush must be seated 2 mm below the outer face of the pedal Warning After working on the gearchange mechanism check the position of the gear pedal To adjust the position of the gear pedal follow the instructions provided in Sect D 4 Adjusting the position of the gearchange an...

Page 184: ...earchange mechanism To refit the gearchange mechanism reverse the operations of the removal procedure Notes Fit new O rings 17 on each reassembly Apply threadlocker to the clamp bolt 16 pivot screw 1 and screw 15 and then tighten them to the specified torque Sect C 3 Frame torque settings 14 15 16 1 LOCK 2 1 ...

Page 185: ...A B C D E F G H L M N P G Wheels Suspension Brakes 0 ...

Page 186: ... 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 syste...

Page 187: ... Screw 3 Spacer 4 Seal 5 Bearing 6 Inner spacer 7 Valve 8 Front wheel axle 9 Front wheel rim Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram FRONT FORKS FRONT AND REAR WHEELS 8 4 3 1 5 2 6 5 7 9 ...

Page 188: ... bike so that the front wheel is raised from the ground Remove the front brake caliper B by unscrewing the two screws A securing the caliper to the fork leg do not disconnect the caliper from the hose Warning Do not operate the brake lever when the calipers are removed This could cause fluid to leak out from the actuating pistons B A B A ...

Page 189: ...Brakes Loosen and remove the nut 1 on left side of the axle Loosen the axle clamp screws 2 on the ends of the fork legs Working from the left side use a plastic mallet to drive the wheel axle 8 out from the opposite side Remove the wheel and recover the spacer 3 on the left hand side 8 2 3 2 1 ...

Page 190: ...osition a drift A against the inner race of the bearing 5 Tap the drift with a hammer to drive out the bearing Apply the drift at different points to keep the bearing square during removal Important Once removed bearings must not be refitted Before fitting new bearings check that the housing is clean and free from scoring and damage Grease the bearing seat and then push the new bearing into its se...

Page 191: ...free of any cracks dents scoring or any signs of damage however light Localised polished areas are permitted Overhaul of the front and rear rim After you have checked the bearings check the rim as follows Visually inspect the rim for cracks scoring and deformation change the wheel if damaged Insert the axle in the wheel and mount it on two fixed reference blocks Using a dial gauge measure rim runo...

Page 192: ...ssary inspections have been completed refit the wheel as follows Lubricate the shank and thread of the wheel axle 8 Insert the front wheel between the fork legs installing the spacer 3 between the wheel hub and the left fork leg Warning Position the front wheel observing the arrow G marked on the rim showing the direction of rotation 8 B 3 G ...

Page 193: ...e 8 Drive the axle 8 fully home into the wheel hub inserting the locating peg of the service tool in the special notches at the bottom end of the fork Grease the thread and the underside of the head of axle nut 1 then screw it onto the end of the wheel axle Tighten the nut 1 to the specified torque Sect C 3 Frame torque settings 8 8000 70139 1 B ...

Page 194: ... or three times Hold the lever pulled in towards the grip and tighten the screws A to the specified torque Sect C 3 Frame torque settings Check that the brake discs turn freely inside the calipers Before tightening the axle clamp screws 2 lower the bike to the ground and push up and down on the handlebars to load the suspension so the fork legs will become properly seated onto the wheel axle Lubri...

Page 195: ...load tube 13 Nut 14 Spring 15 Rubber bush 16 O ring 17 Complete damper 18 Outer tube 19 Left inner tube assembly 20 Bush 21 Overhaul kit 22 Bottom yoke 23 Top yoke 24 Screw 25 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 1 6 4 5 8 14 12 11 18 21 16 9 3 21 2 7 13 ...

Page 196: ...cated for clearer explanation of the procedure Loosen the clamp screws 25 holding the fork legs to the top yoke 23 Loosen the clamp screws 24 securing the fork legs to the bottom yoke 22 Withdraw the fork legs 2 and 1 downwards in order to carry out to all the necessary overhaul operations Operation Section reference Removal of the front brake calipers G 3 Removal of the front brake system Removal...

Page 197: ...top cap 7 when the fork is still fitted to the motorcycle Notes The service tools required for front fork overhaul are listed in Sect C 4 Specific tools for the frame Disassembly of the front fork right leg Remove the top cap 7 Notes The service tools required for front fork overhaul are listed in Sect C 4 Specific tools for the frame Unscrew the top cap 7 7 7 14 ...

Page 198: ... no 88713 0957 engaging its pins A in the upper spacer and secure in place with the screw B Push the tool downwards to compress the spring and then fit the tool spacer C under the cartridge lock nut 13 Apply a wrench to the flats D and counterhold the lock nut to loosen the top cap 7 Remove the cap 7 B C 88713 0957 A A C 13 D ...

Page 199: ...ing and remove the spacer C Remove the service tool no 88713 0957 and slide out the preload tube 12 Remove the spring 9 and pump the outer tube 18 and the damper 8 to expel the oil from the fork Warning This movement generates pressure so that the oil will be rapidly expelled from the fork Aim the jet of oil into a previously prepared container and avoid contact with fork oil 88713 0958 88713 0958...

Page 200: ...Clamp the inner tube 6 in a vice with soft faced jaws Unscrew the screw 3 Remove the adjuster screw 3 and recover the seal 4 Remove the complete damper assembly 8 and locating ring 10 Slide the dust seal E off the outer tube 18 prising it off with a screwdriver Remove the circlip F 3 6 10 8 4 3 18 E F ...

Page 201: ...m the inner tube 6 pull the inner tube sharply outwards repeatedly to gradually displace the bottom bush G Insert the tip of a screwdriver in the slit in the bush H and open it up sufficiently to slide the bush off the inner tube Remove the following parts from the inner tube 6 bush G ring I seal J circlip F dust seal E Disassembly of the front fork left leg Unscrew the top cap 7 6 18 H G I J E 6 ...

Page 202: ...damper asembly 17 Remove the spring 14 and pump the outer tube 18 to expel the oil from the fork leg Warning This movement generates pressure so that the oil will be rapidly expelled from the fork Aim the jet of oil into a previously prepared container and avoid contact with fork oil Slide the dust seal E off the outer tube 18 prising it off with a screwdriver 17 20 15 13 7 18 14 18 E ...

Page 203: ...ube 19 To separate the outer tube 18 from the inner tube 19 pull the inner tube sharply outwards repeatedly to gradually displace the bottom bush G Insert the tip of a screwdriver in the slit in the bush H and open it up sufficiently to slide the bush off the inner tube Remove the following parts from the inner tube 19 bush G ring I seal J circlip F dust seal E F 19 18 H G I J E 9 F ...

Page 204: ...ed limit Inspect the outer surfaces of both fork inner tubes and the internal surfaces of both outer tubes They must be free from scoring steps or dents Check that the outer tubes are straight maximum permissible error 0 10 mm Whenever the inner tube is removed from the outer tube it is good practice to renew the bushes G and H Reassembly of the front fork right leg Locate the outer tube 18 on the...

Page 205: ...ill with fork oil using 500 2 5 cc of the specific oil Check the quantity of oil measuring the distance of the level from the end of the outer tube 18 This distance should be 81 mm Clean off any oil from spring 9 and upper spacer 12 before assembly Notes Install the spring 9 ensuring that the end with tighter coils is towards the bottom of the fork Fit the following components spring 9 upper space...

Page 206: ...per 8 Remove service tool no 88713 0958 Screw the top cap 7 onto the damper 8 Using a hex wrench hold the rebound damping adjuster E and tighten the top cap to 30 to 40 Nm Remove the spacer C by pushing the tool no 88713 0957 downwards Warning The adjuster on the top cap 7 should be screwed fully onto the thread of the damper 8 Lift the outer tube 18 and tighten the top cap 7 to a torque of 30 to ...

Page 207: ...vice limit 270 mm Renew the spring if the length is not within the specified limit Inspect the outer surfaces of both fork inner tubes and the internal surfaces of both outer tubes They must be free from scoring steps or dents Check that the outer tubes are straight maximum permissible error 0 10 mm Whenever the inner tube is removed from the outer tube it is good practice to renew the bushes G an...

Page 208: ...from the spring 14 Notes Install the spring 14 ensuring that the end with tighter coils is towards the bottom of the fork Hold the left fork leg assembly 2 in a vertical position and fill with fork oil using 538 2 5 cc of the specific oil Refit the top cap 7 complete with nut 13 rubber bush 15 bush 20 spring and complete damper assembly 17 on the outer tube 18 and tighten to the specified torque 1...

Page 209: ...A B C D E F G H L M N P section G 2 25 Monster 696 696 M Y 2009 edition 00 Wheels Suspension Brakes 18 7 ...

Page 210: ...ct C 3 Frame torque settings in the sequence 1 2 1 Important If the clamp screws 1 and 2 were removed on disassembly smear the threads with the specified grease before tightening Warning Do not use the motorcycle without the front mudguard fitted to avoid the risk of the brake pipes fouling the wheel on braking Refit any parts removed from the frame Operation Section reference Refitting the front ...

Page 211: ...inder hose 9 Pair of brake pads 10 Left brake caliper 11 Springs 12 Bracket 13 Brake disc 14 Screw 15 Front brake hose 16 Screw 17 Banjo bolt 18 Screw 19 Washer 20 Ring 21 Rubber 22 Clip Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 7 2 15 12 4 17 21 18 8 6 4 19 20 2 3 ...

Page 212: ...doctor if necessary For maintenance instructions brake pad wear check and renewal brake fluid change etc refer to Sect D 4 Draining the brake circuit Removal of the front brake system Unscrew the banjo bolt 6 securing the brake hose to the master cylinder and recover the sealing washers 4 remove the hose 8 from the master cylinder Release hose 15 from the retaining clips 22 and hose 8 from the bra...

Page 213: ...moval of the front brake master cylinder Unscrew the two retaining screws 2 securing the left front brake caliper 10 to the fork leg Repeat the operation for the right brake caliper 3 Unscrew the banjo bolts 17 from both calipers and recover the sealing washers 4 Detach the front brake calipers from the hoses 8 and 15 10 2 3 2 17 4 15 8 15 17 4 ...

Page 214: ...he front brake components Important Critical safety components The manufacturer of the brake caliper advises against servicing the internal components of calipers Incorrect overhaul of this component could endanger rider safety Operations should be limited to renewal of the pads fasteners and bleeder assembly Refer to the exploded view at the beginning of this section for indications on renewal of...

Page 215: ...3 Frame torque settings Refit the wheel to the motorcycle Sect G 1 Refitting the front wheel When refitting the brake system take care to position correctly the end fittings on the hose 8 connecting the master cylinder and caliper Warning If incorrectly positioned the hose can affect brake operation and foul moving parts Position the hose as shown in the figure When reconnecting the brake hose to ...

Page 216: ... torque settings Notes Make sure that internal hose fitting 8 and external hose fitting 15 are installed to the RH brake caliper 10 Fit the RH caliper 10 over the disc Apply the recommended grease to the screws 2 Fit the screws 2 and hand tighten to fix the calipers to the fork legs then pre tighten to the specified torque Sect C 3 Frame torque settings Repeat the operation for the LH brake calipe...

Page 217: ...nd force the pads against the brake disc Hold the lever pulled in towards the grip and tighten the caliper screwts 2 to the specified torque Sect C 3 Frame torque settings Insert the front brake hose 15 in the retaining clip 22 located on the front mudguard and hose 8 in the bracket 12 Operation Section reference Filling the braking system D 4 Draining the brake circuit 22 8 15 8 12 ...

Page 218: ... 6 Inner spacer 7 Valve 8 Wheel 9 Cush drive bush 10 Bearing 11 Brake disc 12 Screw 13 Ring Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram FRONT AND REAR WHEELS SWINGARM AND DRIVE CHAIN 2 10 9 8 6 7 5 11 12 13 3 3 4 4 1 1 13 ...

Page 219: ...it connected to the braking system Place the bike on a service stand so that the rear wheel is clear of the ground Unscrew and remove the whell retaining nut 1 on the right hand side of the swingarm Loosen the screws 4 to slacken the chain Withdraw the axle 2 with the nut 1 from he left hand side Important During this operation support the wheel so that it cannot fall when the axle 2 is removed B ...

Page 220: ... rear sprocket Remove the rear wheel from the motorcycle taking care not to hit the brake caliper mounting bracket which is just resting on the swingarm with the brake disc 11 if necessary secure the mounting bracket to the swingarm with a tie to keep it out of the way Recover the spacer 10 on the sprocket side The wheel is removed complete with the sprocket flange 10 ...

Page 221: ...rear brake disc Unscrew and remove the six screws 12 securing the brake disc 11 to the axle 2 Remove the rear brake disc 11 The disc must be perfectly clean with no signs of rust oil or grease deposits or other contaminants and must be free of any deep scoring Refer to Sect C 1 1 Hydraulic brakes for the brake disc wear tolerance limits Apply threadlocker to the screws 12 Refit the brake disc 11 a...

Page 222: ...tact face of the nut and fit them to the swingarm Lock the special screws 4 in position with the circlips 13 Install the spacer 10 on the sprocket flange with its raised edge facing outwards Hold the caliper mounting bracket anchored to the locating pin C on the swingarm Apply grease to the axle 2 the grease should be applied evenly over the entire surface of the axle and to the contact face of th...

Page 223: ...chain tensioner slider Push the axle 2 until fulyl seated from the left hand side of the swingarm Apply grease to thread of the rear wheel axle 2 and to the contact face of the nut 1 Screw he nut onto the rear wheel axle 2 on the right hand side of the swingarm Hand tighten the nut Proceed with the operations of chain tensioning and wheel alignment Sect D 4 Adjusting the chain tension Check that t...

Page 224: ...6 696 M Y 2009 edition 00 Wheels Suspension Brakes Refit the brake caliper A and tighten the screws B to the specified torque Sect C 3 Frame torque settings Notes The gap between the sensor and the brake disc screw must be between 0 6 and 2 2 mm B A B ...

Page 225: ...m 8 Nut 9 Ring 10 Rear wheel axle 11 Slider 12 Adjuster screw 13 Rear mudguard 14 Pin 15 Screw 16 Nut 17 Shim 18 Swingarm pivot shaft 19 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram SWINGARM AND DRIVE CHAIN 19 18 15 14 7 12 11 10 9 11 8 12 8 9 1 2 16 17 6 5 4 3 1...

Page 226: ... 1 and remove it from the swingarm Operation Section reference Remove the rear wheel G 4 Removal of the rear wheel Remove the final drive assembly G 8 Final drive Remove the rear brake caliper G 6 Removal of the rear brake system Remove the footrests H 4 Removal of the footrest brackets Remove the shock absorber from the swingarm G 7 Removal of the rear shock absorber 2 1 1 2 ...

Page 227: ... 00 Wheels Suspension Brakes Counterhold the nut 16 and loosen the screw 15 on the left side of the swingarm Drive out the pivot shaft 18 using a suitable drift until the swingarm is free of the engine Remove the swingarm 8 from the frame Recover the two shims 17 16 15 18 ...

Page 228: ...sure the swingarm pivot shaft 18 runout using a dial gauge place the pivot shaft 18 on two reference blocks of the same size rotate the shaft and move the gauge horizontally read off the runout Service limit 0 3 mm Sect C 1 1 Rear wheel Renew the pivot shaft when distortion exceeds the specified limit or if cracked or otherwise damaged 18 ...

Page 229: ...inserted with difficulty there is no need to install any further shims Otherwise use the two available shim sizes 0 20 mm and 0 10 mm to obtain the specified endfloat Example Important The thicker of the two shim packs must always be installed on the right hand side of the swingarm The thinnest shim should always be installed so that it is contact with the swingarm NEVER install 0 1 mm shims on th...

Page 230: ...shim 17 on the left hand side Grease the pivot shaft 18 and insert it from the left side of the swingarm together with circlip 5 Insert the shaft to about half its length Push the left arm of swingarm against engine and fit between the right arm and the engine the shim thickness 17 determined after measuring the endfloat Fully insert the swingarm pivot shaft taking care not to damage the shims 17 ...

Page 231: ...e specified torque Sect C 3 Frame torque settings Operation Section reference Refit the shock absorber and tie rod to rear swingarm G 7 Reassembly of the rear shock absorber Refit the vertical cylinder exhaust pipe L 8 Refitting the exhaust system Refit the rear brake caliper G 6 Refitting the rear brake system Refit the final drive assembly G 8 Final drive Refit the rear mudguard E 4 Refitting th...

Page 232: ...per 4 Caliper mounting bracket 5 Screw 6 Rear brake hose 7 Spacer 8 Pin and clip 9 Dust cap 10 Bleed valve 11 Pair of brake pads 12 Screw 13 Speed sensor Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram REAR BRAKE 8 9 10 11 8 2 1 4 3 5 13 7 12 6 ...

Page 233: ...move the banjo bolt 1 securing the hose 6 to the rear brake caliper and recover the sealing washers 2 Notes Keep a cloth at hand to wipe up any brake fluid that leaks out of the hose Undo the screws A securing the brake hose to the swingarm and remove the hose 6 complete with clip B Before removing the brake caliper 3 remove the clips C securing the wire of the rear wheel speed sensor to the brake...

Page 234: ...do the screw 12 securing it to the caliper mounting bracket taking care not to damage the spacer 7 Only the following parts should be renewed caliper pads fasteners and bleed valve assembly master cylinder control pedal bleed valve assembly reservoir and its components Refer to the exploded view at the beginning of this section for indications on renewal of the above components To remove the calip...

Page 235: ... the speed sensor 13 on the caliper mounting bracket with the spacer 7 and tighten the screw 12 to the specified torque Sect C 3 Frame torque settings Fit the copper sealing washers 2 to either side of the hose end fitting when connecting the brake hose 6 to the brake caliper Orientate the end fittings of the hose 6 on the caliper as shown in the photto Warning If incorrectly positioned the hose c...

Page 236: ...g it with the holes in the caliper mounting bracket Grease the threads and undersides of the heads of the screws 5 Tighten the screws 5 to the specified torque Sect C 3 Frame torque settings Notes The gap between the sensor 13 and the brake disc screw 12 must be between 0 6 and 2 2 mm Operation Section reference Tighten the screw securing the hose to the rear brake master cylinder F 4 Refitting th...

Page 237: ...akes 7 Rear suspension 1 Shock absorber 2 Screw 3 Shock absorber mounting 4 Nut 5 Screw 6 Nut Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram REAR SUSPENSION 6 4 5 1 2 3 ...

Page 238: ...k absorber is pivot mounted to the swingarm at the lower end and to the rear subframe frame at the upper end This system gives the motorcycle excellent stability For adjustment of the rear shock absorber refer to Sect D 4 Adjusting the rear shock absorber Removal of the rear shock absorber Remove the seat Sect E 3 Removal of the seat To remove the rear shock absorber from the motorcycle remove the...

Page 239: ...th L The same length must be restored on re assembly Disassembly of the rear shock absorber Remove the shock absorber mounting 3 by counterholding the screw 2 and unscrewing the nut 4 Slacken off locknut A and spring adjuster nut B with a pin wrench or special tool and remove the spring Visually inspect the shock absorber for oil leaks and other problems Renew the shock absorber if necessary L 3 2...

Page 240: ...l turn of the adjuster nut changes the length of the spring by 1 5 mm Tighten down the lock nut A against the adjuster B Lubricate the thread and underside of the head of the screw 2 and the contact face of the nut 4 with the specific grease Refit the shock absorber mounting 3 inserting the screw 2 and screwing on the nut 4 Notes Insert the screw 2 from the side on which the adjuster screw C is lo...

Page 241: ...he hole in the rear sub frame and fit the nut 6 Orientate the rear shock absorber with the prelaod adjuster screw C as shown in the photo Install the lower end of the shock absorber in the swingarm Grease the thread underside and sliding surface of the lower retaining screw 5 and insert it into the swingarm from the LH side Tighten the screw 5 to the specified torque Sect C 3 Frame torque settings...

Page 242: ...ut 7 Circlip 8 Spacer 9 Chain 10 Screw 11 Sprocket retaining plate 12 Front sprocket 13 Front sprocket cover 14 Screw 15 Sprocket flange spacer Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram GEARBOX FRONT AND REAR WHEELS 6 5 9 8 7 3 2 1 4 15 14 13 10 11 12 ...

