Page 2: Table Of Contents
General safety rules 8 General maintenance indications 9 Section 2 02 - Information about the model 1 - Identification data Monster 796 / 796 ABS identification data 3 Section 3 03 - Technical data 1.1 - Technical specifications General 3...
Page 3 1 - General Rear suspension 7 Hydraulic brakes 7 Charging system/alternator 8 Ignition system 8 Fuel system 8 Injection system 8 Lights/instrument panel 8 1.2 - Dimensions 2 - Fuel, lubricants and other fluids 3 - Torque settings Frame torque settings 11 Engine torque settings 17 4 - Service tools Specific tools for the engine 20...
Page 4 1 - General Section 5 05 - Fairings 1 - Headlight fairing - rear-view mirrors Removal of the rear-view mirrors 4 Refitting the rear-view mirrors 4 Removal of the headlight fairing 5 Refit the headlight fairing 8 2 - Fairings Removal of the fuel tank fairings 10 Refitting the fuel tank fairings 12 3 - Seat...
Page 5 1 - General Table S 44 Table T 45 Table U 46 Table V 47 2 - Battery charging system Checking the battery charging system 48 Recharging the battery 49 Topping up the electrolyte 50 Battery 53 Battery support 56 Alternator 57 Rectifier-regulator 60 3 - Electric starting system...
Page 6 Injection and main relay 157 13 - Diagnostic instruments Using a multimeter to check the electrical systems 158 Description of the Ducati Diagnostic System tester 160 Tester power supply 162 DDS diagnosis instrument 165 Checking and adjusting timing belt tension 165...
Page 7 1 - General ABS system operating information 42 ABS system deactivation 44 6 - System components Replacing the front phonic wheel sensor 46 Replacing the rear phonic wheel sensor 48 Removing of the ABS control unit 49 Refitting the ABS control unit 50 Flexible wiring/hoses positioning 53 Table A 54 Table B 55...
Page 8 1 - General Removal of the rear brake disc 127 Refitting the rear brake disc 128 Refitting the rear wheel eccentric hub and rear wheel shaft 129 Removal of the swingarm 133 Inspecting the swingarm pivot 136 Checking swingarm end float 137 Refitting the swingarm 138 14 - Final drive Inspecting the final drive 143...
Page 9 1 - General Refitting the throttle body 25 7 - Air intake Removal of the airbox 32 Removal of the oil breather valve 37 Refitting the oil breather valve 37 Refitting the airbox 38 8 - Exhaust system Operating principle of the catalytic converter 46 Removal of the exhaust system 47 Refitting the exhaust system 52 10 - Evaporative emissions canister...
Page 10 1 - General Inspecting the camshafts 57 Checking the oil seals 57 Refitting the camshafts 58 Refitting side covers 61 4.4 - Cylinder head assemblies: valves - rocker arms Removal of the cylinder head assembly 64 Overhaul of cylinder head components 68 Refitting the cylinder head assembly 76 Refitting the cylinder heads 82 5 - Cylinder/piston assemblies...
Page 11 1 - General 9.1 - Crankcase assembly: external components Removing outer components 176 Refitting the external components 180 Removal of the timing gears 185 Refitting the timing gears 186 Removal of the starter motor idler gear 187 Refitting the starter motor gear 188 9.2 - Crankcase assembly: crankcase halves Separation of the crankcase halves 190 Overhaul of the crankcase halves 193...
Page 12 1 - General 01 - General 1 - How to use this manual Layout of the manual 4 2 - Symbols - Abbreviations - References Product specifications 6 3 - Hazardous Products - Warnings General safety rules 8 General maintenance indications 9...
Page 13: How To Use This Manual
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 to make changes made necessary by the technical evolution of its products without prior notice.
Page 14 How to use this manual 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 for all motorcycle models.
Page 15: Symbols - Abbreviations - References
Symbols - Abbreviations - References 2 -Symbols - Abbreviations - References To allow quick and easy consultation, this manual uses graphic symbols to highlight situations in which maximum care is required, as well as practical advice or information. Pay attention to the meaning of the symbols since they serve to avoid repeating technical concepts or safety warnings throughout the text.
Page 16 Medium-strength threadlocker. Loctite 401 LOCK 12 Instant adhesive gel offering tensile/shear Loctite 454 gel strength. DUCATI liquid gasket. 942470014 Exhaust pipe paste. Self-sealing paste, hardens Holts Firegum when heated; resists temperatures exceeding 1000 °C. Spray used to protect electric systems.
Page 17 Symbols - Abbreviations - References Emulsion for lubrication of rubber P 80...
Page 18: Hazardous Products - Warnings
General maintenance indications Useful tips Ducati recommends that you follow the instructions below in order to prevent problems and obtain the best end result: - when diagnosing faults, primary consideration should always be given to what the customer reports about motorcycle...
Page 19 - Use exclusively Ducati original replacement parts and the recommended brands of lubricants. - Use special service tools where specified. - Ducati Technical Bulletins often contain updated versions of the service procedures described in this manual. Check the latest Bulletins for details.
Page 20: Information About The Model
2 - Information about the model 02 - Information about the model 1 - Identification data Monster 796 / 796 ABS identification data 3...
Page 21: Identification Data
Identification data 1 -Identification data Monster 796 / 796 ABS identification data 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). Note Please quote these numbers, which identify the motorcycle model, when ordering spare parts.
Page 22 Identification data 1 Manufacturer: Ducati Motor Holding 2 Type, same on all Monster models 3 Variant: - 03 Full power - 04 Power limited 4 Version 5 Year of construction (9=2009; A=2010) 6 Manufacturing facility 7 Progressive serial No. Data stamped on the frame...
Page 23 Identification data 3 Progressive production No.
Page 24: Technical Data
3 - Technical data 03 - Technical data 1.1 - Technical specifications General 3 Colours 4 Transmission 4 Timing system/valves 4 Exhaust system 5 Cylinder/Piston 5 Gearbox 6 Cooling system 6 Front wheel 6 Front suspension 6 Rear wheel 6 Rear suspension 7 Hydraulic brakes 7 Charging system/alternator 8...
Page 25: Front Wheel
Technical specifications 1.1 -Technical specifications General Reference Technical specifications Total length 2,114 mm Motorcycle dimensions Total width 784 mm Total height 1,079 mm Wheelbase 1450 mm Height of handlebar grip from 1,000 mm ground Seat height 800 mm Front footrest height 357 mm Rear footrest height 530 mm...
Page 26 Clear lacquer 228.880 (PPG) Red frame with black wheels Artic White Semigloss Artic White Dual Primer L2920057 (Lechler) Base Pearl White Ducati SF L2909004 (Lechler) Clear matt lacquer 2K 923I0652 (Palinal) Red frame with black wheels Diamond Black Semigloss Base primer 2K black...
Page 27: Exhaust System
Technical specifications Intake Opening 18° B.T.D.C. Closing 60° A.B.D.C. Exhaust Opening 53° B.B.D.C. Closing 23° A.T.D.C. Intake valve diameter 44 mm Exhaust valve diameter 38.5 mm With 0 mm valve clearance Intake 11.20 mm Valve lift Exhaust 10.80 mm Opening rocker arm - intake 0.10 to 0.15 mm 0.10 to 0.15 mm Opening rocker arm - exhaust 0.10 to 0.15 mm...
Page 28: Cooling System
Technical specifications Selector fork-to-gear clearance 0.070 to 0.285 mm 0.4 mm Cooling system Reference Technical specifications Air-cooled: heat dispersion through the Type extensive finning on the two cylinder barrel/head assemblies Front wheel Reference Standard value Service limit In the most worn part 2 mm Minimum tread depth Cold...
Page 29: Charging System/Alternator
Technical specifications Shim 4.5 mm 4 mm (min.) Flange material Steel Braking surface material Steel Diameter 320 mm Make Brembo Brake calliper Type P4.32K - 4 piston calliper cylinder diameter 32 mm Pad friction material FERIT I/D 450-FF Type PS 18/19 Cylinder Master cylinder diameter 18 mm...
Page 30 Technical specifications Low beam H7 (12 V - 55 W) Bulbs High beam H1 (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 (13.5 V - 3.2 W / 0.1 W)
Page 31: Dimensions
Dimensions 1.2 -Dimensions...
Page 32: Fuel, Lubricants And Other Fluids
Fuel, lubricants and other fluids 2 -Fuel, lubricants and other fluids Fluids and lubricants Type dm³ (litres) Fuel tank, including a reserve of 3.5 Unleaded fuel with an octane rating of at least 95-98 RON (litres) Sump and filter SHELL Advance Ultra 4 Front/rear brake and clutch circuits SHELL Advance Brake DOT 4 Protection for electrical contacts...
Page 33: Torque Settings
Torque settings 3 -Torque settings Frame torque settings Part Thread/pitch (mm) Nm ±10% Note Tolerance Headlight fairing Screw securing Plexiglas to headlight fairing M4x0.7 Wellnut fixing Screw securing headlight fairing bracket to M6x1 headlight support Lower screws initial tightening Upper screws final tightening Lower screws final tightening Screw securing headlight fairing to bracket M5x0.8...
Page 34 Torque settings Nut securing clamp to steering head M10x1.25 Screws securing brake/clutch hose guide to M6x1 LOCK 2 steering head Screw securing headlight support plate to M6x1 LOCK 2 steering head Electric system Screws securing coil to battery support M5x0.8 RH/LH handlebar switch screw M5x0.8 Screw securing battery lead to battery terminal...
Page 35 Torque settings Swinging arm pivot fastener M8x1.25 GREASE B Chain tensioner eccentric fastener M12x1.25 GREASE B in the sequence 1-2-1 Speed sensor wiring clamp fastener M4x0.7 LOCK 2 Grommet and lower hose guide to swinging arm M5x0.8 fastener (796 ABS) Upper chain slider fastener (796 ABS) M5x0.8 Chain guard to chain slider fastener...
Page 36 Torque settings Rear suspension Nut/screw securing shock absorber to mounting M10x1.25 GREASE B clevis Screw securing shock absorber to swing arm M10x1.5 GREASE B Front mudguard Front mudguard retaining screw M6x1 LOCK 2 Front pipe grommet to mudguard fixing screw AF 3.5 0.35 Rear mudguard...
Page 37 Torque settings Gearchange pedal pivot screw M8x1.25 LOCK 2 Fuel tank Screw securing fuel tank support brackets to M6x1 fuel tank Screw securing fuel pipe guide to fuel tank M5x0.8 Screw securing flange to fuel tank M5x0.8 LOCK 2 Tank filler cap screw M5x0.8 Special screw (twin male thread) securing M5x0.8...
Page 38 Torque settings Screw securing subframe to frame M12x1.25 GREASE B Nut on free play adjuster screw M25x1 GREASE B Free play adjuster screw GREASE B (on thread only) Screw securing LH side fuel tank pin to frame M6x1 Keyswitch cover cap nut M6x1 Keyswitch screw M6x1...
Page 39: Engine Torque Settings
Torque settings Screw securing cable guide to LH side of M6x1 crankcase Clamp securing hoses to airbox Cable guide to LH side of crankcase fastener M5x0.8 EVAP system canister filter Screws securing temperature sensor to intake M3x0.5 LOCK 9 hose Clamp securing hose to throttle body Clamp securing throttle body to intake manifold Stepper tube clamp tightening...
Page 40 Torque settings gasket Oil pump intake service hole plug M15x1 LOCK 5 Oil cooler nipple M14x1.5 LOCK 5 Oil drain plug with magnet M12x1.5 TB1215 Blow-by hole service plug M12x1 LOCK 5 Main oil way plug M10x1.5 LOCK 5 or TB1375B Clutch cover inner oilway screw M10x1.5 LOCK 5...
Page 41 Torque settings Stator wiring clamp bracket screw M5x0.8 LOCK 2 or TB1324 By-pass pump cap M15x1 LOCK 5 or TB1375B Oil pump retaining screw M8x1.25 Oil pump retaining screw M6x1 Oil pump assembly screw M6x1 Special generator cover to stud screw M6x1 13.5 12.5...
Page 42: Service Tools
Service tools 4 -Service tools Spare parts catalogue WORKSHOP SERVICE TOOLS 796 ABS WORKSHOP SERVICE TOOLS Specific tools for the engine Code no. Description 88713.1805 Tool for tightening timing belt driveshaft pulley 88713.3218 Timing belt pulley locking tool 88713.2423 Torque wrench for tightening front sprocket nut 88713.2676 Wrench for tightening cylinder head nuts 88713.2103 Stand for cylinder head assembly 88713.2651 Wet clutch housing service tool...
Page 43 Service tools 88713.0123 Timing check tool 97900.0215 DDS (Ducati Diagnosis System) + cylinder vacuum meter kit 88713.0137 Front sprocket holding wrench 88765.1581 Valve lift gauge 88713.2878 Spacer and fork feeler gauge 0.2/0.3 mm 88713.2916 Tool for fitting spring and closing rocker 88713.2282 Pulley holding tool...
Page 44 Service tools 88700.5749 Crankcase half assembly cap 88713.3334 Plate for gear selector fork positioning 88713.1749 Puller for drive pulley and cover 88765.1297 TDC gauge 88713.2092 Primary drive gears puller 88713.1010 Exhaust gases pick-up connector 88713.3367 Flywheel tool 88713.2442 Valve sealing ring installer Ø 7...
Page 45: Specific Tools For The Frame
Service tools 88713.2906 Oil filter cartridge wrench 88713.2556 Clutch drum holding tool 88713.2591 Clutch screw 88713.3396 Engine repair bench 88713.1994 Rocker arm shafts puller 88713.3394 Punch and sleeve for refitting the camshaft circlip 88713.2355 Timing belt pulley locking tool Spare parts catalogue WORKSHOP SERVICE TOOLS 796 ABS WORKSHOP SERVICE TOOLS...
Page 46 Service tools Code no. Description 88713.1072 Drift to install half bearing in bottom yoke 88713.1344 Chain assembly tool 8000.70139 Front wheel shaft wrench 88713.1096 Tool for forks overhaul - sealing ring installation 88713.1058 Wrench for steering shaft nut 88713.1062 Tool for installing steering head bearings 88713.1010 Exhaust gases pick-up connector 88713.3166 Wrench for tightening frame ring nut...
Page 47 Service tools 88713.0958 Draw bar for SHOWA fork overhauling 88713.0957 Retainer for SHOWA fork spacer 88713.1068 Drift for installing the swingarm needle roller bearings 88713.1038 Wrench for adjustment of the eccentric hub 88713.1073 Rear wheel balancing tool 88713.2409 Swingarm ball bearing installer 88713.1071 Drift for installing the rocker arm needle roller bearings...
Page 48: Appropriate Diagnosis Tools
796 ABS WORKSHOP SERVICE TOOLS Appropriate diagnosis tools Code no. Description 97900.0211 DDS (Ducati Diagnosis System) without cables 97900.0227S SIEMENS power and diagnostic cable 97900.0222 Power cable and diagnosis 1060838 (Measurement Module) 97900.0218 Vacuum sensor 552.1.039.1A Pressure sensor 97900.0220 Pressure/vacuum tube...
Page 49 Service tools 97900.0228 Battery socket adapter 814.1.114.1A Oil pressure coupling 514.1.032.1A Auxiliary test cable 552.1.038.1A Cylinder compression cable M10 fitting 875.1.065.1A Oil pressure tube 97900.0230 Feeder 97900.0224 Feeder...
Page 50 Service tools 88765.1371 Belt tensioning sensor 88765.1374 Belt tensioning sensor bracket 590.1.189.1A Fuel pressure tube 88765.1126V Clamp-type amperemeter...
Page 51 4 - Impianto elettrico 04 - Impianto elettrico 1 - Vehicle pre-delivery 2 - Routine maintenance table Scheduled maintenance chart: operations to be carried out by the dealer 4 Scheduled maintenance chart: operations to be carried out by the customer 5 3 - Maintenance operations Checking the engine oil level 6 Changing the engine oil and filter cartridge 6...
Page 52: Vehicle Pre-Delivery
Vehicle pre-delivery 1 -Vehicle pre-delivery 1 Check the condition of the shipping packaging (if present): 2 Remove from shipping packaging (if present); 3 Check the condition of the motorcycle: 4 Make sure the kit supplied is complete (use the list enclosed to the motorcycle packaging); 5 Installation of the kit supplied, following the instructions enclosed to the vehicle;...
Page 53: Routine Maintenance Table
Routine maintenance table 2 -Routine maintenance table Scheduled maintenance chart: operations to be carried out by the dealer List of operations and type of intervention km x1000 1 [set mileage (km/mi) or time interval *] miles x1000 0.6 22.5 37.5 Months 6 Change the engine oil •...
Page 54 Routine maintenance table Check the brake pads. If necessary, contact your dealer to renew pads • * Service operation to be carried out in accordance with the specified distance or time intervals (km, miles or months), whichever occurs first.
Page 55: Maintenance Operations
Maintenance operations 3 -Maintenance operations Checking the engine oil level Check the engine oil level through the sight glass (1) on the right-hand side of the oil sump. Stop the engine and allow a few minutes for the oil to settle to a steady level. Check the level with the motorcycle perfectly vertical and with the engine warm (but not running).
Page 56 Maintenance operations Install the cartridge in its housing and tighten it to a torque of 11 Nm (Min. 10 Nm - Max. 12 Nm) (Sect. 3 - 3, Engine torque settings). Every two oil changes, clean the oil pickup gauze filter. Remove the outer plug (5).
Page 57: Checking Valve Clearances
Maintenance operations Checking valve clearances In order to check the valve clearances, it is necessary to gain access to the four valve covers on the cylinder heads and then remove the parts listed below. Open the lock and simultaneously apply downward pressure in the area of the catch to release the pin; Pull the seat backwards to release it from the front catches and remove it.
Page 58 Maintenance operations Loosen the screws (6) and remove the deflectors (7) and (8) and conveyor (9). Loosen the screw (10) and recover the spacer (11) and the rubber mounting (12). Slide the oil cooler (13) off the pins of the frame, towards the clutch-side of the motorcycle.
Page 59 Maintenance operations Unscrew the screws securing the horizontal head covers (5) and the vertical head ones then remove the covers. Unscrew the two retaining screws (14) of the centre cap (15) over the end of the crankshaft. Fit the tool handgrip 88713.0123 in the holes of the generator cover to be able to turn the crankshaft so that the valve on which the control is carried out is in rest position.
Page 60 Maintenance operations With the valve in the rest position, slide a feeler gauge between the closing rocker arm and the closing shim to measure the clearance: Closing rocker arm INTAKE: Adjusting clearance 0 to 0.05 mm Checking clearance 0 to 0.05 mm EXHAUST: Adjusting clearance 0 to 0.05 mm...
Page 61: Changing And Cleaning The Air Filters
Maintenance operations If detected values exceed the specified limits, replace opening and/or closing shims, as described in paragraph “Removal of the rocker arms, shims and valves” (sect. 9 - 4.4), with an adequate height to obtain the specified clearance. Note Opening rocker arm shims measuring from 1.8 to 3.45 mm and closing rocker arm shims measuring from 2.2 to 4.5 are available as spare parts.
Page 62: Changing The Brake Fluid
Maintenance operations Important If the motorcycle is used in very damp or dusty conditions, the air filter cartridge must be changed more frequently. Changing the brake fluid Warning Brake fluid is corrosive and will damage paintwork. Avoid contact with eyes and skin. In the case of accidental contact, wash the affected area thoroughly with plenty of running water.
Page 63 Maintenance operations Once that all pistons of both callipers are fully moved back and that all the liquid in the tank has been aspirated, connect to the bleed valve (5) a transparent tube by immersing the end in a container placed on the floor. Fill the reservoir (2) with new brake fluid up to the MAX mark.
Page 64 Maintenance operations ± Tighten the bleed valve (5) to a torque of 4 Nm 10% (Sect. 3 - 3, Frame torque settings) then release the lever. Repeat the operation described above until the old liquid flows completely. Then, with the bleed valve definitely closed to the specified torque actuate repeatedly the lever until a pressure is detected in the brake system.
Page 65: Draining The Brake Circuit
Maintenance operations Loosen the bleed valve (8) to allow fluid to escape. The pedal is at the end of the stroke in lower position. Now tighten the bleed valve (8) to a torque of 10 Nm±10% (Sect. 3 - 3, Frame torque settings) and release the pedal;...
Page 66: Filling The Brake System With Fluid
Maintenance operations Connect a commercial brake bleeder to the front brake calliper bleed valve (5) or rear brake calliper bleed valve (8). Note Follow the manufacturer's instructions when using a commercial brake bleeding tool. Open the bleed valve and pump with the bleeding tool until no more fluid emerges. If you do not have a brake bleeding tool available, attach a length of transparent plastic tubing to the front calliper bleed valve (5) or rear calliper bleed valve (8) and immerse the other end of the tubing in a container on the floor containing old brake fluid.
Page 67 Maintenance operations Brake fluid is corrosive and will damage paintwork. Avoid contact with eyes and skin. In the case of accidental contact, wash the affected area thoroughly with plenty of running water. Refill the tanks (2) and (7) with specified oil (Sect. 3 - 2, Fuel, lubricants and other fluids) taken from an intact container.
Page 68: Changing The Clutch Fluid
Maintenance operations 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. Press the lever or the pedal half way or until the pressure in the system is detected, open the bleed valve and take the lever or pedal through the whole stroke;...
Page 69 Maintenance operations 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 tank (2) with new oil up to the MAX mark. Operate the clutch lever two or three times until the circuit is pressurised.
Page 70: Draining The Clutch Hydraulic Circuit
Maintenance operations Draining the clutch hydraulic circuit Warning Clutch fluid will damage painted surfaces if spilled on them. It is also very harmful if it comes into contact with the skin or with the eyes; In the case of accidental contact, wash the affected area thoroughly with plenty of running water. Remove the dust cap to expose the bleed valve (4).
Page 71: Filling The Clutch Circuit
Maintenance operations ± Refit the cap, tightening the retaining screws (5) to a torque of 10 Nm 10% (Sect. 3 - 3, Frame torque settings) in the sequence 1-2-3-1. ± Tighten the bleed valve (4) to a torque of 4 Nm 10% (Sect.
Page 72: Adjusting The Steering Head Bearings
Maintenance operations bubbles. If you do not have a bleeding tool available, connect a length of transparent plastic tubing to the bleed valve (4) as outlined in the draining procedure. Open the bleed valve (4) by 1/4 of a turn and operate the clutch lever several times until the fluid starts to come out the bleed valve (4).
Page 73: Adjusting The Chain Tension
Maintenance operations Loosen the clamp screw (5) that holds the steering tube to the steering head. ± Using service tool no. 88713.1058, turn the ring nut (6) to a torque of 30 Nm 5% (Sect. 3 - 3, Frame torque settings).