Page 243: ...ear sprocket 5 If the teeth are found to worn as shown in the figure dotted line the sprocket must be renewed To check the amount of wear on the chain 9 keep the chain taut and measure 16 links If the length L is greater than 256 5 mm the chain should be renewed Important The rear sprocket 5 front sprocket 12 and chain 9 must all be renewed together as a set 12 Normal Worn 5 Normal Worn L 9 1st 2n...

Page 244: ... remove the sprocket cover 13 Slacken the chain Sect D 4 Adjusting the chain tension Engage a low gear and unscrew the two screws 10 on the sprocket retaining plate 11 Remove the plate 11 from the gearbox output shaft Slide the front sprocket 12 with the chain 9 off the gearbox output shaft and then unhook the chain from the sprocket 13 14 14 11 12 10 ...

Page 245: ...t retaining plate 11 to the gearbox output shaft B and turn it in the groove A until the holes in the plate 11 are aligned with the threaded holes in the sprocket 12 position the retaining plate with the rounded edge facing the sprocket Apply threadlocker to the threads of the screws 10 Engage first gear Tighten the screws 10 to the specified torque Sect C 3 Frame torque settings Adjust the chain ...

Page 246: ... off the rear wheel Remove the sprocket flange spacer 15 Hold the pins 1 at the cush drive bushes steady and undo the nuts 6 securing the sprocket to the flange Important The pins 1 have left hand threads Remove the rear sprocket Operation Section reference Slacken the chain D 4 Adjusting the chain tension Remove the rear wheel G 4 Removal of the rear wheel 15 1 1 2 2 6 ...

Page 247: ...he larger diameter thread A Tighten them onto the flange to their specified torque Sect C 3 Frame torque settings Fit the sprocket 5 to the flange orientating it so that the side with the recesses for the retaining nuts is facing outwards Apply the specified threadlocker to the small diameter thread B of the pins 1 and screw on the six nuts 6 Tighten the nuts to the specified torque Sect C 3 Frame...

Page 248: ...lange 2 to the rear wheel hub Make sure the pins 1 locate in the corresponding rubber cush drive bushes G Install the spacer 8 with the bevelled side facing the rear sprocket flange Operation Section reference Refit the rear wheel G 4 Refitting the rear wheel Adjust the chain tension D 4 Adjusting the chain tension G 1 2 8 ...

Page 249: ...A B C D E F G H L M N P H Frame 0 ...

Page 250: ...4 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 Refittin...

Page 251: ...ame 1 Handlebar 1 Upper clamp 2 Plug 3 Screw 4 Handlebar 5 Grips Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram HANDLEBAR AND CONTROLS 5 1 2 5 3 4 H ...

Page 252: ...op yoke To remove the grips 5 refer to the exploded view at the beginning of this chapter Operation Section reference Remove the throttle twistgrip F 1 Removal of the throttle twistgrip Remove the right hand and left hand handlebar switches P 5 Checking the indicating devices Remove the front brake lever F 3 Removal of the front brake master cylinder Remove the clutch lever F 2 Removal of the clut...

Page 253: ...arrows B pointing towards the fuel tank Refit the upper clamp 1 and insert the screws 3 Tighten the screws 3 to the specified torque Sect C 3 Frame torque settings in the sequence 1 2 3 4 1 2 as shown in the figure Operation Section reference Refit the front brake lever F 3 Refitting the front brake master cylinder Refit the right hand and left hand handlebar switches P 5 Checking the indicating d...

Page 254: ...2 Nut 13 Washer 14 Screw 15 Bottom yoke 16 Adjuster screw 17 Nut 18 Seal 19 Rubber mounting 20 Guide 21 Bracket 22 Washer 23 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 6 18 3 2 13 12 8 5 1 7 11 4 10 15 16 17 14 11 9 20 19 23 22 21 A HANDLEBAR AND CONTROLS H ...

Page 255: ... bearings Notes See Sect D 4 Adjusting the steering head bearings for adjustment of steering head bearing play If the steering head bearings cannot be adjusted correctly check the bearings 5 and 6 for wear and if necessary renew them as described in Removal of the steering head components in this section 5 6 ...

Page 256: ... 16 on the opposite side to bring it into contact with the stop on the steering head Apply threadlocker to the thread of nut 17 Hold the adjuster screw 16 firm and tighten the nut 17 Turn the forks to the opposite side and repeat the process to adjust the other screw and tighten the relative lock nut On completion of the adjustment turn the handlbars to full right lock and check that between the f...

Page 257: ...88713 1058 loosen the nut 12 and unscrew it from the steering stem Slide the oil seal 8 the inner race A and the ball race B of the upper bearing 5 off the steering stem Remove the bottom yoke 15 complete with the steering stem from the frame tube Remove the ball race B of the lower bearing 6 The inner race A of the lower bearing 6 and the relative oil seal 18 will remain on the steering stem Oper...

Page 258: ...ot to damage the seat Important Once disturbed the oil seals 8 and 18 and bearings 5 and 6 must not be refitted Using a suitable drift remove the outer bearing races C from the steering head Proceed with extreme care to avoid damaging the seats Disassembly of the top yoke While counterholding the nuts 9 unscrew and remove the screws 7 washers 11 and the lower clamp 4 from the top yoke C C 9 7 4 ...

Page 259: ...s 10 were removed from the top yoke lubricate with silicone spray Seat the spacers 10 square in the bores D in the top yoke orienting them as shown in the figure Important To drive in the spacers 10 use a drift that bears only on the outer ring E while applying a counterforce on zone F on the underside of the top yoke On completion of the operation clean all excess lubricant from the components 23...

Page 260: ...ackets 21 the guide 20 and the washers 22 with the screws 23 Tighten the screws 23 to the specified torque Sect C 3 Frame torque settings Locate the lower clamp 4 on the top yoke Fit the screws 7 complete with the washers 11 in the lower clamp 4 Tighten the screws 7 to the specified torque Sect C 3 Frame torque settings while counterholding the nuts 9 23 22 2 19 21 20 7 4 9 ...

Page 261: ...the steering head use the service tool no 88713 1062 and proceed as follows heat the steering head to 150 C fit the outer races C in their seats on the steering head fit the fixed bush G with threaded hole of the tool into the lower race fit the other movable bush H into the upper end of the tool and drive it fully home against the upper bearing race tighten the nut L and use a wrench to seat the ...

Page 262: ...onds Lubricate the inner bearing race A with the recommended grease Fit the ball race B on the stem with the smaller diameter of the cage facing upwards and grease the ball race Insert the steering stem in steering head and push it in until it is axially seated Fit the bottom yoke assembly to frame Grease the ball race B and fit it to frame top outer race C Fit the inner race A of the upper bearin...

Page 263: ...ct C 3 Frame torque settings Fit the top yoke 2 on the steering stem nut 12 aligning the fork leg bores with the corresponding bores on the bottom yoke Relocate the fork legs as described in Sect G 2 Refitting the front forks Grease the screw 3 Tighten the screw 3 on the top yoke to the specified torque Sect C 3 Frame torque settings Operation Section reference Refit the fork legs G 2 Refitting th...

Page 264: ...1 Screw 12 Spring 13 Right rear footrest 14 Left front footrest 15 Left footrest bracket 16 Left rear footrest 17 Washer 18 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram GEARCHANGE LEVER FOOTREST 4 5 10 9 12 10 13 17 3 7 11 1 1 2 11 17 3 18 8 5 15 16 14 6 Right ha...

Page 265: ...remove the rear brake fluid reservoir C Before removing the left footrest bracket unscrew the screw D securing the gearchange lever to the engine but leave the gearchange assembly attached to the bracket Unscrew the upper two screws 3 securing the bracket to the swingarm Recover the washers 17 located between the bracket and the frame Unscrew the lower screws 11 and 18 securing the LH footrest bra...

Page 266: ...ide the master cylinder E off the pushrod G Disconnect the rear brake sensor H from the main wiring harness Remove the RH footrest bracket assembly 8 To separate the rear RH footrest 13 from the footrest bracket 8 remove the circlip 5 and drive out the pin 4 to release the footrest 13 the plates 10 the ball 9 and the spring 12 H E F G 5 4 9 13 12 10 ...

Page 267: ...separate the front RH footrest 7 from the bracket 8 remove the circlip 5 and drive out the pin 4 to release the footrest 7 and the spring 6 The procedure is the same for the LH footrest Notes The footrest may also be removed with the footrest bracket installed on the motorcycle 5 4 7 6 ...

Page 268: ... front RH footrest 7 locate the spring 6 between the footrest lugs and attach it to the footrest bracket inserting the straight end of the spring in the hole in the bracket Grease the pin 4 and insert it from the top securing it on the other side with the circlip 5 Locate the spring 12 the plates 10 the balla 9 and RH rear footrest 13 between the lugs on the RH footrest bracket 8 7 6 4 7 A 5 9 13 ...

Page 269: ...9 edition 00 Frame Grease the pin 4 and insert it from the top securing it on the other side with the circlip 5 Check the condition of the rubber bushes 1 installed on the footrest bracket If they need to be renewed orientate them as shown in the figure 4 A 5 1 1 ...

Page 270: ...ylinder E and tighten the screws F to the specified torque Sect C 3 Frame torque settings Reconnect the rear brake sensor H to the main wiring harness Insert the rear brake pushrod G in the rear brake master cylinder E Fix the footrest brackets 8 and 15 to the swingarm with the screws 3 suitably lubricated with the washers 17 and to the engine with screws 11 and 18 Tighten the screws 3 11 and 18 t...

Page 271: ...e Fix the gearchange control to the engine crankcase applying threadlocker to the screw D and tightening it to the specified torque Sect C 3 Frame torque settings Refit the rear brake reservoir C tightening the screw A to the specified torque Sect C 3 Frame torque settings D B C A ...

Page 272: ... 2 Screw 3 Bracket 4 Screw 5 Switch 6 Inner spring 7 Spring assembly 8 Plate 9 Pivot screw 10 Nut Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram STANDS 3 5 2 1 10 9 7 7 6 4 H ...

Page 273: ...of the sidestand switch 1 from the main wiring harness Unscrew the screw 2 securing the sidestand bracket 3 to the engine and remove the complete sidestand assembly Disassembly of the sidestand Unscrew the retaining screw 4 and remove the sidestand switch 5 Release the sidestand springs 6 and 7 from the connecting plate 8 of the sidestand bracket and remove them Unscrew the pivot screw 9 securing ...

Page 274: ...ch 5 see Sect P 6 Checking protection and safety device components Reassembly of the sidestand Grease the sidestand leg 1 and fit it to the bracket 3 Secure it with the pivot screw 9 and the nut 10 Tighten the pivot screw 9 to the specified torque Sect C 3 Frame torque settings Position the sidestand return springs 6 and 7 and attach them to pivot plate 8 and stand leg 1 Locate the switch 5 on the...

Page 275: ...C and fit the screw 2 Connect the connector 5 of the sidestand switch to the main wiring harness For correct routing of the sidestand switch wiring refer to the plates diagrams in Sect P 1 Routing of wiring on frame Fit the screw A in the footrest bracket C Tighten the screws 2 A and B to the specified torque Sect C 3 Frame torque settings in the indicated sequence B 5 2 C 3 A 1 3 2 ...

Page 276: ... 8 Plate 9 Screw 10 Rear subframe left 11 Nut 12 Screw 13 Pin 14 Special nut 15 Bracket 16 Spacer 17 Rubber mounting 18 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram FRAME A A C D 8 10 11 15 14 3 7 14 13 6 5 4 1 2 3 4 5 6 12 12 9 16 17 16 18 C B B D H ...

Page 277: ...ensional checks on the frame you must remove all the superstructures fitted referring to the removal procedures outlined in the sections of this manual The flow chart below illustrates the logical sequence in which the parts are to be removed from the motorcycle and gives a reference to the section of the manual in which the removal procedure is described ...

Page 278: ...HYDRAULIC FRONT BRAKE CONTROL F 3 HYDRAULIC REAR BRAKE CONTROL F 4 HYDRAULIC CLUTCH CONTROL F 2 STEERING FORKS FRONT WHEEL ASSEMBLY H 2 G 1 G 2 DISCONNECTION OF FRONT WIRING CONNECTIONS P 1 DISCONNECTION OF REAR WIRING CONNECTION P 1 HEADLIGHT FAIRING AND REARVIEW MIRRORS E 1 HANDLEBARS H 1 INSTRUMENT PANEL P 6 SEAT E 3 EXHAUST L 8 COMPLETE MOTORCYCLE FRAME GEARSHIFT CONTROL F 5 CLUTCH SLAVE CYLIN...

Page 279: ...left hand side of the motorcycle restrain the pin 13 securing the front of the frame to the engine and unscrew the nut 3 on the right hand side Withdraw the front retaining pin 13 and remove the frame 1 Secure the rear subframe to the engine block by inserting the pin 13 Refitting the frame Before refitting check that the rubber mountings A are installed on the frame 1 1 3 6 6 1 13 A A A ...

Page 280: ... recommended grease to the threads of the pin 13 and of the nut 3 Locate the frame 1 on the motorcycle and insert the pin 13 from the right hand side Counterhold the pin 13 and tighten the nut 3 to the specified torque Sect C 3 Frame torque settings Align the rear subframe and the frame 1 inserting the special screws 6 but without tightening at this stage Remove the special screws 6 and tighten th...

Page 281: ...A B C D E F G H L M N P section H 6 33 Monster 696 696 M Y 2009 edition 00 Frame 6 1 13 B 5 4 B ...

Page 282: ...ing on frame and remove the silencers Sect L 8 Removal of the exhaust system Remove the frame as indicated in the previous paragraph Removal of the frame On the left hand side of the motorcycle restrain the pin 13 securing the rear of the subframe to the engine and simultaneously unscrew the nut 3 on the right hand side Withdraw the rear retaining pin 13 and remove the complete subframe assembly f...

Page 283: ... Disassembly of the rear subframe Counterhold the nuts 11 present only on the left hand side of the rear subframe unscrew the screws 12 and remove the bracket 15 Unscrew the screws 9 securing the plate 8 and separate the left subframe from the right subframe 11 11 15 15 12 12 9 8 9 ...

Page 284: ...etermine whether it needs to be renewed Important Badly damaged frames cannot be repaired they must be renewed Any work carried out on the frame can give rise to potential danger infringing the requirements of EC directives concerning manufacturers liability and general product safety General dimensions mm 100 205 58 5 690 7 243 6 164 2 110 1 32 24 Ø 55 1 5 315 135 8 27 2 ...

Page 285: ... are installed on the plate 8 Locate the plate 8 on the LH subframeo 10 and on the RH subframe 12 and insert the screws 9 Tighten the screws 9 to the specified torque Sect C 3 Frame torque settings in the sequence 1 2 3 4 Check that the rubber buffer B rubber bushes 17 and spacers 16 are installed on the bracket 15 8 A 9 8 9 1 2 3 4 16 17 16 15 B ...

Page 286: ...e rear subframe and tighten the screws 12 to the specified torque Sect C 3 Frame torque settings in the sequence 5 6 7 8 Refit the rear subframe to the engine Sect N 1 Refitting the engine Reconnect all the wiring connections of the electrical components mounted on the subframe Sect P 1 Routing of wiring on frame and refit the silencers Sect L 8 Removal of the exhaust system 11 11 15 6 5 8 7 15 12...

Page 287: ...0 Frame Refitting the rear subframe Locate the complete rear subframe assembly on the engine apply the recommended grease to the threads of the pin 13 and the nut 3 Counterhold the pin 13 and tighten the nut 3 to the specified torque Sect C 3 Frame torque settings 13 4 B 3 B ...

Page 288: ...ease fastener 16 Screw 17 Plate 18 Rubber mounting 19 Special screw 20 Screw 21 Nut 22 Screw 23 Quick release fastener 24 Plate 25 Screw 26 Latch 27 Seat lock 28 Nut 29 Latch lever 30 Screw 31 Catch Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 3 5 8 17 15 10 9 6 16 20 ...

Page 289: ...arness connector A from the main wiring harness Sect P 1 Routing of wiring on frame Unscrew the four screws 25 and and slide the tail light number plate holder assembly off the rear subframe as shown in the photo Unscrew and remove the screws 30 While counterholding the special screws 19 unscrew the screws 10 and remove the plate 24 from the tail light number plate holder assembly recover the wash...

Page 290: ...rotection 3 from the spray guard 1 by unscrewing the screws 7 The following operations refer to the left side of the motorcycle but apply also to the right side Disconnect the turn indicator wiring from the main wiring harness Working from the inside unscrew and remove the retaining screw 8 and recover the plate 17 Withdraw the turn indicator from the outside taking care not to damage the wiring 1...

Page 291: ...ight side Insert the wiring and left turn indicator 5 in the fixing hole in the protection 3 Position the plate 17 Fit the screws 8 and tighten to the specified torque Sect C 3 Frame tightening torques Reconnect the turn indicator wiring to the main wiring harness Refit the protection 3 to the spray guard 1 and tighten the screws 7 to the specified torque Sect C 3 Frame tightening torques 5 17 8 3...

Page 292: ...ening torques Refit the plate 24 to the tail light number plate holder assembly securing it with the four screws 10 and washers 9 While counterholding the special screws 19 tighten the screws 10 to the specified torque Sect C 3 Frame tightening torques Fit the screws 30 and tighten to the specified torque Sect C 3 Frame tightening torques Refit the tail light number plate holder assembly to the re...

Page 293: ...A B C D E F G H L M N P section H 7 45 Monster 696 696 M Y 2009 edition 00 Frame Fit the four screws 25 and tighten to the specified torque Sect C 3 Frame tightening torques 25 ...

Page 294: ... holder assembly from the rear subframe and the plate 24 as described in the previous paragraph Separate the spray guard 1 from the protection 3 by unscrewing the screws 7 Remove the end fitting A and release the lock cable 26 from the latch lever 31 Remove the end fitting B and release the lock cable 26 from the latch lever 29 7 7 1 26 A 31 29 29 B 26 ...

Page 295: ...A B C D E F G H L M N P section H 7 47 Monster 696 696 M Y 2009 edition 00 Frame Unscrew the nut 28 remove the lever 29 and withdraw the seat lock 27 27 28 29 ...

Page 296: ... the seat lock 27 in the housing in the spray guard 1 inserting the lugs C in the slots D as shown in the figure Fit the lock lever 29 inserting the lugs C in the slots E as shown in the figure Fit the nut 28 on the seat lock 27 and tighten to the specified torque Sect C 3 Frame tightening torques 27 D C E 29 E C 27 28 29 ...

Page 297: ...e cable end fitting B in th elock lever 29 and end fitting A in the latch 31 Refit the spray guard 1 to the protection 3 and tighten the screws 7 to the specified torque Sect C 3 Frame tightening torques Refit the tail light number plate holder assembly from the rear subframe and the plate 24 as described in the previous paragraph 1 26 29 B 26 26 A 31 29 7 7 1 ...

Page 298: ...different design and there is a bracket with side reflectors 13 Refitting the number plate holder Refitting is the reverse of removal in particular apply the recommended to the screws 16 and tighten in the indicated sequence tighten the nuts 21 to the specified torque Sect C 3 Frame tightening torques 20 11 13 16 6 3 13 13 11 14 16 6 USA 20 11 13 16 6 21 2 1 3 2 LOCK 3 13 13 11 14 16 6 USA 2 LOCK ...

Page 299: ...A B C D E F G H L M N P L Fuel Exhaust System 0 ...

Page 300: ... 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 10 Evaporative emissions canister 51 Evaporative emissions c...

Page 301: ...w 18 Fuel outlet hose 19 Fuel return hose 20 Cover 21 Nut 22 Special screw 23 Flange 24 O ring 25 Filter 26 Hose clamps 27 Thermistor 28 Screw 29 Quick release fitting 30 Screw 31 Washer Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 25 24 23 22 29 21 20 18 17 16 19 28 2...

Page 302: ...eather hose cover Sect N 8 Removal of the alternator side crankcase cover Withdraw the breather hose 6 from the cover A Withdraw the hose 6 upwards leaving it attached to the tank breather and drain hose unions Working on the right hand side of the motorcycle disconnect the wiring connector B of the fuel level sensor from the main wiring harness unscrew the screw 30 securing the side of the tank t...

Page 303: ...m Remove the screw 13 and recover the washer 14 Release the fuel hoses 18 and 19 from the clips 16 Detach the lambda sensor cable C from the tank flange cover Warning Before removing the flange cover 20 make sure the tank 1 is empty and position a rag to collect any spilt fuel 14 13 18 19 16 C ...