Page 74: Checking Brake Pad Wear And Changing Brake Pads
Maintenance operations To adjust the tension, proceed as follows. Slacken off the two clamp screws (1) that secure the rear wheel hub to the swingarm. Fit the hook spanner code 88713.1038 inserting its tooth in the eccentric hub (2). Rotate the eccentric hub (2) to obtain the correct chain tension. Turn anticlockwise to tighten the chain;...
Page 75 Maintenance operations Important If either of the pads is worn, both pads must be renewed as a set. Change the brake pads as follows. Remove the cotter pin (3) from the pad retaining pin. Force the calliper pistons back into their bores by forcing the old brake pads apart. Withdraw the pad retaining pins (4) from the outside.
Page 76 Maintenance operations Checking rear brake pad wear Check through the slot between the two half callipers that there is at least 1 mm of friction material on the pads. Important If either of the pads is worn, both pads must be renewed as a set. Change the brake pads as follows.
Page 77: Adjusting The Throttle Cable
Maintenance operations Note If it proves difficult to change the brake pads, first remove the callipers from the motorcycle (Sect. 7 - 4, Removal of the rear brake calliper). Warning Being the brake callipers a security component of the vehicle, follow instructions indicated in Sect. 7 - 3, Removal of the front brake system and Sect.
Page 78: Adjusting The Clutch Lever And Front Brake Lever
Maintenance operations Grease the end of the cable (6) and the pulley. Carefully close the throttle assembly, inserting the cable (6) in the guide (A) on the upper twistgrip housing (4). ± Tighten the twistgrip housing with the two screws (5) to a torque of 1.8 Nm 10% (Sect.
Page 79: Adjusting The Position Of The Gear Change And Rear Brake Pedals
Maintenance operations Warning Clutch lever and front brake lever shall be adjusted when motorcycle is at a standstill. Important Using the clutch properly will avoid damage to transmission parts and spare the engine. Note The engine can be started with the side stand down and the gearbox in neutral. If starting with a gear engaged, pull in the clutch lever (in this case the side stand must be up).
Page 80: Adjusting The Rear Shock Absorber
Maintenance operations Verify, by acting manually on the pedal, that there is a clearance of about 1.5 ÷2 mm before starting the braking operation. If not, check to modify the length of the cylinder push-rod in the following mode. Slacken off the lock nut (7) on the pushrod. Screw the rod into the fork (6) to increase play, or unscrew it to reduce play.
Page 81: Adjusting The Exhaust Valve Bowden Cable
Maintenance operations 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. Important When adjusting the spring preload, do not exceed a spring length of 181 mm to avoid damaging the swingarm.
Page 82 Maintenance operations Operations Section reference Remove the seat 5 - 3, Removal of the seat Remove the protection (1), unscrewing the screw (2) and recovering the washers (3) and corresponding spacer. Remove the clamps (4), (5) and disconnect the exhaust valve motor wiring (6). Loosen the screws (7), recover the washers (8) and remove the exhaust valve motor (9) from the rear number plate holder.
Page 83 Maintenance operations The page opens and you can select to activate the procedure. Press “F6” to close the valve that stays closed. Undo the adjuster of the cable until you obtain a free play in the range of 0.5 mm to 1.5 mm measured between valve stopper and pulley stop.
Page 84: Fitting A New Motor And New Cable
Maintenance operations Press button “X” from this DDS page: the activation procedure page closes and system quits without going through test selection. Disconnect the DDS. Turn the key to on, let make one complete turn and make sure that the vertex of the hexagon (D) in-between the cable mounting holes is secure/fixed next to the notch (B).
Page 85 Maintenance operations Turn the clip indicated by the arrow to the position shown in the figure. Route cable in the tunnel provided between plate and number plate holder. Position and fasten the valve motor to the rear subframe plate by means of two screws (7) and two washers (8). ±...
Page 86 Maintenance operations Lock cable end to plate by means of the circlip (13). Connect the DDS (Sect. 6 - 13, Tester power supply) and open the procedure “EXUP valve act.”. The page opens and you can select to activate the procedure. Press “F6”...
Page 87 Maintenance operations Loosen adjuster ring nut (11) on cable until pulley gets against the limit stop, further loosen it by 1.5 turns. On the DDS, press “F9”: to go back to test selection page. Press “F8” to open function “EXUP 5-cycle test”. The 5-cycle test is performed.
Page 88 Maintenance operations Press “F6” to close the valve that stays closed. Tighten the adjuster ring nut (11) on cable until you obtain a clearance in the range of 0.5 mm to 1.5 mm measured between limit stop and pulley stop. Once adjustment is completed, distance between the stop plate welded to the exhaust pipe and the valve pulley front tab must be 0.5 to 1.5 mm.
Page 89: Fitting A New Exhaust Valve Cable With Used Motor
Maintenance operations Disconnect the DDS. Turn the key to on, let make one complete turn and make sure that the vertex of the hexagon (D) in-between the cable mounting holes is secure/fixed next to the notch (B). If the test result was positive in the previous step, proceed with the remaining operations. While if result was negative, find failure cause before continuing.
Page 90 Maintenance operations The pulley will set with its vertex (in-between the cable end holes) at the motor centreline. Insert cable end coming out of the straight sheath length on motor pulley into hole (A) shown. Insert sheath end into the relevant seat (B) on the motor. Fit the clip to sheath terminal and make sure that it prevents cable from slipping out.
Page 91 Maintenance operations Lock cable end to plate by means of the circlip (13). Connect the DDS (Sect. 6 - 13, Tester power supply) and open the procedure “EXUP valve act.”. The page opens and you can select to activate the procedure.
Page 92 Maintenance operations Press “F6” to close the valve that stays closed. Loosen adjuster ring nut (11) on cable until pulley gets against the limit stop, further loosen it by 1.5 turns. On the DDS, press “F9”: to go back to test selection page. Press “F8”...
Page 93 Maintenance operations On the DDS, press “F9”: to go back to test selection page. Press “F6” to close the valve that stays closed. Tighten the adjuster ring nut (11) on cable until you obtain a clearance in the range of 0.5 mm to 1.5 mm measured between limit stop and pulley stop.
Page 94: Fitting A New Exhaust Valve Motor With Used Cable
Maintenance operations Press button “X” from this DDS page: the activation procedure page closes and system quits without going through test selection. Disconnect the DDS. Turn the key to on, let make one complete turn and make sure that the vertex of the hexagon (D) in-between the cable mounting holes is secure/fixed next to the notch (B).
Page 95 Maintenance operations Turn the clip indicated by the arrow to the position shown in the figure. Route cable in the tunnel provided between plate and number plate holder. Position and fasten the valve motor to the rear subframe plate by means of two screws (7) and two washers (8). Tighten the screws (7) to a torque of 10 Nm ±10% (Sect.
Page 96 Maintenance operations Lock cable end to plate by means of the circlip (13). Connect the DDS (Sect. 6 - 13, Tester power supply) and open the procedure “EXUP valve act.”. The page opens and you can select to activate the procedure. Press “F6”...
Page 97 Maintenance operations Tighten the adjuster ring nut (11) on cable until you obtain a clearance in the range of 0.5 mm to 1.5 mm measured between limit stop and pulley stop. Once adjustment is completed, distance between the stop plate welded to the exhaust pipe and the valve pulley front tab must be 0.5 to 1.5 mm.
Page 98 Maintenance operations Final checks Make sure that, upon the following immediate “KEY ON” cycles, the exhaust valve stays in “fully open position”, i.e. the valve pulley rear tab must be resting against the stop plate welded to the exhaust pipe.
Page 99 5 - Impianto elettrico 05 - Impianto elettrico 1 - Headlight fairing - rear-view mirrors Removal of the rear-view mirrors 4 Refitting the rear-view mirrors 4 Removal of the headlight fairing 5 Refit the headlight fairing 8 2 - Fairings Removal of the fuel tank fairings 10 Refitting the fuel tank fairings 12 3 - Seat...
Page 100: Headlight Fairing - Rear-View Mirrors
Headlight fairing - rear-view mirrors 1 -Headlight fairing - rear-view mirrors 1 Rear-view mirror 2 Screw 3 U-bolt 4 Spring washer 5 Bracket 6 Nut 7 Screw 8 Headlight fairing 9 Screw 10 Windscreen 11 Nut 12 Quick-release fastener 13 Screw 14 Washer Spare parts catalogue INSTRUMENT PANEL - HEADLIGHT FAIRING...
Page 101: Refitting The Rear-View Mirrors
Headlight fairing - rear-view mirrors Refitting the rear-view mirrors Start the screws (2) in their thread on the rear-view mirrors (1), inserting the washers (4) as shown in the picture. Insert the rear-view mirrors (1) in the U-bolts (3). Tighten the screws (2) to a torque of 25 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Page 102 Headlight fairing - rear-view mirrors 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 windscreen (10) from the headlight fairing (8).
Page 103 Headlight fairing - rear-view mirrors Reassembly of the headlight fairing Important On refitting the headlight fairing, always refit the washers (14) in correspondence with the retaining screws (13) to avoid damaging the painted parts and the Plexiglas windshield (10). Fit the Plexiglas windscreen (10) on the headlight fairing (8) as shown. Make sure that the quick-couplings (12) are in place on headlight fairing brackets and oriented as shown in the figure.
Page 104: Refit The Headlight Fairing
Headlight fairing - rear-view mirrors Refit the headlight fairing Fit the brackets (5) to the headlight support, starting the screws (9) and nuts (6). While holding the nuts (6), tighten the screws (9) (Sect. 3 - 3, Frame torque settings) as follows: - tighten the lower screws (9) to a torque of 1.5 Nm ±...
Page 105 Headlight fairing - rear-view mirrors...
Page 106: Fairings
Fairings 2 -Fairings 1 RH fuel tank cover 2 LH fuel tank cover 3 Front fuel tank cover 4 Screw 5 Rear fuel tank cover 6 Spacer 7 Screw 8 Quick-release fastener 9 Banjo bolt 10 Nylon washer 11 Screw 12 Screw 13 Spacer 14 Spacer...
Page 107 Fairings Unscrew the screws (7) and (12) securing the front tank cover (3) but do not remove the cover. Undo the screws (4) and (11) and 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) and the spacers (13).
Page 108: Refitting The Fuel Tank Fairings
Fairings Unscrew the special screws (9) and remove the rear tank cover (5). Refitting 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 a torque of 2 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Page 109 Fairings Locate the front tank cover (3) on the fuel tank. Insert spacers (13) and quick-couplings (15) into the holes inside the right-hand (1) and left-hand tank covers (2). Refit the right-hand tank cover (1), inserting the tabs (A) in the corresponding slots (B) in the rear cover (5). Note Insert the front lugs (C) under the front tank cover (3).
Page 110 Fairings Insert the retaining screws (7) and (12) in the front tank cover (3), starting with the front screws. Insert the screws (11) complete with the nylon washers (10) and screws (4) in the RH tank cover (1) and LH tank cover (2).
Page 111 Fairings Tighten the screws (12) to a torque of 2 Nm ±10% (Sect. 3 - 3, Frame torque settings). Operations Section reference Refit the seat 5 - 3, Refitting the seat...
Page 112: Seat
Seat 3 -Seat 1 Seat 2 Helmet lock cable 3 Screw 4 Tool tray 5 Rubber pad 6 Banjo bolt 7 Spacer 8 Rubber pad 9 Elastic strap 10 Seat cover 11 Stud bolt Spare parts catalogue SEAT 796 ABS SEAT Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in...
Page 113: Refitting The Seat
Seat Disassembly of the seat Unscrew the two special screws (6) and slide out the seat cover (10). Reassembly of the seat Refit the seat cover (10) to the seat inserting and tightening the special screws (6) to a tightening torque of 5 Nm ±10% (Sect.
Page 114: Removal Of The Tool Tray
Seat Removal of the tool tray Remove the seat, as described in the paragraph “Removal of the seat“ of this section. Release the elastic strap (9) and remove the tool bag (B) and free the ABS diagnosis connector (C) and the ABS diagnosis power supply connector (D) in the ABS version.
Page 115 Seat Place the tool bag (B) and the ABS diagnosis connector (C) and the ABS diagnosis power supply connector (D) in the tool tray (4) in the ABS version, as shown in the figure. Secure the tool bag with the elastic strap (9). Refit the seat, as described in the paragraph “Refitting the seat“...
Page 116: Front And Rear Mudguard
Front and rear mudguard 4 -Front and rear mudguard 1 Front mudguard 2 Washer 3 Rivet 4 Clip 5 Screw 6 ABS grommet 7 Screw 8 Rear mudguard 9 Screw 10 Spacer 11 Hose grommet Spare parts catalogue FUEL TANK (COVER) SWINGARM 796 ABS FUEL TANK (COVER)
Page 117 Front and rear mudguard Undo and remove the special retaining screws (5). Remove the front mudguard (1). Warning ABS sensor mounting bracket (E) is located on left-hand fork leg, pay special attention while removing the front mudguard (1).
Page 118: Refitting The Front Mudguard
Front and rear mudguard Note On USA versions, a reflector is mounted on the front mudguard (1). Note The hose grommet (4) is fastened to front mudguard (1) by means of a shear rivet (3) with two washers (2) in-between. Refitting the front mudguard Warning Do not use the motorcycle without the front mudguard fitted to avoid the risk of the brake pipes fouling the wheel on...
Page 119 Front and rear mudguard Engage ABS sensor cable (B) in its inner fastener (D) on front mudguard (1) and refit dust seal (C). Position the front mudguard (1) and start the special screws (5), using the recommended threadlocker. Insert brake rubber block (A) into grommet (4) and ensure it is centred. Fold the grommet (4), secure it by starting and tightening the screw (9) to a torque of 0.4 Nm ±10% (Sect.
Page 120: Removing The Rear Mudguard
Front and rear mudguard Removing the rear mudguard Undo the screws (7), remove the grommet (6) with spacers (10) and then remove the rear mudguard (8) from the swinging arm. Refitting the rear mudguard Set the rear mudguard (8) onto the swinging arm, starting the screws (7) in their thread with the recommended threadlocker, and fitting, on the front one, the spacer (10) and the grommet (12).
Page 121 Front and rear mudguard...
Page 122 6 - Impianto elettrico 06 - Impianto elettrico 1 - Wiring diagram 796 Wiring diagram 4 Key to wiring diagram 5 796 ABS Wiring diagram 6 Key to wiring diagram 7 Wiring diagram colour codes 7 Key to fuse box 8 Routing of wiring on frame 9 Table A 11 Table B 12...
Page 123 Injection and main relay 157 13 - Diagnostic instruments Using a multimeter to check the electrical systems 158 Description of the Ducati Diagnostic System tester 160 Tester power supply 162 DDS diagnosis instrument 165 Checking and adjusting timing belt tension 165...
Page 124 Wiring diagram 1 -Wiring diagram 796 Wiring diagram WIRING DIAGRAM...
Page 125 Wiring diagram Key to wiring diagram 1 Right-hand handlebar switch 2 Ignition switch 3 Horizontal cylinder spark plug 4 Vertical cylinder spark plug 5 Starter motor 6 Solenoid starter 7 Battery 8 Main fuse 9 Regulator 10 Generator 11 RH rear turn indicator 12 Tail light 13 Number plate light 14 LH rear turn indicator...
Page 126 Wiring diagram Key to wiring diagram 1 Right-hand handlebar switch 2 Ignition switch 3 Horizontal cylinder spark plug 4 Vertical cylinder spark plug 5 Starter motor...
Page 127 Wiring diagram 6 Solenoid starter 7 Battery 8 Main fuse 9 Regulator 10 Generator 11 RH rear turn indicator 12 Tail light 13 Number plate light 14 LH rear turn indicator 15 Fuel tank 16 Horizontal cylinder exhaust lambda sensor 17 Injection relay 18 Self-diagnosis/DDA 19 Horizontal cylinder coil...
Page 128 Wiring diagram Rating Position Consumer Key ON 10 A Side lights, high/low beam 15 A El. item 15 A Instrument panel Injection 20 A Spare 20 A Spare 15 A Routing of wiring on frame The routing of the wiring has been optimised to ensure the minimum obstruction. Each section is designed to prevent interference with parts that might damage wires or cause operating failures when riding.
Page 129 Wiring diagram Table G Horn connector Table H/Table E Regulator/alternator connector Table H/Table E Regulator/main wiring harness connector Table H/Table E Voltage regulator Table J/Table F Potentiometer connector Table K Horizontal cylinder coil connector Table L Horizontal cylinder exhaust lambda sensor Table L Horizontal exhaust lambda sensor connector Table L...
Page 130 Table A Table A Table B...
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Page 162 Table A Table V...
Page 163 Battery charging system 2 -Battery charging system Checking the battery charging system To check the current flow in the charging circuit, use the “DDS” tester, which is equipped with an inductive clamp-type amperemeter. Follow the instructions given in the paragraph “Checking the battery charging system”...
Page 164 Battery charging system 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. Type of charging Volt.
Page 165 Battery charging system Important Keep the cap strip (3) to hand because it will be used later as plugs for the battery cells. Warning Do not peel or perforate the sealed areas. Place the electrolyte container (2) upside down. Align the six sealed elements with the six filler holes on the battery. Push the container (2) downwards with sufficient force to break the seals and allow the liquid to flow out.
Page 166 Battery charging system Important Never move the container away from the battery. Do not cut or puncture the liquid container. Make sure that all the electrolyte has flowed out. Carefully extract the container (2) from the battery. Place the sealing cap strip (3) previously removed from the electrolyte container (2) on the battery, taking care not to force it into the filler holes.
Page 167 Battery charging system Battery Safety rules Warning Before carrying out any operations on the battery, keep in mind the safety standards (Sect. 1 - 3, General safety rules). When under charge, batteries produce explosive gases. Keep batteries away from heat sources, sparks or open flames. Instructions for use The battery is a sealed, maintenance-free type and therefore requires no servicing installation.
Page 168 Battery charging system Remove the tank covers (Sect. 5 - 2, Removal of the fuel tank fairings). Remove the fuel tank (Sect. 8 - 2, Refitting the fuel tank). Remove the terminal protection caps and undo the screws (1) starting always from the negative terminal (-). Remove the positive cable (2) and the ABS positive cable (3) from the positive terminal and the negative cable (4) from the negative terminal in the ABS version.
Page 169 Battery charging system Refit the remaining parts in the reverse order with respect to disassembly. Battery support Remove the battery, as previously described in the paragraph “Battery“ of this section. Remove the vertical head coil as described in Sect. 6 - 12, Coil. Unscrew the screws (7) and screw (5) and remove the battery support from the airbox.
Page 170 Battery charging system Warning To check the battery charging system for faults, use the DDS diagnosis instrument and follow the instructions given in the paragraph, “Checking the battery charging system“ (Sect. 6 - 2). The absolute value of voltage measured across the terminals of two of the three yellow cables (the measured value will be the same whichever combination of cable is used) must be within the range indicated in the table below.
Page 171 Battery charging system Refitting the generator Install the rotor (B), the stator (A) and the generator cover (Sect. 9 - 8, Refitting the generator cover). ± Refit the sprocket cover (C) tightening the screws (D) to a torque of 6 Nm 10% (Sect.
Page 172 Battery charging system The rectifier/regulator consists of an aluminium casing containing the diodes that rectify the current produced by the alternator. It also contains an electronic device that regulates the current 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.
Page 173 Battery charging system Remove the regulator (1) from the RH air scoop (2) by unscrewing the two screws (5). Important Do not disconnect the battery cables when engine is running because this would cause irreparable damage to the regulator. Refitting the regulator Check that the two threaded clips (6) are installed on the RH air scoop (2) and positioning as shown in the figure.
Page 174 Battery charging system In order to correctly route regulator cable, indicated with reference numbers (25) and (26), follow instructions given in Tables E and H under “Routing of wiring on frame”, Sect. 6 - 1. Refit the right-hand conveyor (2) together with regulator (1) to frame, then tighten the screws (3) and (4) to a torque of ±...
Page 175 Battery charging system Remove the tank covers (Sect. 5 - 2, Removal of the fuel tank fairings). Remove the fuel tank (Sect. 8 - 2, Removal of the fuel tank). 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.
Page 176 Electric starting system 3 -Electric starting system Note The references of the elements listed below are those of the “Wiring diagram”, Sect. 6 - 1. Electric starting system The key components of the electric starting system are a contactor (7) and a starter motor (6) fed by the battery (8). The engine starting strategy is managed entirely by the engine ECU (28), which monitors the following inputs: - Engine Stop switch on right-hand handlebar switch (1) - Engine starter switch on right-hand handlebar switch (1)
Page 177 Electric starting system rotate freely and at high speed. Take care not to short-circuit the two cables connected to the battery. Removal of the starter motor Operations Section reference Drain the engine oil 4 - 3, Changing the engine oil and filter cartridge Remove the gearchange control 7 - 9,...
Page 178 Electric starting system Note The starter motor retaining screws are assembled with threadlocker. Slide out the starter motor and gasket (2). Refitting the starter motor Inspect the condition of the gasket (2) and renew if necessary. Place the gasket (2) and the starter motor on the crankcase and tighten the retaining screws (1) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm) (Sect.
Page 179 Electric starting system Apply the recommended grease to the nut (A). Place the starter motor/solenoid cable (3) and tighten the nut (A) to a torque of 5 Nm±10% (Sect. 3 - 3, Frame torque settings). Refit the generator cover (Sect. 9 - 8, Refitting the generator cover).
Page 180 Electric starting system Starter contactor The starter motor contactor (1) is elastically mounted to the airbox. Disconnect the battery (Sect. 6 - 2, Battery). To reach the solenoid starter it is necessary to remove the seat, so insert the key in the lock and simultaneously apply downward pressure in the area of the catch to release the pin.
Page 181 Electric starting system Undo the nuts (6), taking care to collect the spring washers (7). Remove the starter motor-contactor cable (8). Remove the contactor-battery cable (9). Checking operation of the starter solenoid Apply 12 V (battery voltage) across the positive terminal (B) and negative terminal (C) of the connector.
Page 182 Electric starting system With a multimeter connected between the two poles (threaded pins (C) and (D) of the contactor, check for electric continuity (Sect. 6 - 13, Using a multimeter to check the electrical systems). If there is no electrical continuity, renew the solenoid.
Page 183 Electric starting system Reconnect the battery (Sect. 6 - 2, Battery). Refit the remaining parts in the reverse order with respect to disassembly.
Page 184 Lights and indicating devices 4 -Lights and indicating devices Renewal of the headlight Undo the screws (8) and remove the instrument panel shroud (1). Disconnect the instrument panel connector (A) from the main wiring harness (refer to the tables of paragraph “Routing of wiring on frame“, Sect.