Page 304: ...M N P section L 2 6 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System Raise the tank remove the flange cover 20 by unscrewing the nuts 21 and disconnect the quick release fittings 29 from the flange 20 21 21 29 29 ...

Page 305: ... Remove the fuel tank covers Sect E 2 Removal of the fuel tank fairings Open the filler cap Unscrew the outer screws 3 securing the ring nut to the filler cap recess Remove hoses 4 and 7 from the filler cap assembly 2 Remove the filler cap assembly 2 Refitting the filler cap Refitting is the reverse of removal Tighten the screws 3 to the specified torque Sect C 3 Frame torque settings 2 3 3 7 4 2 ...

Page 306: ...clips 26 next to the fuel filter 25 Remove the old filter from the connecting hoses and fit a new filter Before reassembly carefully remove any deposits or scale from all parts Important When installing the filter 25 position it so that the arrow on the external housing is pointing towards the flange Notes The flange is supplied as a spare part complete with the fuel pump and pressure regulator th...

Page 307: ... Insert the flange 23 in its housing in the fuel tank Fit the four screws 28 and tighten to the specified torque Sect C 3 Frame torque settings Insert the two screws 22 positioning them so the ends with threadlocker are towards the flange and tighten them to the specified torque Sect C 3 Frame torque settings 23 22 22 28 28 ...

Page 308: ...k has been disassembled into its component parts reposition all the parts as shown in the exploded view In particular tighten the screws 10 and 17 to the specified torque Sect C 3 Frame torque settings Refit the fuel tank inserting the pins D of the mounting brackets 9 and 12 in the correponding locations in the frame 10 10 17 12 D 9 ...

Page 309: ...rting the fitting 29 in its union in the flange identified with the word OUT until you feel a click fit the fuel return hose 19 orienting it as shown in the figure inserting the fitting 29 in its union in the flange identified with the word IN until you feel a click Attach the fuel hoses 18 and 19 to the clips 16 Refit the cover 20 fitting the two nuts 21 to the two screws 22 and tightening the nu...

Page 310: ...e main wiring harness Locate the lambda sensor wire C on the tank flange cover and secure it with a cable tie Fix the fuel tank to the subframe with the screw 13 and washer 14 and to the subframe with the screw 30 and washers 31 Tighten the screws 13 and 30 to the specified torque Sect C 3 Frame torque settings B C 14 13 30 31 ...

Page 311: ...2009 edition 00 Fuel Exhaust System Locate the fulr tank breather drain hose 6 on the motorcycle and refit the breather hose cover A Sect N 8 Refitting the alternator side crankcase cover Refit the fuel tank covers Sect E 2 Refittings the fuel tank fairings A 6 ...

Page 312: ...A B C D E F G H L M N P section L 2 14 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System Positioning of the fuel tank breathe drain hoses ...

Page 313: ...A B C D E F G H L M N P section L 2 15 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System ...

Page 314: ...A B C D E F G H L M N P section L 2 16 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System ...

Page 315: ...A B C D E F G H L M N P section L 2 17 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System Positions of the fuel hoses connecting the fuel tank to the throttle body ...

Page 316: ...A B C D E F G H L M N P section L 2 18 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System ...

Page 317: ...ng 15 Nut 16 Hose 17 Clamp 18 Washer 19 Union 20 Gasket 21 Pressure sensor 22 Hose 23 Sensor support 24 Washer 25 Screw 26 Throttle body assembly 27 Screw 28 Fuel feed hose 29 Fuel return hose 30 Connection hose Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 1 4 28 29 26...

Page 318: ...B connecting the main wiring harness to the air temperature sensor 7 Detach the air pressure sensor 21 from the throttle body and disconnect the wiring connector C from the main wiring harness Operation Section reference Remove the fuel tank L 2 Removal of the fuel tank Remove the airbox L 7 Removal of the airbox Disconnect the throttle cable F 1 Removal of the throttle twistgrip Disconnect the ch...

Page 319: ...he throttle body to the intake manifolds 11 Disconnect the wiring connectors D connecting the main wiring harness to the injectors 10 Remove the throttle body assembly 26 from the motorcycle If necessary slacken off the clamps 3 securing the throttle body to the hoses 4 and 16 and remove the hoses 11 17 11 17 D D 10 4 26 3 16 ...

Page 320: ...rs Undo the injector retaining clips 8 with the fuel feed hose 28 fuel return hose 29 and injector connection hose 30 Undo the screws 25 to remove the injectors from the throttle body recovering the washers 24 Refitting the injectors Lubricate the injector O rings Locate the washers 30 and tighten the screws 25 to the specified torque Sect C 3 Engine torque settings 2 27 30 25 8 29 28 25 8 30 25 8...

Page 321: ...Warning The hose 16 which mounts the air temperature sensor 17 should be installed on the same side of the throttle body as the position sensor 2 Notes The end of the hose with the smaller diameter is to be connected to the throttle body Push the hoses fully onto the throttle body aligning the moulding lines E on the hoses with the moulding lines F on the throttle body as shown in the photo Tighte...

Page 322: ...olds 11 and orient them as shown in the photos Orient the throttle body 26 with the race facing the right hand side relative to the direction of travel and insert it fully into the intake manifolds Tighten the clamps 17 to the specified torque Sect C 3 Frame torque settings making sure that they do not protrude beyond the locating edges of the manifolds 0 14 1 mm E 4 G 17 F 11 17 11 17 ...

Page 323: ... Install the air pressure sensor 21 on the throttle body insert the tubes of the pressure sensor in the manifold and connect the wiring connector C to the main wiring harness Connect the wiring connector B connecting the main wiring harness to the air temperature sensor 7 Connect the connector A connecting the main wiring harness to the throttle position sensor 2 D D 10 21 C 7 B 2 A ...

Page 324: ...imately 15 mm from the sleeve Pass the hot air blower along the sleeve several times moving continuously from one end to the other avoiding heating the same point for a prolonged time Important The sleeve should only be heated for the timer it takes to shrink do not carry on heating it beyond this point Operation Section reference Connect the choke cable F 1 Refitting the choke control Connect the...

Page 325: ...A B C D E F G H L M N P section L 6 27 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System Positioning the injector connection pipe ...

Page 326: ...ilter element 10 Support 11 Clamp 12 Hose 13 Screw 14 Breather valve 15 O ring 16 Screw 17 Spacer 18 Airbox 19 Rubber Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram CRANKCASE HALVES AIR INTAKE OIL BREATHER 1 13 14 15 1 2 16 17 19 5 3 4 6 7 8 9 10 18 11 12 21 20 19 ...

Page 327: ...rain hose 12 from the cover V on the alternator side crankcase cover Sect N 8 Removal of the alternator side crankcase cover Operation Section reference Remove the fuel tank L 2 Removal of the fuel tank Remove the battery P 2 Battery support Remove the ECU connector M 3 Removal of the electronic control unit Connect the starter motor contactor cable P 3 Removal of the starter motor 1 2 12 V 12 ...

Page 328: ...tem Disconnect the HT leads A of the horizontal cylinder head coil B and vertical cylinder head coil C from the respective spark plugs Disconnect the coil wiring connectors D from the main wiring harness Sect P 1 Routing of wiring on frame Loosen the clamps E of the hoses F B A D C D F E F E ...

Page 329: ...L M N P section L 7 31 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System Undo the screws 16 recover the spacers 17 and withdraw the air filter vertically upwards taking care to recover the rubbers 19 17 16 16 17 ...

Page 330: ... the following electrical components A ECU Sect M 3 Electronic Control Unit ECU B Starter contactor Sect P 3 Starter contactor C Battery support Sect P 2 Battery support D Coils Sect M 3 Coil Notes To remove the air filter proceed as described in Sect D 4 Changing and cleaning the air filters Reassembly of the airbox Refitting is the reverse of removal Route the wiring as indicated in Sect P 1 Rou...

Page 331: ...ondition of O rings 15 and renew them if necessary Refitting the oil breather valve Lubricate the two O rings 15 with engine oil Insert the oil breather valve 14 in the hole in the clutch side crankcase half aligning the valve hole G with the threaded hole H in the crankcase half and inserting the screw 13 Tighten the screw 13 to the specified torque Sect C 3 Frame tightening torques 14 13 13 14 1...

Page 332: ...2009 edition 00 Fuel Exhaust System Refitting the airbox Check that the rubber bushes 19 are present on the airbox Check that clamps E are correctly positioned on intake manifolds F with the fixing screws positioned as shown in the figure V cylinder O cylinder ...

Page 333: ...t System Locate the airbox assembly on the throttle body Fit screws 16 with the spacers 17 to the airbox and tighten to the specified torque Sect C 3 Frame torque settings Tighten the hose clamps E on the hoses G to the specified torque Sect C 3 Frame torque settings 17 16 16 17 F E F E ...

Page 334: ...inder head coil B and vertical cylinder head coil C to the respective spark plugs Connect the coil wiring connectors D to the main wiring harness Sect P 1 Routing of wiring on frame Refit the oil breather hose 2 with the clamp 1 on the breather valve and tighten the clamp 1 to the specified torque Sect C 3 Frame torque settings B A D C D 1 2 ...

Page 335: ...V on the alternator side crankcase cover Sect N 8 Refitting the alternator side crankcase cover Operation Section reference Refit the battery P 2 Refitting the battery Connect the starter motor contactor cable P 3 Refitting the starter motor Connect the ECU connector M 3 Refitting the electronic control unit Refit the fuel tank L 2 Refitting the fuel tank 12 V 12 ...

Page 336: ...A B C D E F G H L M N P section L 7 38 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System Positioning of the blow by hose ...

Page 337: ...A B C D E F G H L M N P section L 7 39 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System ...

Page 338: ...A B C D E F G H L M N P section L 7 40 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System Positioning of the airbox drain hose ...

Page 339: ...Spacer 18 Plug 19 Sealing washer 20 Special nut 21 Right hand bracket 22 Left hand bracket 23 Bush 24 Rubber 25 Spacer 26 Screw 27 RH silencer support bracket 28 LH silencer support bracket 29 Screw 30 Screw 31 Nut 32 Quick release fastener 33 LH heat shield 34 Washers Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but wh...

Page 340: ...antaneously to the ECU To ensure that the catalytic converters in the exhaust system work efficiently the ECU controls fuel injection to maintain the air fuel ratio within a tolerance close to the optimal value achieving the minimum possible emissions of hydrocarbons HC carbon monoxide CO and nitrogen oxide NOx The 3 way catalytic converters complete the exhaust fumes cleaning process by convertin...

Page 341: ...ining spring 10 of the LH silencer 8 from the centre exhaust pipe 5 While counterholding the nut 31 unscrew the retaining screw 30 and remove the LH silencer 8 from the motorcycle Recover the spacer 23 and the rubber bushes 24 Operation Section reference Remove the RH footrest bracket H 4 Removal of the footrest brackets 5 10 8 30 31 23 24 ...

Page 342: ...the same procedure to remove the RH silencer 7 Unscrew the two nuts 20 and release the centre exhaust pipe 5 from the fuel tank support bracket and exhaust A Disconnect the two lambda sensors 2 from the main wiring harness Sect P 1 Routing of wiring on frame For details on the lambda sensor refer to Sect M 3 Lambda sensor Unscrew the screw 15 securing the centre exhaust pipe 5 to the engine 33 26 ...

Page 343: ... 00 Fuel Exhaust System Unscrew the clamp 16 and separate the centre exhaust pipe 5 from the horizontal cylinder exhaust pipe 3 and the vertical cylinder exhaust pipe 4 Loosen and remove the nuts 9 securing the exhaust pipe flanges to the cylinder heads 16 4 16 3 5 9 4 9 3 ...

Page 344: ...rom the horizontal cylinder head recovering the gasket 1 Remove the vertical exhaust pipe 4 from the vertical cylinder head recovering the gasket 1 Important Block off the exhaust ports on the head to prevent foreign matter from entering the combustion chamber Remove the horizontal heat shield 13 by unscrewing the retaining screws 26 and recover the spacers 25 and the washers 34 26 13 ...

Page 345: ...t pipe 4 to the respective cylinder heads Tighten the flange nuts 9 to the specified torque Sect C 3 Frame torque settings Check that the quick release fasteners 32 are installed on the horizontal cylinder exhaust pipe 3 Refit the horizontal heat shield 13 securing it with the retaining screws 26 the spacers 25 and the washers 34 Tighten the screws 26 to the specified torque Sect C 3 Frame torque ...

Page 346: ...ngs Insert the centre exhaust pipe 5 in the horizontal cylinder exhaust pipe 3 and vertical cylinder exhaust pipe 4 and secure with the clamps 16 Position the clamps as shown in the figure Position the clamps 16 so they are flush with the end of the exhaust pipes or at least so that the notches B are not completely uncovered Tighten the clamps 16 to the specified torque Sect C 3 Frame torque setti...

Page 347: ... of wiring on frame Connect the silencer 8 to the centre exhaust pipe 5 and locate the springs 10 If removed install the two rubber bushes 24 positioning on either side of the silencer bracket 27 Insert the spacer 23 in the silencer support bracket 27 Move the silencer support brackets so that they rest against the footrest brackets A Insert the screw 30 and on the opposite side fit the nut 31 Tig...

Page 348: ...t the quick release fasteners 32 are installed on the LH silencer 8 Refit the LH heat shield 33 securing it with the retaining screws 26 the spacers 25 and the washers 34 Tighten the screws 26 to the specified torque Sect C 3 Frame torque settings Follow the same procedure to refit the RH silencer 7 33 26 ...

Page 349: ...ter 10 Hose clip 11 Hose clip 12 Filter oil reservoir hose 13 Hose clip 14 Union filter pipe 15 Hose clip 16 Hose 17 Union 18 Aluminium gasket 19 Hose 20 Breather hose Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text Refer to the exploded view diagram 11 17 15 18 17 13 15 19 9 13 11 2 6 5 10 11 21 4 16 12 7 14 1 20 8 3 FUEL...

Page 350: ...nts fuel fumes from being discharged into the atmosphere The hose 12 is connected to the canister 9 when the fuel has been filtered it is returned with the hose 14 to the intake manifolds via the hoses 16 and 21 Hoses 5 and 25 vent to the ground For correct positioning of the connection hoses consult the indications given below 5 18 18 11 11 17 12 15 4 19 11 16 18 14 13 Breather Drain outlet Verti...

Page 351: ...ng the evaporative emissions canister 9 to the fuel filler cap Release the hose 12 dfrom the drain hose 20 by removing the strap A Loosen the hose clamps 15 connecting the canister 9 to the horizontal and vertical cylinders Operation Section reference Raise the fuel tank L 2 Removal of the fuel tank Remove the tank covers E 2 Removal of the fuel tank fairings 12 A 20 15 15 ...

Page 352: ...696 696 M Y 2009 edition 00 Fuel Exhaust System Undo the screws B and remove the LH air deflector 4 taking care to release the clutch hose C from the clips Remove the canister 9 from the LH deflector 4 by releasing it from the plate 6 B 4 4 B 4 C 4 9 ...

Page 353: ...rative emissions canister To refit the canister reverse the steps of the removal procedure taking care to tighten the screws B to the specified torque Sect C 3 Frame torque settings Operation Section reference Refit the fuel tank L 2 Refitting the fuel tank Refit the tank covers E 2 Refittings the fuel tank fairings ...

Page 354: ...A B C D E F G H L M N P section L 10 56 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System Positioning the hoses clamps and canister filter ...

Page 355: ...A B C D E F G H L M N P section L 10 57 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System Positioning the hoses clamps and canister filter ...

Page 356: ...A B C D E F G H L M N P section L 10 58 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System Positioning the hoses clamps and canister filter ...

Page 357: ...A B C D E F G H L M N P section L 10 59 Monster 696 696 M Y 2009 edition 00 Fuel Exhaust System ...

Page 358: ......

Page 359: ...A B C D E F G H L M N P M Fuel injection ignition system 0 ...

Page 360: ...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 ...

Page 361: ...nd the ignition advance are fundamental requirements for optimal engine operation The air fuel mixture is given by the ratio in weight of air to fuel taken in by the engine the ideal or stoichiometric ratio is that which determines complete combustion Excessive or insufficient air give rise to respectively a lean or weak mixture or a rich mixture which affect power and consumption as well as emiss...

Page 362: ...ap which is stored in the Flash EPROM of the Siemens M3C ECU for injection control The Flash Eprom can be programmed via CAN line Fuel injection control is of the phased sequential type i e the injectors are not operated in parallel Fuel delivery to each cylinder may start during the expansion stroke and may extend up to after the beginning of the induction stroke Fuel cut off timing the time when...

Page 363: ...A B C D E F G H L M N P section M 1 5 Monster 696 696 M Y 2009 edition 00 Fuel injection ignition system 1 4 5 7 2 3 6 8 9 10 11 11 13 12 14 ...

Page 364: ...ectors by means of a pump located on a flange installed at the bottom of the fuel tank The flange also incorporates the pressure regulator that controls the fuel feed pressure and keeps it constant at a higher value than the negative pressure generated by the engine Fuel that is not injected in the intake hoses returns to the flange and then to the tank by way of a return hose IN OUT IN OUT IN ...

Page 365: ...located between the V of the engine block connected to the air intakes measures the atmospheric pressure and transmits this information to the ECU where it used to make essential adjustments to the quantity of fuel injected when the motorcycle is ridden at varying altitudes e g a route that starts at sea level and ends at a high altitude they also allow the ECU to make mixture corrections in relat...

Page 366: ...horizontal and vertical cylinder exhaust pipes provide information that is used by the ECU tocontrol the air fuel mixture There is a throttle position sensor 12 fitted on the spindle of the rear cylinder throttle This device sends the ECU a signal that is an indirect indication of the quantity of air aspirated by the engine indirect measurement of engine load 4 14 12 ...

Page 367: ...the starter motor the unit receives the engine RPM and timing signals that allow it to proceed with injection and ignition To facilitate start up the mixture is enriched in accordance with engine temperature During starting the ignition advance angle is maintained at 0 until the engine starts When the engine starts the ECU controls the ignition advance in accordance with the values stored in the m...

Page 368: ...ring diagram Key to fuel injection ignition system diagram 3 Horizontal cylinder spark plug 4 Vertical cylinder spark plug 6 Starter contactor 7 Battery 8 Main fuse 15 Fuel tank 18 Self diagnosis DDA 19 Horizontal cylinder coil 20 Vertical cylinder coil 21 Horizontal cylinder spark plug 22 Vertical cylinder spark plug 23 Horizontal cylinder injector 24 Vertical cylinder injector 25 Throttle positi...

Page 369: ...o monitors battery voltage so that it can adjust injector opening time and ignition coil charging time accordingly The ECU determines the following values Amount of fuel delivered to each cylinder with a sequential non parallel control Injector closing time and therefore injection timing relative to the end of the induction stroke for each cylinder Ignition advance Important The maps which include...

Page 370: ... to the airbox with the fours screws 3 and reconnect the wiring connector 2 Tighten the screws 3 to the specified torque Sect C 3 Engine torque settings The connector 2 is 48 PIN connector Make sure that the clip A for the connector 2 is in its open position as shown in the diagram Rotate the clip A to secure the connector clip in the locked position 2 1 3 ...

Page 371: ... on the duration for which the injector is open This time is determined by the ECU in accordance with the engine operating conditions In this way correct fuel delivery in ensured For removal or refitting of the injectors refer to Sect L 6 Removal of the fuel injectors Notes To test the operation of the injector use the DDS tester and follow the instructions given in the paragraph Guided diagnosis ...

Page 372: ...A B C D E F G H L M N P section M 3 14 Monster 696 696 M Y 2009 edition 00 Fuel injection ignition system Positioning of the HT leads ...

Page 373: ...ium dioxide With a lean mixture the signal voltage is low while with a rich mixture it is high The typical change in signal intensity occurs when the air fuel ratio is 14 7 to 1 14 7 parts of air to 1 part of petrol which is referred to as Lambda 1 This ratio is considered to be an indication of complete combustion hence the name Lambda Sensor oxygen sensor therefore lambda 1 means mixture in stoi...

Page 374: ... 696 M Y 2009 edition 00 Fuel injection ignition system To remove the lambda sensors 1 unscrew them from the horizontal and vertical cylinder exhaust pipes When refitting the sensors tighten them to the specified torque Sect C 3 Frame torque settings 1 ...