Page 185 Lights and indicating devices 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). Note The US version fits a spacer (T) between turn indicator and headlight mount. Refitting is the reverse of removal: if removed, refit the rubber blocks (7) to headlight finger-tight, apply a drop of clear universal silicone onto rubber block (7) where indicated.
Page 186 Lights and indicating devices If removed, reposition the turn indicators to headlight mount, with the drain slot (F) facing down; position the stop plate (5) as shown. Apply the recommended threadlocker to the screws (6). Start the screws (6) in their thread ensuring that the slot on stop plate (5) perfectly matches the tabs on turn indicators.
Page 187 Lights and indicating devices Insert a spacer (7) to a screw (10), positioning it as indicated. Start screw (10) in its thread on the central clip (11) of headlight cover (8). Start the other two screws (10) in their thread on the side clips (11) of headlight cover (8). Tighten the screws (10) to a torque of 3 Nm ±10% (Sect.
Page 188 Lights and indicating devices Refit the instrument panel cover (1) tightening the screws (8) to a torque of 1.5 Nm ±10% (Sect. 3 - 3, Frame torque settings). Changing bulbs Changing the headlight bulbs Before replacing a burnt out light bulb, ensure that the replacement bulb has the same voltage and power rating as specified for the lighting device in question (Sect.
Page 189 Lights and indicating devices Remove the headlight, as described in the paragraph “Renewal of the headlight“ of this section. To access the headlight bulb unscrew the four screws (1) and remove the cover (2). High beam (HI) Disconnect the wiring connector (3) from the headlight bulb (4). Release the retaining clip (5).
Page 190 Lights and indicating devices Replace the lamp with a new one of the same type and rating (Sect. 3 - 1.1, Lights/instrument panel). Note Do not touch the transparent part of the bulb with your fingers, this will darken it and cause a loss of brightness. Side lights (A) To replace the side light bulb, withdraw the bulb holder (7) from the rear of the headlight.
Page 191 Lights and indicating devices Remove the tank covers (Sect. 5 - 2, Removal of the fuel tank fairings). Remove the fuel tank (Sect. 8 - 2, Removal of the fuel tank). Remove the elastic retaining strap (2) and slide out the battery (1). The high beam relay (3) has been added to the electrical circuit to enable the lights power down strategy.
Page 192 Lights and indicating devices 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 voltage) between contacts (86) and (85) (small contacts): you should hear a click that confirms that the internal electromagnet has switched.
Page 193 Lights and indicating devices...
Page 194 Indicating devices 5 -Indicating devices Checking the indicating devices In the event of a fault, the internal connections of the device must be checked in all operating conditions. To do this, it is necessary to disconnect the switch connector from the main wiring harness (Sect. 6 - 1, Routing of wiring on frame).
Page 195 Indicating devices Checking the right-hand handlebar switch To remove the right-hand handlebar switch, undo the retaining screws (1) and disconnect the wiring connector from the electric system. The colours mentioned in the following descriptions refer to the colours of the wires from the switch and not to the colours of the wires of the main electric system.
Page 196 Indicating devices Checking the front and rear brake light switches, neutral light switch, oil pressure switch and clutch switch Brake light switches To check operation of the front (1) and rear (2) stop lights use a multimeter to check that when the front or rear brake is pressed, there is electrical continuity (Pos.
Page 197 Indicating devices Neutral indicator light To check the neutral light switch (3) proceed as follows. The neutral light does not illuminate on the instrument panel. Remove the electric terminal connected to the neutral switch. Switch on the ignition switch (ignition key to ON position) and ensure that the light illuminates when the terminal is earthed.
Page 198 Indicating devices Clutch switch For the clutch switch (5) proceed in the same manner as for the brake light switches (see beginning of this paragraph). Changing light bulbs Changing the turn signal light bulbs Undo the screw (1) and detach the lens (2) from the turn signal support (3). The bulb has a bayonet-type end fitting: to remove it, push it in and turn it counter-clockwise.
Page 199 Protection and safety devices 6 -Protection and safety devices Checking protection and safety device components Checking the key switch Disconnect the ignition key (A) from the electric system by opening its connection (see “Routing of wiring on frame“, Sect. 6 - 1) and use a multimeter to check continuity of its internal connections as follows: - turn the key to OFF and connect a multimeter to contacts (1) and (4) to check electrical continuity (Sect.
Page 200 Protection and safety devices Note The same test may be done using the “DDS” tester (Sect. 6 - 13, DDS diagnosis instrument). Pos. pin (A) El. item Rating. l - s s - n Multimeter pos. Green/ Green/ Green Yellow White Black 0 = Open contact...
Page 201 Protection and safety devices 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.
Page 202 Instruments 7 -Instruments Instrument panel Undo the screws (2) and remove the instrument panel shroud (1). Disconnect the wiring (A) from the instrument panel (3). Undo the screws (4) and remove the instrument panel (3) from the front lights assembly support. For reassembling perform the disassembling operations in the reverse order, in particular tighten the screws (4) to a torque of 3 Nm ±10% and the screws (2) to a torque of 1.5 Nm ±10% (Sect.
Page 203 Instruments The information on the display can be accessed using a 2-position rocker switch (1) and the headlight flash 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 exceeds the rev limiter threshold.
Page 204 Instruments Light off Light flashing Light steady ABS disabled with the menu ABS enabled but not function “DISAB ABS” (*) functioning yet Engine on / speed below 5 Km/h Light off Light flashing Light steady ABS disabled with the menu ABS enabled but not function “DISAB ABS”...
Page 205 Instruments At Key-On, the instrument panel always shows the following information (de-activating any previously activated functions): Odometer speed Rpm bargraph Engine oil temperature bargraph. With the switch (1, fig. 8) in position B “t” the Odometer readout (TOT) will cycle through the following functions: TRIP TRIP FUEL (only if active) Clock...
Page 206 Instruments Important This menu is enabled only if the speed of the vehicle is less than 20 km/h. If this menu 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 “s”...
Page 207 Instruments “TRIP“ meter Holding button (1) pressed in position B “t“ for 3 seconds when this function is displayed resets the trip meter. If the reading exceeds 999.9, it is reset to zero and the count restarts automatically. If the System units of measurement are changed at any time with the “Setting Special” Function, the reading in this Function is reset and the count restarts from zero in the newly set unit of measurement.
Page 208 Instruments “TRIP FUEL” (distance travelled on reserve fuel) indicator When the fuel warning light (4) comes on, the TRIP FUEL meter is activated automatically, regardless of the function displayed. If the fuel level remains in reserve, the reading is saved even after Key-Off. The count stops automatically when the fuel level rises above reserve.
Page 209 Instruments 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 string of dashes “- - -“ (not flashing) is displayed and the “Vehicle/Engine diagnosis - EOBD“ light comes on. Coolant temperature indicator This function describes the engine oil temperature indicator.
Page 210 Instruments Maintenance indicator Indicates that the next service is due. The indicator ( ) signals when the next service is due. The service indicator is displayed at the following intervals: - after the first 1000 km on the odometer; - every 12000 km on the odometer. The service indicator will remain on the display until reset.
Page 211 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 is displayed, always contact an authorised Ducati Service Centre.
Page 212 Instruments INJE Vertical injector (2) short circuit Volt DC INJE Vertical injector (2) short circuit Volt DC or AC INJE Horizontal injector (1) short circuit Volt DC INJE Horizontal injector (1) short circuit Volt DC or AC START Solenoid starter short circuit Volt DC START Solenoid starter short circuit GND or AC R INJ...
Page 213 Instruments Battery voltage indicator (BATT) To display this function, go into the menu and select the “BATT” page. The battery voltage reading is displayed as follows: - if the reading is between 12.1 and 14.9 Volts, it is steadily illuminated on the display; - if the reading is between 10.0 and 12.0 Volts or between 15.0 and 16.0 Volts, it flashes on the display;...
Page 214 Instruments Backlighting adjustment To adjust the backlighting, enter the menu and select the “LIGHT SET” page. Press the button (1) in position B “t” for 3 seconds in this page to access the setup mode and the following pages will be displayed in sequence: page 1 - “LIGHT MAX”...
Page 215 Instruments LAP function To enable this function, enter the menu and set the “LAP“ function to “On“ by holding switch (1) pressed in position B “t“ for 3 seconds.
Page 216 Instruments START and STOP the timer by pressing the high beam FLASH switch (2) on the left-hand handlebar switch. When the LAP function is active, each time you press the flasher switch, the display will show the lap time for 10 seconds, before reverting to normal mode.
Page 217 Instruments LAP Memory display Displays the data saved using the LAP function: lap number and time. To display the saved lap times, enter the menu and select the “LAP MEM” page. Holding switch (1) pressed in position B “t“ in this menu page accesses the “1st lap“ view mode. The display will show the lap number, lap time, MAX speed and the MAX rpm reached for the lap in question.
Page 218 (9). DDA data acquisition This function serves to activate the DDA (Ducati Data Analyzer): in order to acquire data, the DDA must be connected to the motorcycle wiring loom. To enable data acquisition, enter the menu and set the “DDA“ function to “On“ by holding switch (1) pressed in position B “t“...
Page 219 Instruments After use, disconnect the DDA from the main wiring harness. Erase DDA This function enables you to delete the data saved on the DDA: the DDA must be connected to the motorcycle wiring. To delete the data, enter the menu and select the “Erase DDA” page. If you press switch (1) in position B “t“...
Page 220 Instruments ABS disabling function (796 ABS) This function disables the ABS control unit. This operation must be carried out with the vehicle stopped (key ON). To disable the ABS control unit, access the menu on the “DISAB ABS” page and hold down switch (1) in position B “t“ for 3 seconds.
Page 221 Instruments Clock setting function To set the clock, enter the menu and select the “SET” page. Holding switch (1) pressed in position B “t“ for 3 seconds in this menu page gives access to the setup mode. On entering this mode, the message “AM” will flash; if you press switch (1) in position B “t” the message “PM” flashes; if you press switch (1) in position B “t”...
Page 222 Instruments Programming the immobilizer This instrument panel function enables programming of the Immobilizer System. Note Only 2 keys may be programmed. Insert KEY 1 (one of the two black keys) and turn the ignition switch from Off to On; within 3 seconds turn the ignition switch from On to Off; within 15 seconds insert KEY 2 (the other black key) and turn the ignition switch from Off to On;...
Page 223 Instruments switch in position B “t”, the number increases cyclically in steps of one digit every second; if you press the switch in position A “s”, you can set the third digit, which will start flashing. Each time you press the switch in position B “t”, the number increases cyclically in steps of one digit every second;...
Page 224 Instruments If the error is still present, at the next Key-On the instrument panel error and the inhibited status will persist. Intelligent headlight switch-off This function helps reduce battery use by automatically switching off the headlight. The device is triggered in 3 cases: - in the first case, if you turn the key from OFF to ON and do not start the engine within 60 seconds, the headlight is turned off and will be turned on again only when the engine is next switched on;...
Page 225 Instruments Immobilizer Reprogramming (service menu 1) This function is for reprogramming the immobilizer system in the event of loss or damage to one or both of the keys. To display this function, go into the service menu and select the page “0000 COD”. Note Within this function all other functions are excluded and motorcycle starting is disabled.
Page 226 Instruments Loss of the Code Card Without knowing the electronic code on the CODE CARD, it is impossible to: reprogram the immobilizer system in the event of loss of one or both of the keys; temporarily override the immobilizer in the event of a fault. To restore the entire system to full operation, it is necessary to renew the KEY SET (2 black keys + new CODE CARD) and the instrument panel, and therefore programme the immobilizer again.