Page 375: ...g Notes To test the operation of the injector use the DDS tester and follow the instructions given in the paragraph Guided diagnosis Sect D 5 Removing the air pressure sensor To remove the air pressure sensor 1 remove the airbox Sect L 7 Removal of the airbox disconnect the main wiring connector 3 from the sensor and detach the sensor from the throttle body Remove the hoses 2 from the intake manif...

Page 376: ...he DDS tester and follow the instructions given in the paragraph Guided diagnosis Sect D 5 Removal of the air temperature sensor To remove the air temperature sensor 1 first remove the airbox Sect L 7 Removal of the airbox disconnect the main wiring harness connector from the sensor 1 unscrew and remove the two sensor retaining screws 2 and remove the sensor from the intake manifold of the vertica...

Page 377: ...ortant Check the gap between the central and side electrodes If the gap is not as specified or if the spark plug is soiled with heavy sooty deposits renew it Refit the spark plug in the cylinder head first tightening it fully by hand Tighten to the specified torque Sect C 3 Frame torque settings Refit the spark plug caps 1 Important Do not use spark plugs with inadequate thermal rating or incorrec...

Page 378: ...arter contactor The vertical cylinder coil 2 is located on the battery support to remove it it is first necessary to remove the fuel tank Sect L 2 Removal of the fuel tank To remove the coil 1 disconnect the HT lead 3 Unscrew the nuts 4 taking care to recover the spring washers 3 Remove the coil 1 from the airbox To remove the coil 2 disconnect the HT lead 6 and remove the screws 7 Remove the coil...

Page 379: ...A B C D E F G H L M N P section M 3 21 Monster 696 696 M Y 2009 edition 00 Fuel injection ignition system Positioning of the HT leads 6 3 ...

Page 380: ...t measure of the engine load and is used by the ECU as one of the main parameters for defining the fuel flow rate and spark advance Notes To check this component use the DDS tester following the instructions given in the paragraph Guided diagnosis Sect D 5 It is not possible to change the throttle position sensor as a single component in the event of a fault with the sensor the complete throttle b...

Page 381: ...ps each equivalent to 2 teeth positioned 180 apart The signal coming from the pickup on the camshaft gear is used by the ECU to determine the engine speed and as a timing reference point Notes To check these components for faults use the DDS tester and follow the instructions given in the paragraph Guided diagnosis Sect D 5 For instructions on how to renew the sensor and check the air gap see the ...

Page 382: ...ectrical system and apply 12 V battery voltage between contacts 86 and 85 small contacts you should hear a click that confirms that the internal electromagnet has switched Connect a multimeter to contacts 30 and 87 big contacts to check for electrical continuity see Sect P 9 Diagnostic instruments concerning operation of the multimeter The resistance reading should be near zero and if present the ...

Page 383: ...A B C D E F G H L M N P N Engine 0 ...

Page 384: ...s 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 Re...

Page 385: ...moval 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 Remo...

Page 386: ... assembly 1 Engine 2 Bolt 3 Nut 4 Complete frame assembly 5 Swingarm pivot shaft Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram FRAME SWINGARM AND DRIVE CHAIN 5 1 4 2 3 3 B A C A D B D C ...

Page 387: ...e and a reference to the section where the removal procedure is described This section describes only the operations to be carried out after having removed all the parts listed in the flow chart REAR BRAKE MASTER CYLINDER G 6 COMPLETE MOTORCYCLE SEAT E 3 BATTERY BATTERY SUPPORT P 2 EXHAUST SYSTEM L 8 ENGINE ELECTRICAL CONNECTIONS P 1 ENGINE ELECTRICAL CONNECTIONS P 1 ENGINE ELECTRICAL CONNECTIONS ...

Page 388: ...w and remove the nuts 3 on the right hand side of the frame in correspondence with front and rear mounting bolts 2 securing the engine 1 Remove the swingarm from the engine 1 by withdrawing the swingarm pivot shaft 5 Sect G 5 Removal of the swingarm Withdraw the complete engine block 1 from the frame 4 4 2 1 5 1 3 5 4 ...

Page 389: ...Refitting the engine Refitting is the reverse of removal Important Position the correct shims between the engine and the swingarm Sect G 5 Refitting the swingarm Lubricate the nuts 3 of mounting bolts 2 Tighten the nuts 3 to the specified torque Sect C 3 Engine torque settings 3 B 2 ...

Page 390: ...ass plug 4 O ring 5 By pass valve 6 Locating bush 7 Reducer bush 8 Spring washer 9 Screw 10 Screw 11 Spring washer 12 By pass spring Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram FILTERS AND OIL PUMP 2 6 4 6 8 9 8 9 1 5 12 3 7 11 10 ...

Page 391: ...and remove the screws 9 and 10 securing the pump assembly Remove the oil pump assembly 1 and extract the O rings 2 and 4 from the crankcase half together with two locating bushes 6 Operation Section reference Remove the clutch side crankcase cover N 6 2 Removal of the clutch side crankcase cover 10 9 9 1 2 6 4 6 ...

Page 392: ...sure that vice jaws are faced with soft material Remove the plug 3 and extract the spring 12 and by pass valve 5 Check the condition of the above components Reassembly of the oil pump Install in the pump the by pass valve 5 and the spring 12 screw in the plug 3 and tighten to the specified torque Sect C 3 Engine torque settings after applying a medium strength threadlocker A 1 5 3 12 5 3 12 5 LOCK...

Page 393: ...ngine torque settings Check the gear backlash with the driving gear by fixing a dial gauge equipped with the appropriate stylus to the crankcase half Position the dial gauge stylus on one tooth of oil pump gear and set the gauge to zero in this position Move the gear slightly to measure the backlash take four readings in diametrically opposed positions of the gear The backlash should be 0 10 mm Op...

Page 394: ...adjustments 1 Closing shim 2 Camshaft 3 Opening shim 4 Valve Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram CYLINDER HEAD TIMING SYSTEM VERTICAL CYLINDER HEAD HORIZONTAL CYLINDER HEAD 4 4 3 2 1 3 1 ...

Page 395: ... tool no 88713 0123 to zero the horizontal cylinder is at top dead centre of the expansion stroke and therefore we can proceed to check the valve clearances on this cylinder To measure valve clearances in the vertical cylinder rotate the crankshaft counterclockwise through 270 from this position This will bring the vertical cylinder to top dead centre of the expansion stroke and therefore we can p...

Page 396: ... the closing rocker spring and thus eliminate any play in the rocker mechanism then check that the shim can rotate freely The clearance values must be within the specified limits Sect C 1 1 Timing system valves If they are not remove the opening shim 3 as described in the paragraph Valve disassembly Removal of the rocker arms shims and valves Sect N 4 4 and replace it with a shim of appropriate th...

Page 397: ...the shim without any significant play The clearance must be within the specified limits Sect C 1 1 Timing system valves If it is not remove the closing shim 1 as described in the paragraph Removal of the rocker arms shims and valves Sect N 4 4 and replace it with a shim of suitable thickness to obtain the specified clearance Notes Closing rocker arm shims measuring 2 2 to 4 5 are available as repl...

Page 398: ... is centred relative to the valve axis and located against the closing shim Set the dial gauge to zero when the valve is fully closed Rotate the intake camshaft so as to allow the intake valves to lift fully Check that the reading on the dial gauge corresponds to the specified value Sect C 1 1 Timing system valves Perform the same procedure for the exhaust valve fixing the support to the opposite ...

Page 399: ...learance when the camshaft is in rest position by inserting a feeler gauge between the opening rocker arm and the opening shim Check that in this condition the camshaft can rotate If it moves stiffly use a thinner feeler gauge In this condition with the piston of the horizontal cylinder is at TDC and the valves fully closed as confirmed by the reading on gauge E set gauges C to zero Adjust the tim...

Page 400: ...or the compression stroke you obtain a lift of the intake valve of 1 mm on the gauge C Check that the angular displacement reading matches the specified value Sect C 1 1 Timing system valves Rotate clockwise again until obtaining 1 mm lift of the exhaust valve on both valve opening and closure Check the angular displacement value against the specified value Repeat the procedure for the vertical cy...

Page 401: ... assembly 12 Screw 13 Elastic stop nut 14 Washer 15 Special washer 16 Camshaft pulley 17 Flange 18 Screw 19 Screw 20 Screw 21 Tensioner pulley assembly 22 Inner timing belt driveshaft pulley 23 Vertical cylinder timing belt 24 Key 25 Circlip 26 Key 27 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be f...

Page 402: ...rs Unscrew the screw 4 and screws 3 and remove the horizontal timing belt cover 2 Unscrew the screw 4 and remove the vertical timing belt outer cover 1 Operation Section reference Remove the fuel tank L 2 Removal of the fuel tank Remove the hoizontal cylinder exhaust pipe L 8 Removal of the exhaust system 1 4 4 3 2 ...

Page 403: ...w 20 of the tensioner pulley 21 of the horizontal cylinder timing belt Loosen the screw 27 securing the tensioner pulley of the horizontal cylinder timing belt and move the tensioner pulley 21 to the rest position Remove the horizontal cylinder timing belt 9 Repeat the above operations to remove the vertical cylinder timing belt 23 21 9 20 27 23 21 ...

Page 404: ...3 3152 on the pulley to be removed to prevent its rotation and using service scoket no 88700 5644 inserted in a torque wrench or ratchet arm loosen the pulley retaining nut 13 Remove the nut 13 washer 14 and pulley 16 Important On reassembly always fit new nuts Unscrew and remove the idler pulleys 11 88700 5644 13 88713 3152 13 14 16 11 ...

Page 405: ...to lock rotation of the drive roller on the crankcase and using the socket combined with the tool loosen the nut 6 Remove the nut 6 the washer 7 and the outer pulley 8 Remove the first Woodruff key 24 located on the timing belt driveshaft Remove the intermediate spacer 10 and the inner pulley 22 88700 5644 6 8 7 22 24 10 ...

Page 406: ... B C D E F G H L M N P section N 4 2 24 Monster 696 696 M Y 2009 edition 00 Engine Remove the secondt Woodruff key 26 located on the timing belt driveshaft Remove the spacer 5 and the circlip 25 26 5 25 ...

Page 407: ...f the washer and 15 and remove the pulley 16 from the flange 17 To reassemble fit the pulley 16 on the hub 17 aligning the timing mark G on the pulley with the timing mark on the H on the hub Fit the washer 15 against the pulley aligning the timing notch I with the timing marks G and H on the pulley and the hub respectively Insert the three screws 12 in the threaded holes L of the hub 15 16 16 4 I...

Page 408: ...eyway on the end of camshaft is in good condition and without burrs Fit one key C into the camshaft keyway Important During reassembly take care that the timing mark D on the spacer flange is aligned with the mark A on the pulley and washer Fit the assembled pulley 16 onto the camshaft so that is firmly seated Warning Make sure that the Woodruff key is not dislodged C B A 16 ...

Page 409: ...tion Apply a smear of grease to the thread and underside of the ringnut 13 and fit the washer 14 and the ringnut Important Always fit new nuts on reassembly Using the socket of service tool no 88700 5644 in combination with a torque wrench tighten the nuts 13 to their specified torque Sect C 3 Engine torque settings 13 14 16 A 88700 5644 13 88713 3152 ...

Page 410: ... on the pulley side of the timing belt driveshaft Drive it into its seat using the protective cap 88700 5749 and the relative drift Fit the spacer 5 with the slot facing the crankcase Locate on the timing belt drievshaft the first Woodruff key 26 the inner pulley 22 the intermediate spacer 10 and the second Woodruff key 24 88700 5749 25 26 5 22 24 10 ...

Page 411: ...ly Notes Apply a thin coating of grease to the thread and underside of the nut 6 Use the wrench of tool 88700 5644 to restrain the pulleys against rotation and using the bush of the tool in a torque wrench tighten the self locking nut to the specified torque Sect C 3 Engine torque settings Refitting the timing belt tensioner pulleys If removed apply the recommended threadlocker to the idler pulley...

Page 412: ...ng belt driveshaft pulley 8 with the reference notch D on the crankcase cover Important Turn the timing belt driveshaft pulley with the spark plugs removed from the engine Remove the inspection cover C from alternator side crankcase cover by unscrewing the two screws D Install the service tool 88713 2011 in the alternator side crankcase cover to hold the crankshaft against rotation and secure it w...

Page 413: ...ine Remove the srew F from the inner timing belt cover E and recover the washer Restrain the camshafts of both cylinder heads by screwing tool no 88713 2282 into the camshaft end caps Turn the pulleys by hand until the end of the tool engages the slot in the camshaft E F 88713 2282 ...

Page 414: ...tal 9 and vertical 23 timing belts using your hands only and without altering the alignment of the pulleys Locate the tensioner pulleys 21 on the vertical and horizontal cylinders Screw in but do not tighten at this point the screws 27 and 20 so that the tensioner pulleys can rotate 23 9 21 20 27 21 ...

Page 415: ...aragraph Measuring timing belt tension Sect D 5 Warning Check the tension values on sections of belts M and N shown in the figure When the correct belt tensioning value is reached ensure that bolts 20 27 and 12 are tightened to the specified torque Sect C 3 Engine torque settings Vertical Horizontal Tensioner Idler Idler Tensioner Timing belt N M 12 12 20 27 ...

Page 416: ...k the timing Sect N 4 1 Cylinder head assemblies checks and adjustments Remove the service tools no 88713 2282 from the camshaft end caps E and refit the screws F with the washers tightening them to the specified torque Sect C 3 Engine torque settings Remove the crankshaft locking tool 88713 2011 unscrewing first the pin and then the screw from the tool E F 88713 2282 88713 2011 ...

Page 417: ... Engine Refit the inspection cover C in the alternator side crankcase cover inserting the two screws D Tighten the screws to the specified torque Sect C 3 Engine torque settings Notes Before refitting the cover C check the condition of the O ring and renew it if necessary D C D ...

Page 418: ...retaining screws 4 and tighten to the specified torque Sect C 3 Engine torque settings Locate the horizontal timing belt cover 2 on the engine Tighten the screws 4 and 3 to the specified torque Sect C 3 Engine torque settings Operation Section reference Remove the horizontal cylinder exhaust pipe L 8 Refitting the exhaust system Refit the fuel tank L 2 Refitting the fuel tank 1 4 4 3 2 ...

Page 419: ...t 14 Nut 15 Key 16 Camshaft vertical cylinder head 17 Intake manifold 18 Screw 19 O ring 20 Camshaft end cap 21 Screw 22 Horizontal cylinder head camshaft 23 Copper gasket 24 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 18 2 1 20 15 13 17 14 22 15 16 19 21 4 5 20...

Page 420: ... the frame For clarity the photos show the engine removed from the frame Unscrew and remove the nuts 14 securing the intake manifolds of the vertical and horizontal cylinder heads from the studs 13 Remove the manifolds 17 If necessary remove the studs 12 and 13 from the cylinder heads Operation Section reference Remove the throttle body L 6 Removal of the throttle body 17 14 13 13 13 12 ...

Page 421: ... 12 and 13 install them in the cylinder heads and tighten them to the specified torque Sect C 3 Engine torque settings Locate the intake manifolds 17 and secure with the nuts 14 Tighten the nuts 14 to the specified torque Sect C 3 Engine torque settings Operation Section reference Refit the throttle body L 6 Refitting the throttle body 13 2 LOCK 12 2 LOCK 17 14 ...

Page 422: ...ove the retaining screws 18 and 1 and remove the inner timing belt cover 2 from the vertical cylinder head 10 Repeat the operation for the horizontal cylinder head 11 Notes When removing the covers take care not lose the Woodruff keys 15 located on camshafts 16 and 22 Operation Section reference Remove the camshaft timing pulleys N 4 2 Removal of the timing system assembly 2 18 1 10 11 18 2 1 15 1...

Page 423: ...L M N P section N 4 3 41 Monster 696 696 M Y 2009 edition 00 Engine Unscrew the screws 21 of the end cap 20 of the camshaft 16 Remove the camshaft end cap 20 from the cylinder head and recover the O ring 19 20 21 19 20 ...

Page 424: ... E F G H L M N P section N 4 3 42 Monster 696 696 M Y 2009 edition 00 Engine Removal of the valve covers Undo the retaining screws 7 of valve covers 8 and remove the covers with relative O rings 9 8 7 7 8 7 7 ...

Page 425: ...09 edition 00 Engine Refitting the valve covers Always fit new O rings 9 when refitting the valve covers Fix the valve covers 8 with the relative O ring 9 to the cylinder head Tighten the screws 7 to the specified torque Sect C 3 Engine torque settings 8 7 7 8 7 7 ...

Page 426: ...ibed above Remove the key 15 from the camshaft Notes To prevent possible damage to components rotate the camshaft 16 carefully as you go so that the cam lobes do not foul the rockers Notes If the rocker arms are installed in the cylinder head remove the spring A of the opening rocker arm B to facilitate operations Operation Section reference Remove the timing belt covers and the timing belts N 4 2...

Page 427: ...A B C D E F G H L M N P section N 4 3 45 Monster 696 696 M Y 2009 edition 00 Engine Withdraw the camshaft 16 from its housing Remove the oil seal 3 from the cylinder head 16 3 ...

Page 428: ...t between two centres and check for distortion using a dial gauge service limit 0 1 mm Notes The effective distortion will be half the total reading obtained on the dial gauge Each camshaft is stamped with an identification letter O horizontal V vertical Checking the oil seals Fit new oil seals at each engine overhaul Insert the new oil seals squarely in their bores Use suitable drifts Lubricate t...

Page 429: ...side of the cylinder head using a suitable drift Important If the rockers arms are already installed in the cylinder head Sect N 4 4 Refitting the rocker arms shims and valves insert the camshaft 16 carefully rotating it as you go so that the camshaft lobes do not foul the rocker arms Before fitting the camshaft check the punch mark V means vertical O means horizontal 3 6 ...

Page 430: ...00 Engine Apply graphite oil to the seats of the camshaft so that it is lubricated also during the initial revs of the engine Insert the camshaft 16 from the left hand side of the cylinder head If previously removed relocate the spring A of the opening rocker arm B 16 16 B A ...

Page 431: ... key 15 and its groove and install it Operation Section reference Refit the inner timing belt covers N 4 3 Refitting the camshaft end caps Refit the camshaft timing pulleys to the cylinder heads N 4 2 Refitting the timing system assembly Refit the timing belts and timing covers N 4 2 Refitting the timing belt covers 15 ...

Page 432: ...w O rings 19 with the recommended grease and fit on the end cap 20 Fit the end cap 20 on the left hand side of the cylinder head Secure the end cap 20 with the screws 21 Tighten the screws 21 to the specified torque Sect C 3 Engine torque settings Notes Take care not to dislodge the key 15 located on camshaft 16 19 20 B 20 21 15 16 ...

Page 433: ... side of the cylinder head and insert the retaining screws 1 and 18 Tighten the screws 18 and 1 to the specified torque Sect C 3 Engine torque settings Repeat the above operations for the other cylinder head 11 Operation Section reference Refit the camshaft timing pulleys to the cylinder heads N 4 2 Refitting the timing system assembly 2 18 1 10 2 LOCK 11 18 2 1 2 LOCK ...

Page 434: ...xhaust valve guide 12 Washer 13 Intake valve guide 14 Intake valve seat 15 Exhaust valve seat 16 Exhaust valve 17 Intake valve 18 Closing rocker arm 19 Nut Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 11 10 18 19 12 9 18 9 4 7 5 4 2 1 2 3 5 4 4 3 2 1 2 6 7 8 5 13 15 16...

Page 435: ... such a way that they can be refitted in exactly the same position they occupied before being removed Using tool 88713 2676 unscrew the nuts 19 on the cylinder head studs Remove the nuts 19 and recover the special washers 12 positioned between the nuts and the cylinder head Operation Section reference Remove the engine from the frame N 1 Removal of the engine Remove the timing belt covers and the ...

Page 436: ...d bolts Remove the cylinder head gaskets C Removal of the rocker arms shims and valves Remove the clip 1 securing the opening rocker 3 Move the rocker arm 3 to free the valve opening shim 6 Operation Section reference Remove the valve covers N 4 3 Removal of the valve covers Remove the camshaft end caps N 4 3 Removal of the inner timing belt covers C 3 1 6 ...

Page 437: ...2009 edition 00 Engine Screw service tool 88713 2837 to the threaded end of the opening rocker shaft 4 Withdraw the rocker shaft 4 and recover the opening rocker arm 3 and the two shims 2 Remove the camshaft Sect N 4 3 Removal of the camshafts 4 88713 2837 3 2 4 ...

Page 438: ... 8 along the intake valve stem 17 in such a way as to make it possible to remove the two half rings 7 securing the valve Use long nosed pliers or a magnetic screwdriver to remove the half rings 7 from the valve stem Slide the valve closing shim 8 off the valve 17 Withdraw the valve 17 from the underside of the cylinder head Repeat the above operations for the exhaust side 7 18 7 17 8 8 17 17 ...

Page 439: ... 00 Engine Attach the end of the spring 9 of the closing rocker arm 18 to the tool 88713 2783 Remove the closing rocker arm shaft 4 using service tool 88713 2837 Remove the rocker arm 18 the spring 9 and service tool 88713 2783 18 4 88713 2783 88713 2837 9 9 18 88713 2783 4 ...

Page 440: ...696 M Y 2009 edition 00 Engine Overhaul of cylinder head components Overhaul of the cylinder heads Remove any carbon deposits from the combustion chamber and its ducts Check for cracking and inspect the sealing surfaces for scoring ridges or other damage ...

Page 441: ...on 00 Engine The cylinder barrel mating surface must be perfectly flat If this is not the case spread diamond dressing compound 6 to 12 micron thickness on a reference surface and slide the cylinder head on the surface as shown in the figure until a flat finish is obtained ...

Page 442: ...orm the following checks measure the diameter of the valve stem D at various heights along the portion that runs in the valve guide Check that valve head band at 45 to valve head top face is concentric to the valve stem as follows place the valve on a V block set a dial gauge at right angles to the head and rotate the valve Service limit 0 03 mm Checking the valve seats Visually inspect the valve ...

Page 443: ... it may be lapped using the special 45 lapping tools with subsequent grinding of the valve into its seats If the valve seats are excessively damaged fit oversize seats Replacement seats are available with 0 03 and 0 06 mm oversized outside diameters Important When you change the valve seats change the valve guides as well 45 ...

Page 444: ...and choose the oversized valve seat that will give an interference fit of 0 11 to 0 16 mm Replacement valve seats are supplied in outside diameter oversizes of 0 03 and 0 06 mm Heat the cylinder head gradually and evenly up to 200 C and chill the new valve seats in dry ice Install the seats perfectly square into their bores using a suitable installer Allow to cool and then lap the valve seats smoo...

Page 445: ...ducts with fuel to check for leaks if leaking occurs check the sealing surfaces for burrs Overhaul of the valve guides Carefully examine the internal surface of the valve guide for cracking or distortion If the guide is excessively out of round use a reaming tool to make the mating faces more uniform Notes When you change the valve guide you must also change the valve The intake valve guides are m...

Page 446: ...f the seat Select the most suitable replacement valve guide to obtain an interference fit in the cylinder head bore of 0 022 to 0 051 mm replacement valve guides are supplied in O D oversizes of 0 03 0 06 and 0 09 mm complete with lock rings Heat up the cylinder head again and chill the new valve guide in dry ice Lubricate the seat and install the valve guide so that the stop ring is located again...

Page 447: ...r signs of wear grooves or chrome flaking off Check the condition of the rocker arm bore and shaft nominal diameter of rocker arm bore 10 040 to 10 062 mm nominal diameter of rocker arm shaft 10 001 to 10 010 mm Check the contact surfaces of the shims and the valve return collets are perfectly flat with no signs of wear ...

Page 448: ...aximum permissible wear limit 0 08 mm The rocker arm shafts should be a light force fit in the cylinder head In the event of excessive clearance fit 0 02 mm oversize shafts available from Parts Service Checking the rocker arm springs Carefully examine the springs 9 of the closing rocker arms 18 There must be no signs of cracking distortion or loss of elasticity 9 18 ...

Page 449: ...y particular attention to those operations mentioned specifically It is very important that all the components are carefully cleaned If removed fit new valve guide seal rings 10 lubricate with engine oil and insert from the spring side with tool part no 88713 2442 Fit the end of the tool into the valve guide and use a mallet to tap the seal rings 10 home into the valve guides 10 88713 2442 10 ...

Page 450: ...ervice tool no 88713 2783 Insstall the service tool rocker arm spring assembly in the cylinder head and insert the shaft 4 with a new seal ring 5 suitably lubricated Important When assembling the rocker arm shafts 4 make sure that threaded hole is on the external side of the cylinder head Detach the spring 9 and remove the tool no 88713 2783 9 18 88713 2783 18 4 88713 2783 B 5 9 4 9 ...

Page 451: ... section N 4 4 69 Monster 696 696 M Y 2009 edition 00 Engine Proceed in the same way for the exhaust side Install the valve 17 and valves 16 first lubricating them with engine oil Provisionally install the camshaft C 17 16 C ...

Page 452: ...on the valve stem Remove the screwdriver and position the closing rocker arm 18 in the rest position With the valve in rest position and while pushing on the rocker arm to oppose the force of the return spring check that the clearance between the rocker and the closing shim is within the specified tolerance limits Sect N 4 1 Checking the closing clearance Sc of the intake exhaust valves If not adj...

Page 453: ... Locate the opening rocker arm 3 and the two shims 2 on the shaft 4 Refit the camshaft end cap Sect N 4 3 Refitting the camshaft end caps Refit the camshaft timing pulleys Sect N 4 2 Refitting the timing belt driveshaft pulleys Locate the valve opening shim 6 on the valve stem With the valve in rest position check that clearance between the rocker arm 3 and the shim 6 is within the specified toler...

Page 454: ...removed it is essential to remove also the cylinder barrel piston in order to be able to clean the crankcase and cylinder barrel to renew if necessary damaged gaskets and O rings and to apply new liquid gasket Sect N 5 Refitting the cylinder piston assembly Before refitting the cylinder head assemblies fit new head gaskets C and check that the locating dowels A and bushes B are installed Sect N 5 ...

Page 455: ...and the threads of the studs with the recommended grease Using tool no 88713 2676 in conjunction with a torque wrench gradually tighten the cylinder head nuts to the specified torque in a crosswise sequence Sect C 3 Engine torque settings Important Incorrect tightening could cause abnormal elongation of the studs and serious damage to the engine Operation Section reference Refit the timing belt co...

Page 456: ...ings 6 Cylinder crankcase gasket 7 Dowel 8 Horizontal cylinder 9 Piston 10 Centring bush 11 Cylinder head gasket 12 Cylinder temperature sensor Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram CYLINDERS PISTONS 6 4 7 2 3 5 6 8 7 9 11 11 10 1 12 N ...

Page 457: ... bring the piston 9 of the horizontal cylinder 8 close to TDC Carefully lift the cylinder barrel 8 off the crankcase keeping it vertical If necessary rock the cylinder slightly using both hands or tap its base gently with a rubber mallet Continue to lift the cylinder until you can access the gudgeon pin 3 Operation Section reference Remove the cylinder heads from the engine N 4 4 Refitting the cyl...

Page 458: ...Close the opening in the engine crankcase with a rag or soft paper to prevent foreign material or solid combustion residue from falling in Remove the circlip 2 of the gudgeon pin 3 from the clutch side Working from the opposite side drive out the gudgeon pin 3 sufficiently to release the connecting rod Lift the cylinder piston assembly clear of the engine crankcase studs If work is to be carried o...

Page 459: ... 00 Engine To remove the vertical cylinder piston assembly proceed as described above for the horizontal cylinder Remove cylinder crankcase gaskets 6 from the cylinder barrel Important Mark the pistons to show from which cylinder they were removed V Vertical H Horizontal 6 ...

Page 460: ...y determining the assembly clearance taper and ovality see specified values in Sect C 1 1 Cylinder Piston In the event of damage or excessive wear the barrel must be renewed as it has a silicon carbide coating which provides the cylinder walls with excellent anti friction and anti wear properties and therefore cannot be rebored The cylinders are marked by a letter punched into the specific surface...

Page 461: ...rhaul of the piston Clean the piston crown and piston ring grooves removing any carbon deposits Inspect the piston and check its dimensions carefully there must be no signs of scuffing scoring cracks or other damage Check the piston diameter The pistons must always be renewed as a pair ...

Page 462: ...n pins must be perfectly smooth without signs of scoring steps or blueing due to overheating The well lubricated gudgeon pin must slide smoothly inside the piston without stiffness The assembly clearance with the piston at the time of installation must be 0 002 to 0 008 mm The maximum permissible wear limit is 0 035 mm If a new gudgeon pin is fitted you must also change the connecting rod small en...

Page 463: ...groove clearance The maximum permissible wear limit is 0 15 mm for the top compression ring 1st and 0 10 mm for the others 2nd and oil control ring Notes The piston rings must always be installed with markings facing upwards MARK 1st compression ring MARK 2nd compression ring MARK Oil control ring ...

Page 464: ... edition 00 Engine Gudgeon pin piston clearance Measure the diameter of the gudgeon pin bore in the piston Measure the diameter of the gudgeon pin Maximum wear limit 0 025 mm Notes If you fit a new gudgeon pin you must also change the connecting rod small end bush ...

Page 465: ...on ring A positioned perfectly square in the cylinder For this reason the piston 9 should be inserted in the cylinder without piston rings fitted and then place the piston ring to be checked on top of the piston Measure the piston ring gap Top and second piston ring nominal 0 20 to 0 40 mm Wear limit 0 80 mm Oil control ring nominal 0 030 to 0 060 mm Wear limit 1 0 mm 9 A A ...

Page 466: ...rown in between the two recesses If the pistons have been separated from their cylinders before reassembling these components position the piston ring gaps at 120 from one another the markings must always face the piston crown Use a universal tool to carefully insert the piston into the cylinder first lubricate the inside of the cylinder with engine oil Position the cylinder with the smallest valv...

Page 467: ...ket is for the 6 for the vertical cylinder V and the horizontal cylinder O The illustrations below the the various configurations Face in contact with cylinder barrel vertical cylinder A Face in contact with crankcase vertical cylinder B Face in contact with cylinder barrel horizontal cylinder C Face in contact with crankcase horizontal cylinder D Locate the gasket 6 on the crankcase with the word...

Page 468: ... the piston close to the gudgeon pin 3 bore Lubricate and insert the gudgeon pin The gudgeon pin must slide smoothly in the connecting rod small end bush and in the piston 9 Stuff the crankcase opening with a cloth to prevent foreign objects from falling inside and then fit the circlip 2 using service tool 88713 2270 Important Always fit new circlips 2 on reassembly Push the cylinder barrel 4 down...

Page 469: ...96 696 M Y 2009 edition 00 Engine Important Locate the locating dowel 7 head gasket 11 and centring bushes 10 Repeat the procedure for the other cylinder Operation Section reference Refit the cylinder heads N 4 4 Refitting the cylinder heads 11 7 10 ...

Page 470: ...tch lifter 4 Clutch spring 5 Pressure plate 6 Bearing 7 Clutch plates 8 Nut 9 Lock washer 10 Clutch centre 11 Shim 12 Spring 13 Hub Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram CLUTCH 11 10 9 12 8 7 3 6 5 13 4 2 1 ...

Page 471: ...eleration and thus with driving torque the clutch pack will tend to be under a greater load from springs initially more loaded while during hard downshifting the reverse acting torque will tend to take load off the springs thus causing the plates to slip Before working on the internal clutch parts check that the clutch operates correctly Then deal with the problem in a systematic manner The follow...

Page 472: ...rs 2 and the clutch springs 4 Remove the pressure plate 5 with the clutch control pin 3 If necessary using a drift of suitable diameter remove the bearing 6 installed on the inner side of the pressure plate 5 Operation Section reference Drain the engine oil D 4 Changing the engine oil and filter cartridge Remove the clutch side crankcase cover N 6 2 Removal of the clutch side crankcase cover 88713...

Page 473: ...00 Engine Hold the clutch drum with the service tool no 88713 2556 and unscrew the nut 8 Remove the washer 9 Withdraw the clutch hub plates centre assembly B from the clutch drum A marking the components so as to be able to install them in the same position 88713 2556 8 9 A B ...

Page 474: ...hub plates centre assembly Unscrew the three tools 88713 2591 Withdraw the hub 13 and the plates 7 from the clutch centre 10 Recover the three springs 12 Remove the clutch plates 7 from the hub 13 Important When removing the plates keep them in the same order as they were originally installed tying them together if necessary 11 A 7 88713 2591 7 12 13 10 ...

Page 475: ... clearance S must not exceed 0 6 mm If it does renew the plates and if necessary the clutch drum Overhaul of the clutch plates The clutch plates must not show any signs of blackening grooves or deformation Measure the thickness of the friction plates It should not be less than 3 2 mm Important The total thickness of the clutch plate pack must not be less than 50 2 mm Place the plate on a flat surf...

Page 476: ...sively scored use a reference plate and diamond lapping paste 6 12 microns thick and rub the friction plate on it to obtain a smooth uniform surface Check the condition of the spring guide cups D of the pressure plate 5 and always replace the spring retainer caps 2 at each overhaul Overhauling the pressure plate springs Measure the length L of each spring 4 minimum length 41 mm Renew any springs t...

Page 477: ...springs 12 on the pin E on the drum 10 Install the clutch plates 7 in the hub 13 starting with one of the 11 friction plates F and alternate with the 10 driven plates G Install the clutch plate assembly 7 with hub 13 in the drum 10 Warning When refitting the clutch centre 10 with the hub 13 align the reference notches H and L 10 12 E G F 13 7 7 H L 13 10 ...

Page 478: ...ols 88713 2591 to fix the hub 13 to the clutch centre 10 Screw in the three tools 88713 2591 by hand pressing down on the clutch plates with the hub 13 so as to overcome the resistance of the springs Notes Screw in the three tools 88713 2591 to put the clutch plates under a light load 7 88713 2591 10 13 ...

Page 479: ... the APTC clutch Locate the spacer 11 on the drum A Position the hub plates drum assembly B inside the drum A Notes Position the last friction plate M so that it is offset relative to others Locate the lock washer 9 on the gearbox input shaft seating it against the clutch assembly 11 A A B M 9 ...

Page 480: ...the nut to the input shaft and tighten by hand Restrain the clutch drum with tool part no 88713 2556 when tightening nut 8 Tighten the nut 8 to the specified torque Sect C 3 Engine torque settings Remove service tool no 88713 2556 Install the pressure plate 5 in the clutch asembly B aligning the three tools 88713 2591 with the three indents N in the pressure plate 8 B 88713 2556 5 B 88713 2591 N ...

Page 481: ...a spring 4 and a cap 2 Tighten the screws 1 to the specified torque Sect C 3 Engine torque settings working in a crosswise pattern Unscrew and remove the service tools 88713 2591 Operation Section reference Refit the clutch side crankcase cover N 6 2 Refitting the clutch side crankcase cover Top up the engine oil D 4 Changing the engine oil and filter cartridge 5 13 P 1 2 2 2 4 4 4 1 1 4 ...

Page 482: ...7 O ring 8 Bush 9 Seal 10 Shim 11 Circlip 12 O ring 13 Locating bush 14 Sealing washer thickness 2 15 Plug 16 Pressure switch 17 Cover 18 Plug 19 Sealing washer 20 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 3 2 13 19 18 5 4 8 9 10 11 12 15 7 14 16 6 17 20 1 CLU...

Page 483: ...tic mallet to detach it from the crankcase Remove the crankcase cover 1 taking care not to damage the locating bush 13 Check the condition of the locating bush 13 and replace if deformed Operation Section reference Drain the engine oil D 4 Changing the engine oil and filter cartridge Disconnect the oil pressure sensor P 5 Checking the front and rear brake light switches neutral light switch oil pr...

Page 484: ...engine oil pressure switch 16 and its seal 14 Unscrew the screw 20 securing the inner cover 17 Remove the inner cover 17 and sound proofing panel 6 Remove the circlip 11 and slide off the shim 10 and the oil seal 9 The drilled bush 8 is mounted to the cover by a forced interference fit Remove it using a suitable puller Inspect the oil seal 9 and renew it if necessary 15 7 16 14 6 17 20 11 10 8 9 ...

Page 485: ... a spring is facing the circlip 11 Before fitting check that the edges of the circlip groove show no sign of burrs which might otherwise damage the oil seal Then fit the shim 10 and the circlip 11 Important In order for the oil seal 9 to function correctly it must have an assembly clearance that allows the circlip 11 to rotate Position the sound proofing panel 6 inside the clutch side crankcase co...

Page 486: ...an and degrease mating surfaces on the clutch side crankcase cover and crankcase and ensure that locating bush 13 and the O ring 12 located in correspondence with the oil way are installed in the crankcase Apply a uniform continuous bead of DUCATI liquid gasket B onto crankcase mating surfaces working around all the holes 13 12 B ...

Page 487: ... Tighten the screws 2 3 and 5 to the specified torque Sect C 3 Engine torque settings in a crosswise pattern Operation Section reference Connect the oil pressure sensor P 5 Checking the front and rear brake light switches neutral light switch oil pressure switch and clutch switch Top up the engine oil D 4 Changing the engine oil and filter cartridge 2 5 1 3 5 5 ...

Page 488: ...ars 1 Clutch drum Primary drive gears 2 Inner ring 3 Inner bearing 4 Spacer 5 Threaded ringnut 6 Lock washer Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram CLUTCH CONNECTING RODS 6 5 1 4 3 2 A B ...

Page 489: ... the circlip 2 and the internal spacer 4 Straighten out the lock washer 6 on the nut 5 securing the primary driving gear B Operation Section reference Drain the engine oil D 4 Changing the engine oil and filter cartridge Remove the clutch side crankcase cover N 6 2 Removal of the clutch side crankcase cover Remove the clutch assembly N 6 1 Removal of the APTC clutch Remove the oil pump N 2 1 Remov...

Page 490: ... and unscrew the threaded nut 5 securing the pinion Remove the nut 5 and lockwasher 6 Remove the primary driving gear B using puller 88713 2092 and interposing a packing piece of aluminium or copper between the crankshaft and the screw of the puller Take care to recover the key C from the crankshaft and the internal spacer 88713 2423 B 5 6 88713 2092 B C ...

Page 491: ...he backlash To check the gear backlash temporarily fit the clutch drum 1 complete with internal spacer 4 driven gear A roller bearing 3 and internal bush 2 on the gearbox input shaft Fix a dial gauge to the engine crankcase positioning the stylus against a gear tooth Turn the driven gear A to mesh the teeth and check with the dial tool that backlash ranges between 0 05 and 0 07 mm Repeat the check...

Page 492: ... 696 M Y 2009 edition 00 Engine After checking the backlash restrain the driving gear B with service wrench no 88713 2423 and tighten the nut 5 to the specified torque Sect C 3 Engine torque settings Stake the lock washer 6 onto the nut 5 88713 2423 6 B 5 ...

Page 493: ...drum 1 the internal bearing 3 and the bush 2 Fit the internal spacer 4 to the input shaft with its flat side facing outwards Install the inner bush 2 and clutch drum 1 with driven gear A complete with roller bearing 3 Operation Section reference Refit the complete clutch assembly N 6 1 Refitting the APTC clutch Refit the clutch side crankcase cover N 6 2 Refitting the clutch side crankcase cover R...

Page 494: ... 2 12 Circlip 13 Nut 14 Selector drum control fork 15 Gearchange lever pin 16 Shaft with gearchange lever arm 17 Gearchange lever arm return spring 18 Screw 19 Washer 20 Screw 21 Washer 22 Locating ring 23 Stop plate 24 Shim thickness 0 2 24 Shim thickness 0 5 25 Gearchange mechanism Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside ...

Page 495: ...1 and withdraw the gear selector mechnaism complete with the gear lever shaft spring and stop plate Important Visually inspect the gear selector claw 14 for wear particularly around the area where it contacts the selector drum Operation Section reference Remove the alternator side crankcase cover and flywheel alternator assembly N 8 Flywheel alternator Remove the clutch drum N 6 3 Removal of the p...

Page 496: ... 1 114 Monster 696 696 M Y 2009 edition 00 Engine Disassembly of the gear selector mechanism If it is necessary to renew any components disassemble the gearchange mechanism as shown in the exploded view 14 12 11 10 13 16 23 24 15 22 17 9 ...

Page 497: ... 2009 edition 00 Engine Disassembly of the gear interlock plunger and pawl assembly Unscrew the interlock plunger screw 5 and remove seal 6 spring 7 and detent ball 8 Unscrew the clutch side crankcase screw 3 and remove the pawl 4 washer 2 and spring 1 5 7 6 4 3 ...