Page 227 Instruments COUNTRY speed Coolant temperature Counters km/h °C °C miles °F miles km/h °C km/h °C km/h °C ECU ld. The instrument configures the unit of measurement parameters in accordance with information relayed from the ECU Press button (1) in position B “t” for 3 seconds to store the displayed settings, the message “MEM” confirms storage. The new parameter setting will applied at the next Key-On.
Page 228 immobilizer and transponder 8 -immobilizer and transponder The immobilizer allows the vehicle to be started only if the rider uses the special ignition key which sends the identification code to a decoder housed in the instrument panel. The transmission-receiving system is composed of a TRANSPONDER housed in the ignition key heads and an antenna in the vicinity of the ignition switch.
Page 229 immobilizer and transponder Removal of the immobilizer Set the ignition switch to OFF. Disconnect the antenna wiring connector (A) from the main wiring loom. Unscrew the two nuts (1) and remove the cover (2). Undo the screw (3) fastening ignition switch cover (4) and remove the cover (4). Slide out the immobilizer antenna (5) from ignition switch.
Page 230 immobilizer and transponder Refitting the immobilizer Refitting is the reverse of removal; in particular, tighten the screw (3) and nuts (1) to a torque of 7 Nm ±10%) (Sect. 3 - Frame torque settings).
Page 231 Description of the system 10 - Description of the system General information on the fuel injection-ignition system Integrated electronically-controlled ignition and injection controlled by just one control unit ensure optimal Otto cycle engine performance and output, thus reducing consumption and harmful substances into the exhaust gas. This system ensures an accurately metered air-fuel ratio and optimal management of ignition advance.
Page 232 Description of the system Siemens M3C injection-ignition system The Siemens M3C injection-ignition system is the Alfa/N type, in which the engine speed and throttle position are used as main parameters for measuring the quantity of intake air. If the quantity of air is known, the quantity of fuel can be dosed accordingly to obtain the required ratio.
Page 233 Description of the system Fuel circuit A pump located on a flange at the bottom of fuel tank pumps fuel into delivery tube (OUT) and toward injectors. The flange also fits the pressure regulator controlling fuel feed and keeping it constant at a value higher than engine- generated vacuum.
Page 234 Description of the system Intake air circuit The air circuit consists of two intake ducts (A), a throttle body (B) and an intake air box (C) (airbox) above the throttle body. This motorcycle is also equipped with a stepper motor (14) that defines the magnitude of the supply of supplementary air, down-line from the throttles, during the engine starting phase (see “Operating phases”...
Page 235 Description of the system The engine control system (ignition and injection) relies on several sensors which correct mixture strength according to air pressure and temperature and engine load. An air temperature sensor (6) located on the intake manifold of the vertical cylinder and an air pressure sensor (5) located between the “V”...
Page 236 Description of the system Operating phases Normal operation When the engine is fully warm, the control unit calculates injection time and ignition advance, by comparing the stored map values, in accordance with the RPM and throttle position. The calculated quantity of fuel is fed through injectors in one single sequential delivery to the two cylinders, during the useful cycle.
Page 237 Fuel injection - ignition system 11 - Fuel injection - ignition system The electrical components of the fuel injection-ignition system are listed below: indicated reference number refers to the diagram in Sect. 6 - 1, Key to wiring diagram: Key to fuel injection–ignition system diagram 3) Horizontal cylinder spark plug 4) Vertical cylinder spark plug 6) Starter contactor...
Page 238 System components 12 - System components Electronic Control Unit (ECU) The engine ECU (1) is an electronic digital microprocessor-based unit. It controls both the injectors and the coils, thus controlling fuel injection and ignition in accordance with the engine operating conditions detected by the following sensors: - Absolute pressure sensor (measures barometric pressure and engine load in Speed Density mode) - Air temperature sensor (measures intake air temperature) - Engine temperature sensor (measures the engine temperature)
Page 239 System components Tighten the screws (3) to a torque of 5 Nm ±10% (Sect. 3 - 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 “locked”...
Page 240 System components The ECU controls injector opening by feeding current to the coil of an electromagnet which creates a magnetic field to attract the armature, thereby generating fuel spray. If we take the physical characteristics of the fuel to be constant (viscosity, density), as well as the injector delivery and pressure head (controlled by the fuel pressure regulator), the amount of fuel injected depends on the duration for which the injector is open.
Page 241 System components The stepper motor simultaneously controls two by-pass ports having an air flow capacity of around 6 kg/h. The by-pass ports with adjuster screws are present because it is necessary to balance the air flow to the two cylinders. In order to compensate for the quantity of supplementary air supplied by the stepper motor and consequently deliver the correct amount of fuel, the ECU converts the stepper motor steps into angular degrees of the throttle: this system means that opening the stepper motor is equivalent to opening the throttle.
Page 242 System components 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”: thus lambda = 1 means mixture in stoichiometric (ideal) ratio lambda >1 means a lean mixture...
Page 243 System components Refitting the air pressure sensor Refitting is the reverse of removal. On completion of the refitting operation, reconnect the wiring connector (3) to the sensor. Operations Section reference Refit the airbox 8 - 7, Refitting the airbox Refit the battery 6 - 2, Refitting the battery Connect the starter motor/solenoid...
Page 244 System components Temperature sensor This sensor is powered by the ECU and provides information regarding the temperature of the aspirated air. The electronic signals thus obtained are transmitted to the ECU, where they are used to make corrections in accordance with the temperature reading.
Page 245 System components Refitting the air temperature sensor Refitting is the reverse of removal. On completion of the refitting operation, reconnect the wiring connector to the sensor (1). Operations Section reference Refit the airbox 8 - 7, Refitting the airbox Refit the battery 6 - 2, Refitting the battery Connect the starter motor/solenoid...
Page 246 System components Important Do not use spark plugs with inadequate thermal rating or incorrect thread length. The spark plug must be securely installed. If a spark plug is loose, it can overheat and damage the engine. Spark plug type: Make: CHAMPION Type: RA6HC Alternative: Make: NGK...
Page 247 System components The vertical head coil (2) is on the battery mount, so that to remove it, you shall: Remove the seat (Sect. 5 - 3, Removal of the seat). Remove the tank covers (Sect. 5 - 2, Removal of the fuel tank fairings).
Page 248 System components Refit the left-hand side conveyor (Sect. 6 - 3, Starter contactor). Refit the fuel tank (Sect. 8 - 2, Refitting the fuel tank). Refit the tank covers (Sect. 5 - 2, Refitting the fuel tank fairings). Refit the seat (Sect. 5 - 3, Refitting the seat).
Page 249 System components Throttle Position Sensor (TPS) The TPS is powered by the ECU to which it sends a signal indicating the throttle position. This information is an indirect 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.
Page 250 System components Note To check this component, use the DDS diagnosis instrument, following the instructions given in the paragraph “Guided diagnosis“ (Sect. 6 - 13). For throttle position sensor replacement, please refer to Sect. 8 - 2, Removal of the throttle body.
Page 251 System components...
Page 252 Diagnostic instruments 13 - Diagnostic instruments For information on the “DDS” tester, refer to Sect. 6 - 13, DDS diagnosis instrument. Using a multimeter to check the electrical systems Introduction This instrument allows you to measure resistance, voltages, and current values. Multimeters can be divided into two basic types: those with an analogue display and those with a digital display.
Page 253 NEVER connect the multimeter in parallel to make current measurements, and NEVER connect it in series to carry out voltage measurements. Description of the Ducati Diagnostic System tester The “DDS” diagnostic system lets you diagnose any faults in the injection-ignition system via a serial port. The system is also equipped with functions to test various devices on the motorcycle.
Page 254 Diagnostic instruments 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 between the DDS diagnosis instrument (1) and the motorcycle’s on-board electronic control unit (ECU). The user interface software resides in the display memory card (C) which is housed in the Palmtop display unit (A).
Page 255 Diagnostic instruments - Power and diagnostic cable complete with fuse - CD containing DDS installation software for PC - USB cable - Belt tension sensor Tester power supply The DDS diagnosis instrument (1) tool part no. 97900.0215 may be powered in any of the following ways: - from the mains power supply: by connecting the mains adapter (2) to the power connection socket (N) part no.
Page 256 Diagnostic instruments The tester requires a power supply voltage within 9 and 16 Volts D.C. Make sure voltage never drops below this limit during operation: this situation could occur during engine starting and idling on motorcycles in which the battery is not in perfect working order. If the tester detects a power supply voltage lower than 9 Volts, the current procedures will be reset;...
Page 257 Diagnostic instruments DDS diagnosis instrument The main functions of the DDS diagnosis instrument can be summarised as follows: - Retrieval of errors (faults) of the ignition-injection system stored in the engine control unit memory and their subsequent deletion, if required. - Reading of engine parameters (rpm, coolant and air temperature, atmospheric pressure, throttle opening, battery voltage, injection times and ignition advance, etc.).
Page 258 Diagnostic instruments Position the crankshaft so that the piston of the horizontal cylinder is at TDC of its power stroke, using the whole tool. This is achieved by aligning the timing mark (C) of the timing driveshaft pulley (13) with the reference notch (D) on the clutch cover (T).
Page 259 Diagnostic instruments Connect the belt tension sensor (1) tool part no.88765.1371 to the jack (V) of the power supply and diagnosis cable (Measurement Module) (17) tool part no. 97900.0222. Fix the mounting bracket of the belt tension sensor (1) using the timing belt cover screw (18). Direct the central green LED of the sensor (1) at the midpoint of the belt section, placing the sensor (1) parallel to the belt and at a distance of about 1÷1.5 cm from it.
Page 260 Diagnostic instruments The socket to which the cable (Measurement Module) (17) is to be connected is indicated on the screen with a capital letter: A, B or C. Flick the belt lightly with your finger and read the frequency value (Hz) on the DDS diagnosis instrument. Note Do not stress the belt several times repeatedly, since the necessary minimum time for the DDS diagnosis instrument to take a reading is 1 second.
Page 261 Diagnostic instruments Recheck the timing belt tension. Repeat the above procedure until the correct belt tension is obtained. Once the desired tension is obtained, tighten the screws (19) to a torque of 26 Nm (Mim. 23 Nm - Max 29 Nm) (Sect. 3 - Engine torque settings).
Page 262 Diagnostic instruments Enter the general functions menu by pressing the icon “Menu 1” (A). Press the “Select vehicle” icon and, on the next screen, press the “Select motorcycle” icon; select the motorcycle model and confirm, then select the version and confirm. Press the icon “Select system”...
Page 263 Diagnostic instruments The DDS diagnosis instrument will interrogate the electronic control unit and display the parameters analysed with their relative values. Note Make all connections with the motorcycle ignition key in the OFF position. Press the “Settings” icon to display the special parameters. Select the option “Self-adaptation of the throttle position sensor (TPS)”...
Page 264 Adjusting the idle speed Note Check that the motorcycle is fitted with a genuine Ducati ECU, intake system and exhaust system; if not, fit genuine components. Connect the inserts of the exhaust gas analyser code 88713.1010 to the outlets on the exhaust pipes, using the fittings...
Page 265 Diagnostic instruments Connect the DDS and select MONSTER 796 / MONSTER 796 ABS. Make sure that the throttle body pulley is seated against the stop screw when the throttle twistgrip is fully closed. Make sure that the throttle cable free play is correctly adjusted.
Page 266 Connect the Measurement Module cable (4) tool part no. 97900.0222 to the DDS Measurement Module connector, as described in the paragraph “Description of the Ducati Diagnostic System tester“. Connect the cable (4) connectors (A) and (C) to the depression/pressure pipes (5) part no. 97900.0220 and to the latter the fittings (6) part no.