Page 498: ... gear pawl lever 4 orienting it as shown in the figure the washer 2 with the square edge side D facing the clutch side crankcase and the spring 1 positioning it so that the hook end A is facing the gear pawl lever Locate the hook end A of the spring on the gear pawl lever as shown in the figure Start the screw in the crankcase half Position end B of the spring so that it rests against rib C of the...

Page 499: ...2009 edition 00 Engine Apply grease and then fit the ball 8 spring 7 and seal 6 into interlock plunger 5 and screw the interlock plunger assembly into the crankcase Tighten the gear interlock plunger to the specified torque Sect C 3 Engine torque settings 5 7 6 B ...

Page 500: ...d on removal fit the spring 17 on the shaft 16 in the position indicated in the photo Grease the threaded end of the eccentric gearchange lever pin 15 and install it on the upper part of the gearchange lever securing it with the nut 13 Screw the nut on by hand do not tighten Insert the shaft 16 in stop plate 23 and washer 24 and secure with circlip 9 A 16 17 15 13 16 17 24 23 16 24 9 ...

Page 501: ... from the pin of the lever to adjust the position loosen the locknut 13 and turn eccentric pin 15 Position the spring 10 between the shaft 16 and the fork 14 Fit the ring 12 to secure the assembly Check that the spring 10 is installed correctly as shown in the figure Tighten the nut 13 to the specified torque Sect C 3 Engine torque settings 23 13 15 16 16 23 14 12 10 16 10 10 Incorrect assembly Co...

Page 502: ...A B C D E F G H L M N P section N 7 1 120 Monster 696 696 M Y 2009 edition 00 Engine 13 16 ...

Page 503: ...f the drum rollers Temporarily fit the gearbox lever or a service lever and engage third gear Fit the plate 88713 1091 in the claw shaft pins see figure Align the notch that marks the centreline of the fork shaft pawl with the end of the plate Then fit the gearchange mechanism retaining screws 18 and 20 with respective washers 19 and 20 and tighten to the specified torque Sect C 3 Engine torque se...

Page 504: ...gear is engaged Operate the gearchange lever and turn the front sprocket at the same time to check that all the gears engage when shifting up and down Remove the gearbox lever Operation Section reference Refit the clutch drum N 6 3 Refitting the primary drive gears and checking backlash Refit the flywheel alternator assembly and alternator side crankcase cover N 8 Refitting the flywheel alternator...

Page 505: ...ed driven gear 19 Shim thickness 1 20 5th speed driven gear 21 4th speed driven gear 22 3rd speed driven gear 23 6th speed driven gear 24 2nd speed driven gear 25 Gearbox output shaft 26 Shim 27 Shim thickness 1 28 1st 4th 2nd 3rd speed selector fork 29 5th 6th speed selector fork 30 Selector fork shaft 31 Shim thickness 1 32 Needle roller retaining circlip square cross section Parts catalogue Imp...

Page 506: ...om the slots in the selector drum 13 Withdraw the selector drum 13 taking care not to lose shims 31 and 27 mounted on the shaft Note that the positions of the shims must not be inverted Now you can renew the needle roller retaining ring 32 and the special needle rollers 14 Operation Section reference Separation of the crankcase halves N 9 2 Separation of the crankcase halves 30 29 28 13 30 28 13 2...

Page 507: ...afts complete with gears taking care to recover the spacers on the ends of the shafts If the bearing inner races A are left on the shafts slide them off the ends of the gearbox input 2 and output 25 shafts Sect N 9 2 Overhaul of the main bearings After removing them from the shafts install them in the respective outer bearings in the engine crankcase half 28 A 25 2 ...

Page 508: ...portant Take care not to invert the positions of the shims on reassembly this would potentially lead to jamming when using the gear selector control making it necessary to reopen the engine crankcase Disassembly of the gearbox output shaft Remove the chain side shim 15 and clutch side shim 26 from the output shaft Withdraw the first speed driven gear 18 with the roller cage 17 and the shim 19 15 1...

Page 509: ... 127 Monster 696 696 M Y 2009 edition 00 Engine Remove the fifth speed driven gear 20 Use two flat blade screwdrivers to remove the circlip 7 taking care not to damage the shaft surface Remove the circlip 7 and the splined washer 6 20 7 6 ...

Page 510: ... 2 128 Monster 696 696 M Y 2009 edition 00 Engine Withdraw the fourth speed driven gear 21 with the roller cage 4 and splined washer 12 Remove the third speed driven gear 22 with the roller cage 4 and the splined washer 6 4 21 12 4 22 6 ...

Page 511: ... section N 7 2 129 Monster 696 696 M Y 2009 edition 00 Engine Remove the circlip 7 and remove the sixth speed driven gear 23 Remove the circlip 7 and withdraw the splined washer 6 and the second speed driven gear 24 7 23 7 6 ...

Page 512: ...09 edition 00 Engine Withdraw the roller cage 4 and the shim 3 All the components have thus been removed from gearbox output shaft 25 Disassembly of the gearbox input shaft Remove the chain side shim 11 and the clutch side shim 1 from the input shaft 24 25 3 4 25 11 ...

Page 513: ...ster 696 696 M Y 2009 edition 00 Engine Remove the second speed driving gear 10 Use two screwdrivers to prise out the circlip 7 and the splined washer 6 Important Take care to avoid damaging the surface of the shaft while removing circlip 7 10 7 6 ...

Page 514: ...ection N 7 2 132 Monster 696 696 M Y 2009 edition 00 Engine Remove the sixth speed driving gear 9 with its roller cage 4 Remove the splined washer 6 and the circlip 7 Withdraw the third and fourth speed driving gear 8 4 9 6 7 8 ...

Page 515: ...A B C D E F G H L M N P section N 7 2 133 Monster 696 696 M Y 2009 edition 00 Engine Remove the circlip 7 and the splined washer 6 Remove the fifth speed driving gear 5 with the roller cage 4 7 6 5 4 ...

Page 516: ... are correctly positioned Check the needle roller bearings for wear The threads and splines of the shafts must be in perfect condition Also check that the component parts of the gear selector mechanism are in good condition Engage the gears and check that the gearchange mechanism does not stick selector fork gear groove and fork pin desmodromic drum groove due to incorrect end float Restore the co...

Page 517: ...ent forks must be renewed as they may lead to difficulties in gear changing or may suddenly disengage when under load Use a feeler gauge to check the clearance of each fork in its gear groove If the service limit has been exceeded check whether or not it is necessary to renew the gear or the fork by referring to the limits specified for each part Sect C 1 1 Gearbox ...

Page 518: ...e selector drum If the service limit is exceeded determine which part must be renewed by comparing these dimensions with those of new components Sect C 1 1 Gearbox Also check the wear on the drum support pins these must not show any signs of scoring burrs or deformation Turn the drum in the crankcase to establish the extent of radial play If play is excessive change whichever part is most worn ...

Page 519: ... Figure 1 shows all the parts to be reassembled on the gearbox input shaft 2 with the calculated end shims 1 and 11 Sect N 9 2 Shimming the shafts Figure 2 shows all the parts to be reassembled on the gearbox output shaft 25 with calculated end shims 15 and 26 Sect N 9 2 Shimming the shafts Fig 1 11 1 2 Fig 2 26 15 25 ...

Page 520: ...t shaft is given as an example Fit the circlip 7 checking that it is fully inserted into its groove on the shaft Push the circlip into position with a suitable size tubular drift Slide the washer with three internal points 6 over the shaft until it locates against the circlip you have just fitted To fit the needle roller cage 4 onto the shaft first lubricate it with plenty of grease of recommended...

Page 521: ...696 696 M Y 2009 edition 00 Engine Fit the three pointed washer 12 which can be distinguished from its counterpart 6 by its bigger outside diameter Fit another needle roller cage 4 using the method already described Fit the 4th speed gear 21 12 4 4 21 ...

Page 522: ...B C D E F G H L M N P section N 7 2 140 Monster 696 696 M Y 2009 edition 00 Engine Fit another 3 pointed washer 6 and another circlip 7 onto the shaft Seat the circlip using the drift used previously 6 7 ...

Page 523: ...al test ensure that with the gearbox in neutral the front coupling dogs A of sliding gears B are equidistant on both sides with respect to the corresponding coupling dogs on the fixed gears C Check also that there is always a small amount of clearance between fork D and relative groove E on sliding gear B when engaging the gears Operation Section reference Reassemble the engine crankcase halves N ...

Page 524: ...lutch assembly 23 Alternator rotor 24 Screw 25 Screw 26 Bearing 27 Circlip 28 Alternator side crankcase cover 29 Locating bush 30 Bracket 31 Screw 32 Alternator stator 33 Belleville washer 34 Flanged nut 35 Washer 36 Breather hose cover 37 Screw Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the ...

Page 525: ...t Unscrew the screws 10 11 12 and 37 securing the alternator side crankcase cover 36 Recover the spacer 8 the Belleville washer 35 and the cable guide 9 Operation Section reference Drain the engine oil D 4 Changing the engine oil and filter cartridge Remove the gearchange mechanism F 5 Removal of the gearchange mechanism Remoe the clutch slave cylinder F 2 Removal of the clutch slave cylinder Remo...

Page 526: ...Monster 696 696 M Y 2009 edition 00 Engine Fix service tool no 88713 1749 to the holes left vacant by the two screws 6 you have just removed Turn the tool shaft slowly to separate the cover 28 from the LH crankcase half 11 36 37 88713 1749 28 ...

Page 527: ...two screws 31 securing the cable guide bracket 30 from inside the alternator side crankcase cover Remove the stator 32 and the cable guide 30 The alternator side crankcase cover is fitted with a bearing 26 held in place by circlip 27 which locates on the end of the crankshaft Remove the circlip 27 with circlip pliers Remove the bearing 26 using a universal puller 32 30 24 31 27 26 26 ...

Page 528: ...ith the screw E Unscrew the alternator flywheel nut 34 heating it with a hot air gun do not use a naked flame as this could damage the starting system components Warning While unscrewing the nut apply axial pressure to the socket to avoid damage or injury in the event of the wrench suddenly slipping off the nut Remove the nut 34 the Belleville washer 33 and the flywheel assembly 22 complete with t...

Page 529: ...ne Remove the inner race 18 the needle roller bearing 19 and the washer 17 Important Examine the inner race 18 needle roller bearing 19 and internal washer 17 for wear Notes The hole in the inner race 18 allows the passage of oil for lubrication of needle roller bearing 19 18 19 17 ...

Page 530: ...any kind If there is any malfunction remove the whole assembly Disassembly of the flywheel alternator assembly Undo the eight screwss 25 and remove the alternator rotor 23 from the flywheel Slide out locating dowel 14 and circlip 15 Insert two of the screws 25 just removed from flywheel rotor side in their holes in order to remove the flange 13 and the starter clutch 21 The starter clutch is a sli...

Page 531: ... 2009 edition 00 Engine Reassembly of the flywheel alternator assembly Install the starter clutch 21 in the flange 13 making sure it is properly seated Important Orient the flange so that the side with the bevelled edge A faces the starter clutch 21 13 13 21 A ...

Page 532: ...eel insert a pin or a wrench inside the hole C for the rotor flywheel locating dowel 14 in order to line up the flywheel holes with flange threads This is a useful tip as the holes cannot be aligned after having fitted the flange to the flywheel due to the interference fit Orient the flange so that the side with the bevelled edge faces the flywheel Fit the locating dowel 14 with the circlip 15 in ...

Page 533: ... 2009 edition 00 Engine Install the rotor 23 on the flywheel 16 aligning the flywheel locating dowel 14 with the rotor locating hole D Apply threadlocker to the rotor flywheel fixing screws 25 and start them in their threads 25 23 16 D 5 LOCK 14 25 23 16 5 LOCK ...

Page 534: ...que settings Install the driven gear 20 on the starter clutch ensuring it is properly seated Check that the driven gear can rotate freely in the direction of the green arrow but not in the direction of the red arrow If either of these two conditions is not met this means that the starter clutch has not been installed correctly 25 25 25 16 20 16 20 ...

Page 535: ... race is centred relative to the washer Install the flywheel rotor driven gear assembly on the crankshaft taking care not to alter the position of the inner race 18 relative to the washer 17 The flywheel reference mark must be aligned with the groove on the crankshaft in correspondence with the keyway Lubricate the contact surfaces of Belleville washer 33 with engine oil Fit the Belleville washer ...

Page 536: ...o the threads of the crankshaft and the flywheel nut 34 Restrain the rotation of the flywheel with the holding tool 88713 2036 Important Tighten the nut 34 to the specified torque Sect C 3 Engine torque settings Remove all traces of Loctite from the threads of the nut 34 and the crankshaft A 34 5 LOCK 88713 2036 33 34 A ...

Page 537: ... that the crankshaft end bearing 26 and relative retaining ring 27 are installed in the alternator side crankcase cover 28 Refitting the alternator side crankcase cover Remove any scale and grease from the mating surfaces of the left hand crankcase half and the crankcase cover Fit the two locating bushes 29 Spread a continuous uniform bead of DUCATI liquid gasket on the mating surface of the cover...

Page 538: ... motor the spacer 8 the guide 9 the washer 35 and install the cover 36 under screw 11 in correspondence with the alternator lead for instructions on the positioning of the wiring under the cover 36 see below Tighten the fixing screws to the specified torque Sect C 3 Engine torque settings Ref Qty Description 10 2 M6x20 mm screws 11 8 M6x25 mm screws 12 2 M6x30 mm screws 37 1 M6x30 mm screws 11 12 ...

Page 539: ...the lower slot of the cover 36 as shown Offer the cover 36 up to the alternator side crankcase cover and position the fuel tank breather hose T and the airbox drain hose U the sidestand cable R alternator cable S and the starter motor cable Q as shown Important The starter motor cable Q is the only cable that should be routed outside the cover 36 36 T U U R Q S 36 T ...

Page 540: ...he fuel tank drain hose T inserting it in the guide 9 Dampen the oil seal 3 with alcohol and install it in the alternator side crankcase cover in correspondence with the gearchange shaft Sect F 5 Refitting the gearchange mechanism using the specific installation tool 88713 1411 T 9 3 88713 1411 ...

Page 541: ... inspection cover 5 over the end of the crankshaft to the specified torque Sect C 3 Engine torque settings Operation Section reference Refit the sprocket cover G 8 Refitting the front sprocket Refit the clutch slave cylinder F 2 Refitting the clutch slave cylinder Refit the gearchange mechanism F 5 Refitting the gearchange mechanism Top up the engine oil D 4 Changing the engine oil and filter cart...

Page 542: ...A B C D E F G H L M N P section N 8 160 Monster 696 696 M Y 2009 edition 00 Engine Positioning of cables hoses under the breather hose cover mounted on the alternator side crankcase cover ...

Page 543: ...A B C D E F G H L M N P section N 8 161 Monster 696 696 M Y 2009 edition 00 Engine ...

Page 544: ...al switch 20 Seal 21 Gear shaft 22 Washer 23 Starter motor gear 24 Washer 25 Circlip 26 Screw 27 Plug 28 Seal 29 Seal 30 Screw 31 Screw 32 Washer 33 O ring 34 Pickup sensor 35 Seal 36 Plug 37 Seal 38 Ball 39 Spring 40 Bush Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 4...

Page 545: ...rew and remove the two plugs 14 from the clutch side crankcase with the relative seals 8 Unscrew and remove the oil filter cartridge Sect D 4 Changing the engine oil and filter cartridge Unscrew and remove the oil filter support nipple 17 Operation Section reference Remove the engine from the frame N 1 Removal of the engine Remove the lubrication system N 2 1 Removal of the oil pump Remove the cyl...

Page 546: ...rth cable screw 7 with its seal 6 Remove the gauze pickup filter 18 with its seal from the clutch side crankcase half as described in Sect D 4 Changing the engine oil and filter cartridge Unscrew the plug 27 taking care to recover the relative seal 28 Remove drain plug 9 with its seal 29 7 6 28 27 18 18 9 29 ...

Page 547: ...of the appropriate tool Remove the gear interlock pawl and plunger as described in Sect N 7 1 Disassembly of the gear interlock plunger and pawl assembly To remove the engine sensor 34 unscrew the screw 31 and recover the washer 32 Check the condition of the O ring 33 in the crankcase half and the O ring A on the sensor 34 and renew them if necessary 20 19 12 12 31 32 34 33 ...

Page 548: ...A B C D E F G H L M N P section N 9 1 166 Monster 696 696 M Y 2009 edition 00 Engine Remove the bush 40 and recover the seal 37 the spring 39 and the ball 38 34 A 37 40 ...

Page 549: ...f O rings 11 and renew if necessary Install the oil vapour breather valve 10 in the crankcase along with O rings 11 previously lubricated Tighten the screw 30 to the specified torque Sect C 3 Engine torque settings Tighten the two plugs 14 with the seals 8 to the specified torque Sect C 3 Engine torque settings 11 30 10 10 11 30 8 14 2 LOCK ...

Page 550: ...he specified torque Sect C 3 Engine torque settings after applying the recommended threadlocker Refit the neutral switch 19 with its seal 20 and tighten to the specified torque Sect C 3 Engine torque settings Apply threadlocker to the plug 27 fit it with its seal 28 and tighten to the specified torque Sect C 3 Engine torque settings Refit the gauze pickup filter 18 with its seal as described in Se...

Page 551: ...and tightening to the specified torque value Sect C 3 Engine torque settings Use a tool of the type shown in the illustration Check that the O ring 33 is installed in the crankcase Grease the engine pickup 34 in the area indicated and check that the O ring A is installed Fit the engine pickup 34 in its seat in the crankcase Insert the screw 31 with the washer 32 and tighten to the specified torque...

Page 552: ...ar 2 The value must be between 0 6 and 0 8 mm Fit the earth lead retaining screw 7 with the seal 6 in the crankcase and tighten to the specified torque Sect C 3 Engine torque settings Insert the ball 38 and the spring 39 in the crankcase and screw in th bush 40 with its seal 37 tighteing it to the specified torque Sect C 3 Engine torque settings 34 2 7 6 38 39 37 40 37 40 ...

Page 553: ...d tighten it to the specified torque Sect C 3 Engine torque settings Operation Section reference Refit the starter motor P 3 Refitting the starter motor Refit the cylinder barrel piston assemblies N 5 Refitting the cylinder piston assembly Refit the cylinder head assemblies and the timing parts N 4 2 Cylinder head assemblies timing belt covers timing system Refit the lubrication system N 2 1 Refit...

Page 554: ...r A of timing gear pair 2 and remove the Woodruff key 5 Relieve the staking on the lock washer 3 of the nut 4 Restrain the driven timing gear by inserting a pin in one of the holes and unscrew the nut 4 Operation Section reference Remove the alternator side crankcase cover and the alternator assembly N 8 Flywheel alternator A 2 5 4 3 ...

Page 555: ...A B C D E F G H L M N P section N 9 1 173 Monster 696 696 M Y 2009 edition 00 Engine Remove the nut 4 washer 3 driven timing gear B and Woodruff key 1 from the timing belt driveshaft shaft B 4 3 1 ...

Page 556: ...ecessary Important The timing gears 2 must always be renewed as a pair Refitting is the reverse of removal Important On completion of the refitting operations check that tab washer 3 is staked against nut 4 in such a way as to prevent the nut from working loose Operation Section reference Refit the alternator side crankcase cover and alternator assembly N 8 Flywheel alternator 2 4 3 ...

Page 557: ...tarter motor idler gear Remove the circlip 25 and the washer 24 Remove the starter motor idler gear 23 and shim 22 Undo the screw 26 securing the idler gear shaft 21 and remove the shaft Operation Section reference Remove the flywheel alternator assembly N 8 Flywheel alternator 24 23 25 26 22 21 26 23 ...

Page 558: ...ng the starter motor idler gear Refitting is the reverse of removal Notes Apply the prescribed threadlocker to the screw 26 and tighten to the prescribed torque Sect C 3 Engine torque settings Operation Section reference Refit the flywheel alternator assembly N 8 Flywheel alternator 26 2 LOCK ...

Page 559: ...eal 14 Bearing 15 Bearing 16 Clutch side crankcase half 17 Spacer 18 Screw 19 Bush 20 Seal 21 Bearing 22 Circlip 23 Bearing 24 Roller bearing 25 Screw 26 Screw 27 Screw 28 Seal 29 Circlip Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram 19 15 8 9 10 11 25 27 26 16 14 17 18...