Page 267 Diagnostic instruments Take both by-pass screws (2) and (3) one turn open, from fully closed position. Warning Press the “Reset“ icon (G), then connect the sensors (8) part no. 97900.0218 and (9) part no. 553.1.039.1A to the connectors (A) and (C) of the cable (3) and to the depression/pressure pipes (6). Press the “Start”...
Page 268 Diagnostic instruments To adjust the balance (consider a tolerance between 260 and 270), turn the by-pass screws (2) and (3) until the two lines on the graph coincide, if in graphic mode, or until identical numerical values are displayed, if in numerical mode. Balance is obtained when the two lines of the graph nearly coincide or when the two indicated values are within the tolerance range.
Page 269 Diagnostic instruments connector (A). Connect the pressure sensor (5) part no. 552.1.039.1A to the pipe (2) to transform the pressure signal into an electrical signal. Switch on the DDS diagnosis instrument (6) part no. 97900.0215 as indicated in the paragraph “Tester power supply“.
Page 270 Diagnostic instruments On the DDS diagnosis instrument (6), select the “Measurement module” function by pressing the corresponding icon; then press the “Pressure Test” 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 (7).
Page 271 Diagnostic instruments Start the engine. The values may be displayed in three different ways: in one numeric form and in two graphic forms; to select the desired display type, press the “Value display” icon. 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 (7), the value measured will displayed next to the letter (A) on the screen.
Page 272 Diagnostic instruments Note The on-screen icons used during this procedure are explained in a table at the end of this section. Engine performance is directly correlated to the pressure that can be measured in the combustion chambers of the two cylinders.
Page 273 Diagnostic instruments On the DDS diagnosis instrument (4), select the “Measurement module” function by pressing the corresponding icon; then press the “Cylinder Compression” icon (D) followed by the “Start” icon (E). The letter A is displayed on the screen to indicate the connector of the Measurement Module cable (3). Open the throttles completely.
Page 274 Diagnostic instruments - worn cylinder or piston rings. Refit the spark plugs and reconnect the HT leads (1). Fuel pressure test Note The on-screen icons used during this procedure are explained in a table at the end of this section. In order to check the valve clearances, it is necessary to gain access to the four valve covers on the cylinder heads and then remove the parts listed below.
Page 275 Diagnostic instruments Raise the tank but leave it connected to the fuel system and wiring then position it on the side, duly supported, to be able to work on the fuel system flange. Remove the fuel feed hose (5). Use the fuel pressure pipe (6) part no. 590.1.189.1A connecting one end (D) to the coupling of the delivery pipe to the tank and the other end (E) to the fuel delivery pipe (5): in this way you create a pressure pick-up socket (F).
Page 276 Diagnostic instruments Connect the pressure sensor (7) to socket (A) or (C) of the cable (9). On the DDS diagnosis instrument, select the “Measurement module” function by pressing the “Measurement Module“ icon; then press the “Pressure Test” icon (F) followed by the “Start” icon (G). The socket to which the cable (Measurement Module) (9) is to be connected is indicated on the screen with a capital letter: A, B or C.
Page 277 Diagnostic instruments 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 value measured will displayed next to the letter (A) on the screen. The maximum pressure must be equal 3 bar (nominal).
Page 278 Diagnostic instruments Apply the recommended threadlocker to the screw (4). Secure the tank to the subframe with the screw (4) and the washer (3). Tighten the screw (4) to a torque of 10 Nm ±10% (Sect. 3 - 3, Frame torque settings), using a 5 mm Allen wrench to counterhold the threaded insert (12) located on the upper part of the tank.
Page 279 Diagnostic instruments Note The on-screen icons used during this procedure are explained in a table at the end of this section. In the event of a malfunction of the immobilizer system, it is possible to start the engine using the emergency procedure described in Section 6 - 8, immobilizer and transponder, which requires a secret code that can be entered using the DDS...
Page 280 Diagnostic instruments 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 diagnosis instrument will interrogate the electronic control unit and display the parameters analysed with their relative values.
Page 281 Diagnostic instruments A screen will appear in which you can enter the 5 digit secret code. Use the red arrows (E) and (F) to enter each digit: after entering each digit, 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?”...
Page 282 Diagnostic instruments Enter the general functions menu by pressing the icon “Menu 1” (A). Press the “Select vehicle” icon and, on the next screen, press the “Select motorcycle” icon; select the motorcycle model and confirm, then select the version and confirm. Press the icon “Select system”...
Page 283 Diagnostic instruments Select “Engine electronics” and press the “Confirm” icon (B). Press the “Guided diagnosis” icon (C) to access the corresponding function. A series of screens are displayed indicating the operations required for correct diagnosis. To determine whether the system has any internal problems, you can access the “Self-diagnosis” function by pressing the corresponding icon.
Page 284 Diagnostic instruments The DDS diagnosis instrument will interrogate the electronic control unit and display the parameters analysed with their relative values. Testing the battery charging system Note The on-screen icons used during this procedure are explained in a table at the end of this section. You can determine the engine rpm required for generator to produce just enough current to charge battery, feed the injection ignition system and all electric items fitted to motorcycle.
Page 285 Diagnostic instruments Connect the clamp-type amperemeter (1) to the connector (E) of the power and diagnostics cable (Measurement Module) (3). Warning The clamp-type amperemeter must not be connected to wires through which electrical current is flowing. Insert the clamp-type amperemeter into the battery positive terminal lead with the arrow on the clamp pointing towards the battery positive terminal (+).
Page 286 Diagnostic instruments If the measured current is a positive quantity, it means that generator is feeding all electric items and charging 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.
Page 287 Diagnostic instruments 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...
Page 288 Diagnostic instruments Pressure test Cylinder compression Actuators Guided diagnosis Select system Errors Clamp-type amperemeter...
Page 289 7 - Impianto elettrico 07 - Impianto elettrico 1 - Front wheel Removal of the front wheel 6 Overhauling the front wheel 8 Refitting the front wheel 10 2 - Rear wheel Removal of the rear wheel 14 Overhauling the rear wheel 15 Refitting the rear wheel 16 3 - Front brake control Removal of the front brake master cylinder 19...
Page 290 7 - Impianto elettrico 8.2 - Handlebar unit: clutch lever Removal of the clutch master cylinder assembly 75 Refitting the clutch master cylinder assembly 76 Removal of the clutch transmission unit 78 Refitting the clutch transmission unit 79 9 - Gearchange mechanism Removal of the gearchange control 85 Disassembly of the gearchange control 86 Refitting the gearchange mechanism 87...
Page 291 7 - Impianto elettrico Removal of the rear subframe 171 Checking the frame 173 Reassembly of the rear subframe 174 Refitting the rear subframe 176 18 - Tail light-number plate holder and locks Removal of the tail light-protection-number plate holder assembly 178 Refitting the tail light-protection-number plate holder assembly 182 Removal of the seat release mechanism 186 Refitting the seat release mechanism 187...
Page 292: Front Wheel
Front wheel 1 -Front wheel 1 Nut 2 Screw 3 Left spacer 4 Sealing ring 5 Bearing 6 Inner spacer 7 Valve 8 Front wheel shaft 9 Front wheel rim 10 Right spacer 11 Phonic wheel* Spare parts catalogue FRONT FORKS FRONT AND REAR WHEELS 796 ABS FRONT FORKS...
Page 293: Overhauling The Front Wheel
Front wheel Support the bike so that the front wheel is raised from the ground. Remove the front brake calliper (B) by unscrewing the two screws (A) securing the calliper to the fork leg; do not disconnect the calliper from the hose. Warning Do not operate the brake lever when the callipers are removed.
Page 294 Front wheel Overhauling the front wheel bearings Before checking the dimensions, check the wear on wheel bearings. Check for wear by hand after cleaning and degreasing the bearings in their seats. Turn the inner race. Check the amount of radial and axial play. Excessive play will cause vibration and make the bike unstable;...
Page 295: Refitting The Front Wheel
Front wheel Check the wheel shaft for straightness. Turn the pin on a reference surface and measure maximum distortion using a feeler gauge (see Sect. 3 - 1.1, Front wheel). Maximum permissible distortion: 0.05 mm. The surfaces of the shaft must be free of any cracks, dents, scoring or any signs of damage, however light. Localised polished areas are permitted.
Page 296 Front wheel Fit the front wheel between the fork legs, installing spacer (10) in-between wheel hub and right-hand fork bottom end, and spacer (3) in-between wheel hub and left-hand fork bottom end. Warning Position the front wheel considering that arrow (E), marked on wheel left-hand side, indicates direction of rotation when running.
Page 297 Front wheel Grease the thread and the underside of the head of shaft nut (1), then screw it onto the end of the wheel shaft. Tighten the nut (1) to a torque of 63 Nm ±5% (Sect. 3 - 3, Frame torque settings).
Page 298 Front wheel...
Page 299: Rear Wheel
Rear wheel 2 -Rear wheel 1 Right-hand wheel nut 2 Washer 3 Bush 4 Valve 5 Wheel 6 Circlip Spare parts catalogue FRONT AND REAR WHEELS 796 ABS FRONT AND REAR WHEELS 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.
Page 300: Overhauling The Rear Wheel
Rear wheel Remove the rear wheel from the motorcycle. Overhauling the rear wheel Inspect the condition of the rear wheel. As the rear wheel has no bearings, it should be supported on the service tool part no. 88713.1073. Note This service tool can also be used to install the wheel on a balancing machine. Overhauling the wheel Inspect the wheel as follows: Visually inspect the wheel for cracks, scoring and deformation;...
Page 301 Rear wheel Refitting the rear wheel Clean the mating surfaces and lubricate the threaded end of the wheel shaft with the recommended grease. Fit the rear wheel centring it in the shaft and engaging pegs (A) into holes (B) on wheel. Apply the recommended grease to the threads of the pin and of the nut (1).
Page 302 Rear wheel Operations Section reference Check the AIR-GAP G 9.3, Adjusting of the AIR-GAP phonic wheel sensor...
Page 303: Front Brake Control
Front brake control 3 -Front brake control 1 Front brake master cylinder 2 Lever with grub screw 3 Rubber pad 4 Bracket 5 Microswitch 6 Lever pivot pin 7 Left brake calliper 8 U-bolt 9 Fluid reservoir cover 10 Inspection plug (replacement part) 11 Screw 12 Sealing washer 13 Banjo bolt...
Page 304 Front brake control FRONT BRAKE FRONT AND REAR WHEELS 796 ABS FRONT BRAKE 796 ABS FRONT AND REAR WHEELS 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.
Page 305 Front brake control Refit the U-bolt (11) on the handlebar and insert the screws (8). Locate the pipe (14) and the gaskets (12) on the master cylinder unit (1) and secure with the special screw (15), but do not tighten at this stage. Tighten the retaining screws (11) to a torque of 10 Nm ±10% (Sect.
Page 306 Front brake control Operations Section reference Fill the brake circuit 4 - 3, Filling the brake system with fluid Refit the rear-view mirrors 5 - 1, Refitting the rear-view mirrors Maintenance operations Warning Brake fluid is corrosive and will damage paintwork. Avoid contact with eyes and skin. In case of accidental contact, wash the affected area with abundant running water and consult a doctor if necessary.
Page 307 Front brake control Loosen the screw (16) and slide the pipe (14) from the bracket (4) on the bottom yoke. Warning While removing the front brake hose, if you damage the hose clip (B) you shall renew it (Sect. 5 - 4, Removal of the front mudguard).