Page 560: ... of the engine Remove the lubrication system N 2 1 Removal of the oil pump Remove the cylinder head assemblies and the timing parts N 4 2 Removal of the timing belt covers Remove the cylinder barrel piston assemblies N 5 Removal of the cylinder piston assembly Remove the alternator side crankcase cover and the alternator assembly N 8 Flywheel alternator Remove the gauze pickup filter D 4 Changing ...

Page 561: ...ankcase cover or a service cover with puller 88713 1749 Secure it to the crankcase half using several of the original screws and begin to separate the crankcase halves by turning the central pin of the tool Tap the end of the gearbox output shaft with a plastic mallet to separate the crankcase halves Notes Take care not to lose the shims on the shafts and on the selector drum 25 16 88713 1749 8871...

Page 562: ... A and gearbox selector drum B from the crankcase Sect N 7 2 Gearbox assembly gearbox shafts Drive out the crankshaft C using a plastic mallet and taking care not to lose the shims D Remove the timing belt driveshaft 2 Recover the O Ring 5 from the communicating oil way between the crankcase halves B A 2 C D 5 ...

Page 563: ...he bearings 10 and 15 on the ends of the gearbox output shaft and the timing belt driveshaft bearings 7 and 21 After having renewed the gearbox shaft bearings 14 and 12 secure them in the crankcase with the spacers 17 and the retaining plate 9 fixed respectively with screws 18 and 8 At each overhaul it is recommended to renew also the oil seal 13 located between the bearing 12 and the chain side c...

Page 564: ...s with the recommended grease Install the inner oil seal 28 as shown in figure E ansd seated against the circlip 29 the outer oil seal must also be installed as shown in figure E Use a suitable drift see figure to install the oil seals 28 and roller bearings 24 Check that the oilways are free of restrictions or clogging The bearings 24 are to be installed with writing F oriented as shown in the fi...

Page 565: ...vident signs of distortion or excessive assembly clearance in their bores remove the locating bushes using appropriate tools If the removal of the bushes 19 from the casing proves difficult use a left handed thread tap to force the bushes out Important The bushes 19 must always be renewed when they have been removed using the above procedure 19 ...

Page 566: ... fitted back to back in pairs To renew the bearings proceed as follows heat the crankcase half in an oven to 100 C remove the bearing using a drift and hammer install the new bearing while the crankcase is still hot keeping it perfectly square in its seat using a tubular drift that only bears on the outer ring of the bearing allow the parts to cool and check that the bearing is securely seated in ...

Page 567: ...taining spacer 17 apply the recommended threadlocker to the screws 18 and tighten them to the specified torque Sect C 3 Engine torque settings the roller bearing 21 with retaining circlip 22 at the timing belt driveshaft Refitting the alternator side crankcase half The following parts must be present on the internal side of the crankcase half the double race ball bearing 10 supporting the selector...

Page 568: ...pply grease to the inner race The main bearing 4 The ball bearing 7 with circlip 6 in correspondence with the timing belt driveshaft oriented si that the closed side of the plastic roller cage faces the crankcase half Notes None of the bearings except the main bearings have an obligatory assembly direction it is good practice to install the bearings so that the side bearing the writing is facing u...

Page 569: ...he crankshaft measure the depths LA1 and LA2 corresponding to the distance between contact surface of the crankcase half and the contact surface of the inner race of the bearings add a pre load of 0 30 mm to prevent excessive crankshaft end float when the crankcase halves are at their normal operating temperature This gives SA LA1 LA2 0 30 LA To calculate the thickness of each shim note that SA SA...

Page 570: ...rankshaft shim thicknesses accurately Install a shim R of minimum thickness 1 90 mm on each side of the crankshaft to prevent contact between the crankshaft web and the engine block Install the crankshaft and assemble the two crankcase halves Fit three M8 screws 25 into the holes shown in the photo and tighten to the specified torque Sect C 3 Engine torque settings Place a dial gauge T with magnet...

Page 571: ...and the crank web and force the crankshaft towards the dial gauge Note the dial gauge reading This is the crankshaft endfloat Add a preload of 0 30 mm plus the thickness of the shims used 1 90x2 3 8 mm Divide the resulting value by two to obtain the thickness of the shim packs to be installed at either end of the crankshaft Notes After assembling the crankcase the crankshaft should turn with some ...

Page 572: ...ut shaft CP1 and CP2 and for the output shaft CS1 and CS2 given that end float should be in the range 0 to 0 15 mm we will take the optimal value of 0 15 mm which gives SP CP1 CP2 LP 0 15 and SS CS1 CS2 LS 0 15 To determine the thickness of each single shim pack note that SP SP1 SP2 and SS SS1 SS2 Where SP1 and SP2 are the clutch and chain side input shaft shimming values respectively and SS1 and ...

Page 573: ...ankcase half depth LT2 chain side crankcase half depth LT gearbox selector drum shoulder Given that the end float should be 0 10 to 0 40 mm and taking the mean optimal value of 0 25 mm This gives ST LT1 LT2 LT 0 25 Given that ST ST1 ST2 we obtain ST1 LT1 59 0 125 so that ST2 ST ST1 Notes The method described for the crankshaft can also be used to calculate the shim thicknesses for the gearbox shaf...

Page 574: ...shaft protect the threaded end of the shaft with the special protective cap 88700 5749 Dampen the oil seal 20 with alcohol and fit it on the timing belt driveshaft seating it against the roller bearing 21 Fit the circlip 1 in the groove on the shaft and remove the protective cap Notes When refitting used components make sure that the inner races D of the gearbox shaft bearings are fitted to the co...

Page 575: ...alf with the calculated shims Install the forks of the 1st 4th and 2nd 3rd gears F in their respective grooves in the secondary shaft driven gears Notes The two selector forks are identical Install the 5th 6th gear selector fork G in the input shaft driven gear Install the selector drum P in the crankcase with the previously calculated shim thickness F G P ...

Page 576: ...s 19 are correctly installed Grease O ring 5 to hold it in position and install it on the oil way connecting the two crankcase halves Important Make sure that the connecting rods B are correctly positioned in the respective cylinder bores Incorrect positioning of the connecting rods at this stage will inevitably lead to the need to re open the crankcase Apply a uniform and continuous bead of DUCAT...

Page 577: ...nkcase half 3 note that the screws are of different lengths Progressively tighten the crankcase screws until fully seated starting with the screws of the largest diameter M8 and following the order indicated Insert two M8 screws 25 in the clutch side crankcase 16 Tighten all the screws to the specified torque Sect C 3 Engine torque settings Ref Qty Description 25 7 M8x75 mm screws 26 5 M6x35 mm sc...

Page 578: ...pickup filter D 4 Changing the engine oil and filter cartridge Refit the clutch assembly N 6 1 Refitting the APTC clutch Refit the clutch side crankcase cover N 6 2 Refitting the clutch side crankcase cover Refit the engine starter system P 3 Electric starting system Refit the alternator side crankcase cover and alternator assembly N 8 Flywheel alternator Refit the cylinder barrel piston assemblie...

Page 579: ...t 2 Drilled grub screw 3 Plug 4 Grub screw 5 Connecting rod assembly 6 Bush 7 Half bearing 8 Special screw 9 Shim 10 Key Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text but which can be found in the exploded view diagram CONNECTING RODS 7 5 8 7 6 4 10 2 1 8 7 9 9 10 6 7 5 5 5 4 3 ...

Page 580: ...Operation Section reference Remove the engine from the frame N 1 Removal of the engine Remove the lubrication system N 2 1 Removal of the oil pump Remove the cylinder head assemblies and the timing parts N 4 3 Cylinder head assemblies camshafts Remove the cylinder barrel piston assemblies N 5 Removal of the cylinder piston assembly Remove the alternator side crankcase cover and the alternator asse...

Page 581: ...ssive wear renew the connecting rod The small end bushing must be in good condition and firmly driven into its seat Check for parallelism error measured at 100 mm from the connecting rod longitudinal axis the value must be H h less than 0 02 mm otherwise renew the connecting rod The diameter of the big end must be within the specified tolerance limits Sect C 1 1 Cylinder Piston It is preferable to...

Page 582: ... M Y 2009 edition 00 Engine Renewal of the connecting rod bearings It is good practice to renew the bearings 7 each time the engine is overhauled Replacement bearings are supplied ready for assembly and they must not be reworked with scrapers or emery cloth 7 ...

Page 583: ...e out the old bushing and install the new one A Position the new small end bushing so that the split is at 90 relative to the upper hole in the small end Drill lubrication holes into the new bushing in correspondence with the existing lubrication holes on the connecting rod small end Now ream out the bushing until the inside diameter D is 18 006 to 18 024 mm 6 A ø 3 5 90 mm Split ø 4 5 D mm ...

Page 584: ...ulder Fillet radius 1 5 mm With the aid of a micrometer measure out of round and taper of the big end journals taking the measurements in various different directions Sect C 1 1 Cylinder Piston Use a dial gauge to measure the alignment of the main journals by setting the crankshaft between two opposing centres Sect C 1 1 Cylinder Piston Unscrew all the plugs 4 3 and 2 from the crankshaft heating t...

Page 585: ... 696 696 M Y 2009 edition 00 Engine Use a hot air gun capable of reaching 150 C Clean all the oilways using suitable diameter metal brushes and then blow with compressed air to remove any residues that have accumulated and are restricting the oil flow ...

Page 586: ...ournals you will lay a strip A of GREEN Plastigage PG 1 on the journal Fit the connecting rod with the original big end bearing shells 7 see procedure on next page and tighten the bolts 8 to a torque of 49 Nm Remove the connecting rod and compare the width of the Plastigage strip to the scale B If the width which corresponds to the existing clearance is not within the specified tolerance limits bi...

Page 587: ... fit the con rods in their original mounting positions Fit the caps to the corresponding connecting rods Make sure that the mark on the cap is the on the same side as the mark on the connecting rod Use the recommended grease to lubricate the threads and underside of the heads of the new screws 8 and the threaded hole in the connecting rod packing in grease from both sides of the hole Warning The g...

Page 588: ...th the fork feeler gauge I of the tool 88713 2878 which is available in the following thicknesses 0 1 mm 0 2 mm 0 3 mm Tighten the screws 8 in three stages to the specified torque Sect C 3 Engine torque settings using a torque wrench Hold the wrench as shown in the photo Withdraw the feeler gauge and check that the connecting rod crankshaft endfloat is 0 15 to 0 35 mm 88713 2878 I H 8 8 ...

Page 589: ...tably lead to the need to re open the crankcase Operation Section reference Refit the clutch assembly N 6 1 Refitting the APTC clutch Refit the clutch side crankcase cover N 6 2 Refitting the clutch side crankcase cover Refit the engine starter system P 3 Electric starting system Refit the alternator side crankcase cover and alternator assembly N 8 Flywheel alternator Refit the cylinder barrel pis...

Page 590: ......

Page 591: ...A B C D E F G H L M N P P Electrical system 0 ...

Page 592: ... 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 ...

Page 593: ... C D E F G H L M N P section P 3 Monster 696 696 M Y 2009 edition 00 Electrical system 8 Immobilizer and transponder 102 9 Diagnostic instruments 105 Using a multimeter to check the electrical systems 105 ...

Page 594: ...Gr G W Bk n c 1 2 AMP 3 B W B Lb 1 2 AMP 3 W R O W R Gr G O O V Gr B R B Bn W Bn Bk 1 2 3 Br BY N O A B MODE 1 2 1 2 1 2 Y O W Bk V f f f Bk W G 3 2 1 W P Bk Br BW RB RB W W Y 1 2 3 4 1 2 3 4 1 2 1 2 f f Bn W 1 2 P Y f f Bk V W R Bk Bk W 1 2 1 2 4 3 2 1 A 1 A 2 A 3 A 4 B 1 B 2 B 3 B 4 C 1 C 2 C 3 C 4 D 1 D 2 D 3 D 4 E 1 E 2 E 3 E 4 F 1 F 2 F 3 F 4 G 1 G 2 G 3 G 4 H 1 H 2 H 3 H 4 J 1 J 2 J 3 J 4 K ...

Page 595: ...ntal cylinder coil 20 Vertical cylinder coil 21 Headlight 22 MAP sensor 23 Horizontal cylinder injector 24 Vertical cylinder injector 25 Throttle position sensor 26 Rpm timing sensor 27 Cylinder sensor 28 Speed sensor 29 Sidestand 30 Horn 31 Neutral switch 32 Oil pressure switch 33 Rear brake light switch 34 ECU 35 Fuses 36 Clutch switch 37 Front brake light switch 38 Left hand handlebar switch 39...

Page 596: ...P 1 6 Monster 696 696 M Y 2009 edition 00 Electrical system Key to fusebox Position Item Rating 1 Key ON 10 A 2 Side lights high low beam 15 A 3 Consumers 15 A 4 Instrument panel 5 A 5 Injection 20 A 6 ECU 5 A 7 Spare 20 A 8 Spare 5 A ...

Page 597: ...antenna wire 11 Plate C Key switch 12 Plate D Front right turn indicator connector 13 Plate D Front left turn indicator connector 14 Plate D Headlight connector 15 Plate D Instrument panel connector 16 Plate E Vertical cylinder injector connector 17 Plate E Air temperature sensor 18 Plate E Horizontal cylinder injector connector 19 Plate F Engine earth 20 Plate F Sidestand connector 21 Plate F Bat...

Page 598: ...minal cable 44 Plate P Injection lights relay 45 Plate P ECU connector 46 Plate P Vertical cylinder coil connector 47 Plate P Starter contactor connector 48 Plate Q Vertical cylinder temperature sensor 49 Plate R Pickup connector 50 Plate R Pickup sensor 51 Plate P Starter motor contactor cable 52 Plate S Oil pressure switch connector 53 Plate T Neutral cable switch connection 54 Plate U Rear brak...

Page 599: ...A B C D E F G H L M N P section P 1 9 Monster 696 696 M Y 2009 edition 00 Electrical system Plate A Plate B Point 0 A 7 5 6 4 3 2 D ...

Page 600: ...A B C D E F G H L M N P section P 1 10 Monster 696 696 M Y 2009 edition 00 Electrical system 4 2 6 7 ...

Page 601: ...A B C D E F G H L M N P section P 1 11 Monster 696 696 M Y 2009 edition 00 Electrical system Plate C 8 11 9 A 10 D ...

Page 602: ...A B C D E F G H L M N P section P 1 12 Monster 696 696 M Y 2009 edition 00 Electrical system Plate D 12 14 15 C 13 15 ...

Page 603: ...A B C D E F G H L M N P section P 1 13 Monster 696 696 M Y 2009 edition 00 Electrical system Plate E O 18 17 V 16 O 17 ...

Page 604: ...A B C D E F G H L M N P section P 1 14 Monster 696 696 M Y 2009 edition 00 Electrical system 17 ...

Page 605: ...A B C D E F G H L M N P section P 1 15 Monster 696 696 M Y 2009 edition 00 Electrical system Plate F 20 22 21 21 22 19 23 H ...

Page 606: ...A B C D E F G H L M N P section P 1 16 Monster 696 696 M Y 2009 edition 00 Electrical system Plate G Plate H 24 27 25 27 26 F J ...

Page 607: ...A B C D E F G H L M N P section P 1 17 Monster 696 696 M Y 2009 edition 00 Electrical system 25 26 F J ...

Page 608: ...A B C D E F G H L M N P section P 1 18 Monster 696 696 M Y 2009 edition 00 Electrical system Plate J Plate K 28 H 29 O ...

Page 609: ...A B C D E F G H L M N P section P 1 19 Monster 696 696 M Y 2009 edition 00 Electrical system Plate L O V 34 V 32 31 33 30 O V 34 ...

Page 610: ...A B C D E F G H L M N P section P 1 20 Monster 696 696 M Y 2009 edition 00 Electrical system 33 ...

Page 611: ...A B C D E F G H L M N P section P 1 21 Monster 696 696 M Y 2009 edition 00 Electrical system Plate M Plate N 35 N 36 ...

Page 612: ...A B C D E F G H L M N P section P 1 22 Monster 696 696 M Y 2009 edition 00 Electrical system 36 36 39 38 40 37 ...

Page 613: ...A B C D E F G H L M N P section P 1 23 Monster 696 696 M Y 2009 edition 00 Electrical system Plate O 42 S Q R E 41 ...

Page 614: ...A B C D E F G H L M N P section P 1 24 Monster 696 696 M Y 2009 edition 00 Electrical system 42 ...

Page 615: ...A B C D E F G H L M N P section P 1 25 Monster 696 696 M Y 2009 edition 00 Electrical system Plate P 46 V 47 45 44 43 51 51 ...

Page 616: ...A B C D E F G H L M N P section P 1 26 Monster 696 696 M Y 2009 edition 00 Electrical system 51 51 ...

Page 617: ...A B C D E F G H L M N P section P 1 27 Monster 696 696 M Y 2009 edition 00 Electrical system Plate Q 48 O 48 ...

Page 618: ...A B C D E F G H L M N P section P 1 28 Monster 696 696 M Y 2009 edition 00 Electrical system Plate R 50 O 49 ...

Page 619: ...A B C D E F G H L M N P section P 1 29 Monster 696 696 M Y 2009 edition 00 Electrical system Plate S 52 T O ...

Page 620: ...A B C D E F G H L M N P section P 1 30 Monster 696 696 M Y 2009 edition 00 Electrical system ...

Page 621: ...A B C D E F G H L M N P section P 1 31 Monster 696 696 M Y 2009 edition 00 Electrical system Plate T 53 U ...

Page 622: ...A B C D E F G H L M N P section P 1 32 Monster 696 696 M Y 2009 edition 00 Electrical system Plate U T 55 54 T 55 ...

Page 623: ...A B C D E F G H L M N P section P 1 33 Monster 696 696 M Y 2009 edition 00 Electrical system V T 54 55 ...

Page 624: ...A B C D E F G H L M N P section P 1 34 Monster 696 696 M Y 2009 edition 00 Electrical system Plate V 56 ...

Page 625: ...A B C D E F G H L M N P section P 1 35 Monster 696 696 M Y 2009 edition 00 Electrical system U ...

Page 626: ...ative value means that charging system is not powering the loads and a significant amount of current must be supplied by the battery which is discharging at the time of the measurement Alternatively you can use a multimeter Sect P 9 Diagnostic instruments connect the multimeter probes to the battery terminals select the DC scale on the instrument and check for the presence of 14 5 V 0 5 at an engi...

Page 627: ...ately if the battery becomes too hot to the touch Leave to cool before resuming charging Use only constant voltage battery chargers Check that battery terminals are properly connected to the battery charger For recharging follow the instructions on the battery for further details consult the table below Use fast charging in emergencies only Storing the battery If the battery voltage is less than o...

Page 628: ... with the eyes wash thoroughly with water for 15 minutes and consult an ophthalmologist In the event of accidental ingestion drink large quantities of water or milk and continue with milk of magnesia beaten egg or vegetable oil Do not allow sparks flames cigarettes or any other heat source to come near the battery as it produces explosive gases When recharging or using the battery indoors make sur...

Page 629: ...t tilt the electrolyte container as this could interrupt the flow temporarily or even permanently Make certain that air bubbles emerge from all six filler holes Leave the container in this position for at least twenty minutes If no bubbles emerge from one of the holes tap gently on the bottom of the respective container Important Never move the container away from the battery Do not cut or punctur...

Page 630: ...ries of over 12 Ah leave to stand for at least 1 hour Notes If using an automatic charge reducing battery charger make certain that the charger current amps is greater than or equal to the standard STD recharging system indicated on the battery Press down firmly with both hands until the caps are firmly in place do not use a hammer R Bk Bk 30A Y Y Y Bk Bk R R ...

Page 631: ...ver or add more liquid to the battery If the casing the cover or the terminals are broken or if the sealing cap strip has been tampered with the battery must be renewed Important If the motorcycle is left unused for more than 30 days remove the battery and store it in a safe cool place Always charge the battery before the first use and after long storage periods such as before selling the vehicle ...

Page 632: ... the positive terminal and the negative lead 16 to the negative terminal as shown in the photo Insert the screws in the terminals 16 and 19 always starting with the positive terminal red lead Warning Position the leads 16 and 19 as shown in the photo Tighten the terminal screws to the specified torque Sect C 3 Frame torque settings and apply grease to the terminals to prevent corrosion Fit the pro...

Page 633: ...ribed in this section in the paragraph Battery Remove the vertical cylinder coil as described in Sect M 3 Coil Unscrew the screws 7 and screw 5 and remove the battery support from the airbox Refit the components reversing the order in which they were removed tighten the screws to the specified torque Sect C 3 Frame torque settings 5 2 ...

Page 634: ...lectrical system when the ignition key is set to OFF Values significantly lower than those indicated above can be due to partially demagnetised rotor short circuited windings In the above cases the whole alternator assembly rotor and stator should be renewed If checks have a favourable outcome reconnect the alternator to the regulator with ignition key on OFF Make sure that no cables are damaged o...

Page 635: ... supplied by the alternator in accordance with battery voltage If the battery is drained the current has the value necessary to restore optimum operating conditions of the battery In contrast if the battery is fully charged the current value will be lower Notes Check the charging current using the DDS tester following the instructions given in the paragraph Testing the battery charging system Sect...

Page 636: ... 5 and remove the RH air scoop 4 from the frame Disconnect the alternator regulator connector B from the main wiring harness Sect P 1 Routing of wiring on frame Remove the regulator 7 from the RH air scoop 4 by unscrewing the two screws 6 Important Do not disconnect the battery cables when engine is running because this would cause irreparable damage to the regulator 4 3 5 B 4 7 6 ...

Page 637: ... figure Fix the regulator 7 to the RH air scoop 4 with the two screws 6 Tighten the screws 6 to the specified torque Sect C 3 Frame torque settings Connect the alternator regulator connector B to the main wiring harness Sect P 1 Routing of wiring on frame Refit the RH air scoop 4 and tighten the screws 5 to the specified torque Sect C 3 Frame torque settings Fix the clutch hose A to the LH air sco...

Page 638: ...2 to the RH air scoop 4 with the screws 3 Refit the LH air scoop 2 to the frame and tighten the screws 1 to the specified torque Sect C 3 Frame torque settings Notes To position the regulator wiring correctly designated 14 follow the indications in plate E in the chapter Routing of wiring on frame Sect P 1 4 3 2 1 1 ...

Page 639: ... fuel tank Sect L 2 Removal of the fuel tank and disconnect the regulator A A blown fuse can be identified by breakage of the inner filament B Important Switch the ignition key to OFF before replacing a fuse to avoid possible short circuits Warning Never use a fuse with a rating other than the specified value Failure to observe this rule may damage the electric system or even cause fire A B In goo...

Page 640: ...itch 43 When these inputs are combined in the required manner the engine control unit 28 enables engine starting The table lists possible engine starting combinations In accordance with the status of specific engine control unit inputs and the indications given in the table the control unit enables operation of the starter motor ON status when the START button is pressed X generic status of neutra...

Page 641: ...12 V battery for the test Use battery motor connection cables which are no longer than 70 cm and with the same cross section as the cable on the motorcycle itself Connect the negative terminal of the battery to an unpainted area of the starter motor casing and the positive terminal to its electrical terminal The shaft of the starter motor should rotate freely and at high speed Take care not to sho...

Page 642: ...ter motor and gasket 2 Refitting the starter motor Inspect the condition of the gasket 2 and renew if necessary Locate the gasket 2 and the starter motor on the crankcase and tighten the bolts 1 to the specified torque Sect C 3 Frame torque settings Connect the starter motor contactor cable 3 Important Fill the cap with protective grease before fitting it on the starter motor 2 2 3 D ...

Page 643: ...9 1 Refitting the starter motor idler gear Refit the alternator side crankcase cover Sect N 8 Reassembly of the alternator side crankcase cover Starter contactor The starter motor contactor 1 is elastically mounted to the airbox Disconnect the wiring connector 2 of the starter contactor from the wiring harness Disconnect the battery Sect P 2 Battery Remove the contactor from its seat 1 1 1 LOCK 2 ...

Page 644: ...ge across the positive terminal A and negative terminal B of the connector With a multimeter connected between the two poles threaded studs C and D of the contactor check for electrical continuity Sect P 9 Using a multimeter to check the electrical systems If there is no electrical continuity renew the contactor On refitting ensure that studs C and D are not oxidized apply water repellent spray Po...

Page 645: ...3 55 Monster 696 696 M Y 2009 edition 00 Electrical system Fit the contactor by inserting it on the tabs E orienting it as shown in the figure Refit the wiring connector 2 to the wiring and refit the protective caps A 5 4 3 4 C D 2 1 A ...

Page 646: ...ud 1 Disconnect the instrument panel connector A from the main wiring harness see plates in the chapter Routing of wiring on frame Sect P 1 Disconnect theheadlight wiring connector B and the front turn indicator conectors from the main wiring harness connector see plates in the chapter Routing of wiring on frame Sect P 1 Unscrew the nuts 2 securing the front light assembly to the bottom yoke 2 1 A...

Page 647: ...awing the pins C from the support bracket Release the headlight from the front light assembly by unscrewing the screws 3 Remove the front turn indicators 4 by removing the circlip 5 and unscrewing the screw 6 Notes On the USA version a spacer is installed between the turn indicator and the front light asssembly support C 3 3 5 4 6 ...

Page 648: ...rse of removal check that the rubber mountings 7 are installed on the headlight apply the recommended grease to the washers 8 reconnect the wiring connectors of the headlight B and the front turn indicators tighten the screws 3 6 and nuts 2 to the specified torque Sect C 3 Frame torque settings 7 8 LOCK 11 6 3 3 A ...

Page 649: ...A B C D E F G H L M N P section P 4 59 Monster 696 696 M Y 2009 edition 00 Electrical system 2 2 B ...

Page 650: ... C 1 1 Lights instrument panel Warning The halogen light bulbs in the headlight become hot when switched on and remain hot for some time after they are switched off Allow bulbs to cool before replacing them The position of the light bulbs in the headlight is as indicated below low beam LO high beam HI and side light A Remove the headlight as described in the paragraph Renewal of the headlight in t...

Page 651: ...lb is correctly positioned push the bulb in and turn clockwise until it clicks into place Refit the connector 3 to the bulb 4 and the cover 2 to the headlight tightening the screws 1 to the specified torque Sect C 3 Frame torque settings Low beam LO To change the Lo beam headlight bulb 6 see the procedure described above for the Hi beam headlight bulb Replace the bulb with a new bulb of the same t...

Page 652: ...Side lights A To replace the side light bulb withdraw the bulb holder 7 from the rear of the headlight Extract the bulb and renew it Changing the number plate light bulb To access the bulb in the number plate light 8 open the number plate lens pull the bulb out of the holder and renew it 7 8 9 ...

Page 653: ...ew 1 and detach the lens 2 from the direction indicator support The bulb has a bayonet type end fitting to remove it push it in and turn it counter clockwise Push in the new bulb and turn it clockwise until it clicks into place Refit the lens by inserting the tab in the corresponding slot in the direction indicator Refit and tighten the screw 1 1 2 1 2 ...

Page 654: ...switch back on the moment the motorcycle is started again 2 if the lights are switched on they will switch off automatically after 60 seconds after key ON if the engine remains stopped If this strategy is not performed check the correct operation of the various parts involved Checking operation of the high beam lights relay Disconnect the relay 1 from the electrical system and apply 12 V battery v...

Page 655: ...t and a vertical line aligned with the longitudinal axis of the motorcycle Notes If possible perform this check in conditions of low ambient light Switch on the low beam The height of the upper limit between the dark area and the lit area must not be more than nine tenths of the height of the centre of the headlight from the ground Notes This is the procedure specified by Italian regulations for c...

Page 656: ...the multimeter When the horn button is pressed the resistance value shown by the multimeter should be close to zero and if available a continuity beep should be heard When the horn button is not pressed the resistance value should be infinity there is no continuity as the electrical contacts inside the pushbutton are open and no continuity beep should be heard If these conditions are not met the d...

Page 657: ...s refer to the colours of the wires from the switch and not to the colours of the wires of the main electrical system Engine Stop button Check for continuity between the Red White and Red Black wires with a multimeter see Sect P 9 Diagnostic instruments for information on operation of the multimeter When the switch is in the RUN position there should be electrical continuity between the two wires ...

Page 658: ...heck for continuity between the Blue White and Black wires when the STARTER switch is pressed see Sect P 9 Diagnostic instruments concerning operation of the multimeter If there is no continuity the STARTER switch is defective and must be renewed Refit the left hand handlebar switch and tighten the screws 1 to the specified torque Sect C 3 Frame torque settings ...

Page 659: ...r brake is pressed there is electrical continuity Pos A between the terminals of the corresponding switch Sect P 9 Diagnostic instruments concerning operation of the multimeter When the brake is released there must be no electrical continuity across the terminals of the corresponding switch Pos B If these tests fail to produce positive results the part in question must be renewed Neutral indicator...

Page 660: ...oil circuit components and service as necessary If engine oil pressure value is within the specified range and the oil pressure warning light on the instrument panel stays off switch on the instrument panel ignition key set to ON without starting the engine and disconnect the electrical terminal from the pressure sensor and connect it to earth If the warning light now illuminates this means the se...

Page 661: ...tting to remove it push it in and turn it counter clockwise To remove the support 3 for the front turn signals refer to Sect P 4 Renewal of the headlight while for the rear turn signals refer to Sect H 7 Removal of the tail light protection number plate holder assembly Push in the new bulb and turn it clockwise until it clicks into place Refit the lens by inserting the tab A in the corresponding s...

Page 662: ... be near zero and if present the audible continuity signal should be emitted turn the key to ON and connect the multimeter to contacts 1 and 2 and then to 3 and 4 to check for electrical continuity The resistance reading should be near zero and if present the audible continuity signal should be emitted turn the key to PARK and connect the multimeter to contacts 1 and 4 to check electrical continui...

Page 663: ...g harness connector from the switch see Routing of wiring on frame Sect P 1 Use an analogue or digital multimeter Sect P 9 Using a multimeter to check the electrical systems to check operation of the switch see table Notes The same checks can also be performed using the DDS tester Sect D 5 DDS tester 0 Open contact X Closed contact Pos pin A Consumers Rating 0 X X 0 Multimeter pos Green Green Whit...

Page 664: ...ed fuse with a new one of the same rating identify the cause of the problem A blown fuse can be identified by the breakage of inner filament A Important Switch the ignition key to OFF before replacing a fuse to avoid possible short circuits Warning Never use a fuse with a rating other than the specified value Failure to observe this rule may damage the electric system or even cause fire As well as...

Page 665: ...he headlight flasher button 2 on the left hand handlebar switch Underneath the digital display there are six indicator lights three per side and a further auxiliary light that illuminates when the engine rpm approaches the rev limiter threshold The instrument panel is equipped with a sensor that detects the intensity of the ambient light The instrument panel automatically switches its backlighting...

Page 666: ...A B C D E F G H L M N P section P 7 76 Monster 696 696 M Y 2009 edition 00 Electrical system 1 2 ...

Page 667: ... pressure light red illuminates when the engine oil pressure is too low This light should come on when the ignition is switched to ON and normally goes out a few seconds after engine starts It may come on briefly if the engine is very hot but should go out again as engine speed increases 7 High beam warning light blue illuminates when the high beam headlight is on 8 EOBD Engine diagnostics warning...

Page 668: ...he model and for 2 seconds also the version EU UK USA CND FRA JAP The model is scrolled on the display once only At Key On the instrument panel always shows the following information de activating any previously activated functions Odometer Speed Engine rpm bargraph Coolant temperature bargraph At this point with the switch 1 fig 8 in position B it is possible to switch from the odometer function ...

Page 669: ...is on the display and the speed of the motorcycle exceeds 20 km h the instrument panel automatically exits the menu and returns to the initial display It is possible to exit the menu at any time however by pressing switch 1 in position A for 3 seconds Total distance travelled indicator odometer At Key On the system automatically enters this function The total distance travelled value is stored per...

Page 670: ... is 299 km h 186 mph Over 299 km h 186 mph the display will show a series of dashes steadily lit not flashing TRIP meter While in this function if you press switch 1 in position B for 3 seconds the reading is reset to zero If the reading exceeds 999 9 it is reset to zero and the count restarts automatically If the system s units of measurement are changed at any time using the Setting Special func...

Page 671: ...mains in reserve the reading is saved even after Key Off The count stops automatically when the fuel level rises above reserve If the reading exceeds 999 9 it is reset and the count restarts automatically Air temperature indicator Shows the outside air temperature Display limits 39 C to 124 C In the event of a sensor FAULT 40 C 125 C or disconnected a series of dashes is displayed steadily and the...

Page 672: ...f the temperature is between 111 C and 135 C the display shows STATUS 4 if the temperature is between 136 C and 160 C the display shows STATUS 5 if the temperature is between 161 C and 175 C the display shows STATUS 6 if the temperature is between 176 C and 190 C the display shows STATUS 7 if the temperature is between 191 C and 200 C the display shows STATUS 8 if the temperature is 201 C the disp...

Page 673: ...le renew components identified as faulty To display this function enter the menu and select the Error page This menu is only present if at least one error is detected otherwise this page will NOT appear If there are several errors they are displayed in rolling mode every 3 seconds In any case a more detailed diagnosis can be obtained using the Ducati Diagnostic System Warning Every time an error i...

Page 674: ...tween 15 0 and 16 0 Volts it flashes on the display if the reading is less than or equal to 9 9 Volts the message LO flashes on the display and the EOBD engine diagnostics warning light 8 comes on if the reading is greater than or equal to 16 1 Volts the message HI flashes on the display and the EOBD engine diagnostics warning light 8 comes on PKUP Pickup sensor SPEED Speed sensor if present IMMO ...

Page 675: ...A B C D E F G H L M N P section P 7 85 Monster 696 696 M Y 2009 edition 00 Electrical system FIXED FLASHING FLASHING FLASHING FLASHING ...

Page 676: ...n sequence page 1 LIGHT MAX setting This page sets backlighting to maximum brightness press switch B to move to page 2 page 2 LIGHT MID setting This page reduces the backlighting by approximately 30 relative to maximum brightness press switch B to return to page 3 page 3 LIGHT MIN setting This page reduces the backlighting by approximately 70 relative to maximum brightness press switch B to return...

Page 677: ... 696 M Y 2009 edition 00 Electrical system LAP function To activate this function enter the menu and set the LAP function to On by keeping switch 1 in position B for 3 seconds B ON for 3 secs Press B Press B Press B B ON for 3 secs B ON for 3 secs 1 B ...

Page 678: ...ction off from the menu the lap in progress will not be saved If the LAP function is active and the display is suddenly switched off Key Off the LAP function is switched off automatically even if the timer was ON the lap in progress is not saved If the timer is not stopped when it reaches 9 minutes 59 seconds and 99 hundredths it restarts from 0 zero and continues until the function is switched of...

Page 679: ...A B C D E F G H L M N P section P 7 89 Monster 696 696 M Y 2009 edition 00 Electrical system NORMAL display Press FLASH Once Press FLASH Twice Press FLASH from 32nd time onwards unless times are reset ...

Page 680: ...lls through the 30 saved times before returning to the 1st lap If you hold the switch 1 in position B for 3 seconds while displaying the saved times the display immediately resets all the saved times In this case if the LAP function was active it is switched off automatically The MAX speed saved is the maximum speed indicated on the display in Lap function To exit display of the lap times memory p...

Page 681: ...a Analyzer in order to acquire data the DDA must be connected to the motorcycle wiring loom To activate the DDA enter the menu and set the DDA function to On by holding the switch 1 in position B for 3 seconds To START and STOP the lap separator press the high beam FLASH button 2 on the left hand handlebar switch If the DDA function is active and the motorcycle is suddenly switched off Key Off the...

Page 682: ...ou press the switch 1 in position B for 3 seconds and the DDA is not acquiring data the message WAIT appears on the display for 10 seconds After 10 seconds the message ERASE OK appears for 3 seconds to confirm that the DDA data has been deleted If you press the switch 1 in position B for 3 seconds and the DDA is acquiring data the DDA memory is not erased and the display shows the message FAIL for...

Page 683: ...sition B the count advances cyclically in steps of 1 hour every second when the switch is held down continuously the hours do not flash If you press the switch 1 in position A you enter the minutes setting mode and the minute digits will start flashing Each time you press the switch in position B the count advances cyclically in steps of 1 minute if you hold the switch down in position B the count...

Page 684: ...h in position B the number increases cyclically in steps of one digit every second if you press the switch in position A you can set the second digit which will start flashing Each time you press the switch in position B the number increases cyclically in steps of one digit every second if you press the switch in position A you can set the third digit which will start flashing Each time you press ...

Page 685: ...lf will flash simultaneously for 4 seconds The EOBD diagnostics warning light 8 will go off The instrument panel then automatically exits the menu thus allowing temporary starting of the motorcycle If the error persists at the next key on the instrument panel will return to an error state and immobilize the engine Press B for 3 secs flash flash Press A NO CODE OK flash flash flash flash flash flas...

Page 686: ...ivation of the headlight even with the motorcycle off Key Off Immediately after key off the instrument panel remains active for 60 seconds thus allowing the headlight to be switched on if switch 1 is pressed in position A or A During these 60 seconds each time the switch 1 is pressed in position A or B the instrument panel will activate the headlight for 30 seconds each press of the switch will ad...

Page 687: ... in steps of one digit every second if you press the switch in position A you can set the second digit which will start flashing Each time you press the switch in position B the number increases cyclically in steps of one digit every second If you press the switch in position A you can set the third digit which will start flashing Each time you press the switch in position B the number increases c...

Page 688: ...tion it is necessary to renew the KEY SET 2 black keys new CODE CARD and the instrument panel and therfore programme the immobilizer again Loss of one key After purchasing a new key perform the Reprogramming procedure by entering the code shown on the CODE CARD with the new key and the remaining key 1 A B Press B for 3 secs NO Enter CODE OK flash flash flash Press A Press A Press A Press A Press A...

Page 689: ... temporarily override the immobilizer in the event of a fault Special settings vehicle model and units of measurement This function allows you to select the units of measurement displayed on the instrument panel The ECU automatically communicates to the instrument panel the motorcycle model and the units of measurement to be used on the display to change these parameters go into the Service Menu a...

Page 690: ...turn the ignition switch from Off to On within 3 seconds turn the ignition switch from On to Off within 15 seconds insert KEY X again either Key 1 or Key 2 and turn the ignition switch from Off to ON If the procedure was successful the instrument panel will display the message PROG OK steadily for 3 seconds before returning to the normal display mode Key Off to exit Press B for 3 secs Press B for ...

Page 691: ...ode Important During the programming procedure the instrument panel in addition to saving the key codes in its memory retrieves two electronic codes from the insertion of KEY 1 the first black key to be inserted and KEY 2 the second black key to be inserted If the immobilizer is reprogrammed the key codes will be erased and replaced with the new codes of the new keys the two electronic codes howev...

Page 692: ...s fitted inside the key grip and consists of a power supply circuit a ROM Read Only Memory and a transmission circuit The transponder is supplied with power by the magnetic field generated by the antenna which is enabled as soon as the instrument panel is switched on Since the transponder is very compact and needs no external battery power supply it is moulded permanently into the key grip Warning...

Page 693: ...the ignition key is turned from ON to OFF the immobilizer system activates the engine start protection system When the engine is started and the key is turned from OFF to ON the system generates the following signals if the code is recognised the protection system releases the engine lock When you press the START button C the engine starts if the code is not recognised the EOBD diagnostics warning...

Page 694: ...e ignition switch 9 routing the antenna wire through the slot A in the plate Apply the recommended threadlocker to the two special screws 6 Fit the ignition switch with the plate and antenna to the frame 7 with the two special screws 6 Tighten the screws fully to the specified torque Sect C 3 Frame torque settings Apply a drop of threadlocker inside the cover 2 at the points indicated in the figur...

Page 695: ...e allowed by the tester when measuring voltage or current signals Notes The DDS tester Sect D 5 DDS tester can perform the functions of a digital multimeter Voltage measurement Voltage measurements must be carried out by connecting the terminals of the tester in parallel to the load e g to the wires feeding a light bulb or a relay the two battery terminals or the two wires supplying power to a con...

Page 696: ... If this value is close to zero i e lower than approximately 0 3 ohm this means that the cable is not interrupted Some instruments feature an audible signal that is emitted when the resistance approaches a value of zero The same procedure must be adopted to check whether for example two contacts of a switch relay or manual type are making the contact correctly when closed In this case the terminal...

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