Page 308 Front brake control For correct position of the ties fastening the ABS sensor cable (A) to front brake lines, please refer to Sect. 7 - 6, Flexible wiring/hoses positioning. Removal of the brake discs Operations Section reference Remove the front wheel 7 - 1, Removal of the front wheel The front brake discs consist of an inner carrier, which is mounted to the wheel, and an outer rotor.
Page 309 Front brake control Refitting the front brake system When refitting the system, pay attention to the orientation of the couplings of the hoses (14) and (24).
Page 310 Front brake control 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 the calliper or master cylinder, make sure to install the sealing washers (12) either side of the hose end fitting.
Page 311 Front brake control Operate the front brake lever two or three times until the circuit is pressurised and force the pads against the brake disc. Hold the lever pulled in towards the grip and tighten the calliper screws (7) to a torque of 45 Nm ± 5% (Sect. 3 - 3, Frame torque settings).
Page 312 Rear brake control 4 -Rear brake control 1 Banjo bolt 2 Sealing washer 3 Rear brake hose 4 Hose clip 5 Pin 6 Spring 7 Adjuster screw 8 Rubber pad 9 Brake lever 10 Nut 11 Quick-release fastener 12 Washer 13 Switch 14 Bush 15 Fork...
Page 313 Rear brake control Spare parts catalogue REAR BRAKE 796 ABS REAR BRAKE 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. Removal of the rear brake lever Warning The brake master cylinder manufacturer advises against servicing the brake master cylinder due to the safety critical nature of this component.
Page 314 Rear brake control 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). Disassembly of the rear brake control The brake master cylinder is supplied only as a complete unit; internal components cannot be replaced. To disassemble master cylinder external components, follow the indications given in the exploded view at the beginning of this section.
Page 315 Rear brake control in Sect. 4 - 3, Adjusting the position of the gear change and rear brake pedals. Refitting the rear brake control Lubricate the O-ring (24) and install it on the pin (5). Lubricate also the other O-ring (24). Fit the spring (6) and the rotation pivot pin (5) to the footrest bracket, pushing the pivot pin fully home and positioning the spring (6) as shown in the figure.
Page 316 Rear brake control If the pushrod (19), clip (11) and fork (15) assembly has been dismantled, reassemble by screwing the nut (25) onto the pushrod (19) and then screw the pushrod into the clevis (15) to obtain the measurement indicated in the figure. Restrain the pushrod and tighten the nut (25) against fork (15) to a torque of 7.5 Nm ±10% (Sect.
Page 317 Rear brake control 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 clamp (C).
Page 318 Rear brake control Important The brake master cylinder manufacturer advises against servicing the brake master cylinder due to the safety critical nature of this component. Incorrect overhaul of this component could endanger rider safety. Operations should be limited to renewal of the pads, fasteners and the bleed valve assembly. Operations Section reference Draining the brake system...
Page 319 Rear brake control Only the following parts should be renewed: brake calliper: 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 replace the speed wheel sensor (796 ABS) please refer to section 7-6 “Replacing the rear phonic wheel sensor“.
Page 320 Rear brake control Fit the copper sealing washers (2) to either side of the hose end fitting when connecting the brake hose to the brake calliper. Orientate the end fittings of the hose (6) on the calliper as shown in the photo. Tighten the special screws (1) to a torque of 23 Nm ±10% (Sect.
Page 321 Rear brake control Tension the chain 4 - 3, Adjusting the chain tension Fill the brake circuit 4 - 3, Filling the brake system with fluid...
Page 322: Operating Principle
Operating principle The Ducati ABS brake system manages the front and rear brakes separately. A pulse generator (phonic wheel), with a ring of slots, is fixed onto each wheel. On the left calliper mounting bracket of the front fork and on the rear brake calliper holder plate are HALL effect sensors which detect the full sections and voids on the phonic wheel as the vehicle moves, providing and instantaneous wheel speed reading.
Page 323 ABS system information fault warning indicator on the instrument panel and restores conventional braking functionality without ABS. Hydraulic faults in the brake system and faults not directly related to the ABS system (e.g.: worn brake pads) cannot be detected by the ABS control unit. Important The response of the system is based on the values read for the front and rear wheel speeds;...
Page 324: Abs System Deactivation
ABS system information The abbreviations for all the errors displayed are given as follows: Errors Description Front ABS speed sensor signal Disconnected/short circuit to GND/short circuit to Uz of rear wheel speed sensor Plausibility of signal from front Front wheel speed sensor fault – Plausibility wheel speed sensor Rear speed sensor signal Disconnected/short circuit to GND/short circuit to Uz of front wheel speed...
Page 325: System Components
System components 6 - System components 1 Screw 2 ABS / speed sensor (Front) 3 Sealing washer 4 ABS / speed sensor mount (Front) 5 Speed sensor / ABS (Rear) 6 ABS control unit 7 Front pump - control unit pipe 8 Control unit - front calliper pipe 9 Rear pump - control unit pipe 10 Control unit - rear calliper pipe...
Page 326: Replacing The Front Phonic Wheel Sensor
System components Replacing the front phonic wheel sensor Disconnect the front ABS sensor (2) connector (A) from the main electric wiring. Open all the retainer clamps of the front ABS sensor cable (2): refer to the tables in Sect. 7 - 6, Flexible wiring/hoses positioning.
Page 327: Replacing The Rear Phonic Wheel Sensor
System components Connect the connector (A) to the main wiring. Restore all the retainer clamps of the front ABS sensor cable (2): refer to table of Sect. 7 - 6, Flexible wiring/hoses positioning. Replacing the rear phonic wheel sensor Remove the right-hand footrest bracket (Sect. 7 - 15, Removal of the footrest brackets).
Page 328: Removing Of The Abs Control Unit
System components Refit the right-hand footrest bracket (Sect. 7 - 15, Refitting the footrest brackets). Removing of the ABS control unit Operations Section reference Remove the seat 5 - 3, Removal of the seat Remove the fuel tank 8 - 2, Removal of the fuel tank Drain the brake fluid in the pipes disconnecting these from the cylinder and from the calliper (Sect.
Page 329: Refitting The Abs Control Unit
System components Refitting the ABS control unit When refitting the system, pay attention to the orientation of the couplings of the hoses (7), (8), (9) and (10). Warning If incorrectly positioned, the hose can affect brake operation and foul moving parts. Position the hose as shown in the figure.
Page 330: Flexible Wiring/Hoses Positioning
System components To fill up the system, carry out the instructions for replacement of fluid of the pump or calliper to which the pipe is connected (Sect. 4 - 3, Filling the brake system with fluid). Important If the ABS control unit is replaced, this must be supplied with secondary circuit already full of fluid; the control unit must be fitted and the system filled and bled as a traditional system.
Page 331 System components Table B...
Page 332 System components Table C...
Page 333 System components...
Page 334 System components Table D...
Page 335 System components Table E...
Page 336 System components...
Page 337 System components...
Page 338 System components Table F...
Page 339 System components...
Page 340 System components...
Page 341: Abs Components Maintenance
ABS components maintenance 7 -ABS components maintenance Adjusting of the AIR-GAP phonic wheel sensor (For front as well as rear sensor) In each case of maintenance that foresees: - replacement or refitting of the wheel - replacement or refitting of the phonic wheel (1) or (2) - replacement or refitting of the brake discs - replacement or refitting of the speed sensor (3) or (4) - (front) replacement or refitting of the sensor holder bracket...
Page 342: Bleeding Of The Abs Hydraulic System
ABS components maintenance Bleeding of the ABS hydraulic system If some “sponginess” is detected on the brake control, due to air bubbles in the system, bleed the system, as indicated in Sect. 4 - 3, Changing the brake fluid. Before bleeding a brake master cylinder, move back the calliper pistons, as indicated in (Sect. 4 - 3, Filling the brake system with fluid) to drain in the pump the air collected near the ABS control unit...
Page 343 ABS components maintenance...
Page 344: Handlebar Unit: Throttle Twistgrip
Handlebar unit: Throttle twistgrip 8.1 -Handlebar unit: Throttle twistgrip 1 Upper clamp 2 Plug 3 Screw 4 Handlebar 5 Grips 6 Throttle twistgrip 7 Cover 8 Screw 9 Screw 10 Throttle cable 11 Throttle cable adjuster on handlebar 12 Throttle cable adjuster on throttle body Spare parts catalogue HANDLEBAR AND CONTROLS 796 ABS...
Page 345: Refitting The Handlebar
Handlebar unit: Throttle twistgrip switches devices Remove the front brake lever 7 - 3, Removal of the front brake master cylinder Remove the clutch lever 7 - 8.2, Removal of the clutch master cylinder assembly Unscrew and remove the screws (3) securing the upper clamp (1). Remove the upper clamp (1).
Page 346: Adjusting The Throttle Cable
Handlebar unit: Throttle twistgrip master cylinder Refit the right-hand and left-hand 6 - 5, Checking the indicating handlebar switches devices Refit the throttle twistgrip 7 - 8.1, Refitting the throttle twistgrip Refit the clutch lever 7 - 8.2, Refitting the clutch master cylinder assembly Adjusting the throttle cable To operate on the set screws of the throttle grip cables, consult Sect.
Page 347: Refitting The Throttle Twistgrip
Handlebar unit: Throttle twistgrip Remove the throttle cable (10) from the vehicle. Remove the plug (2) from the handlebar. Loosen the two screws (9) fixing the throttle twistgrip to handlebar. Remove the throttle twistgrip (6) from the handlebar. Refitting the throttle twistgrip To refit 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.
Page 348 Handlebar unit: Throttle twistgrip Note Refer to the tables on the next page for correct routing of the throttle grip cable.
Page 349: Handlebar Unit: Clutch Lever
Handlebar unit: clutch lever 8.2 -Handlebar unit: clutch lever 1 Clutch master cylinder 2 Inspection plug (replacement part) 3 Lever pivot pin 4 Lever with grub screw 5 Fluid reservoir cover 6 Clutch hose 7 Mounting clamp 8 Sealing washer 9 Banjo bolt 10 Banjo bolt 11 Bleed valve...
Page 350: Removal Of The Clutch Master Cylinder Assembly
Handlebar unit: clutch lever 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. Removal of the clutch master cylinder assembly Warning The clutch master cylinder manufacturer advises against servicing of the clutch master cylinder (1) due to the safety- critical nature of this component.
Page 351 Handlebar unit: clutch lever Tighten the fixing screws (7) to a torque of 10 Nm ±10% (Sect. 3 - 3, Frame torque settings) following the sequence 1-2- 1 starting from the upper 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.
Page 352: Removal Of The Clutch Transmission Unit
Handlebar unit: clutch lever Operations Section reference Fill the clutch circuit 4 - 3, Filling the clutch circuit Refit the LH mirror 5 - 1, Refitting the rear-view mirrors Removal of the clutch transmission unit Warning The clutch slave cylinder manufacturer advises against servicing of internal components of clutch slave cylinder(23) due to the safety critical nature of this component.
Page 353: Refitting The Clutch Transmission Unit
Handlebar unit: clutch lever them, if necessary. Note If the two O-rings (17) need to be replaced, it is necessary to replace also the O-ring (13) of the unit (14). Refitting the clutch transmission unit Note If the clutch pushrod (16) is replaced, it is necessary also to replace the O-rings (17) and (13) of the unit (14). Grease and refit the clutch pushrod (16) with the two O-rings (17).
Page 354 Handlebar unit: clutch lever Warning An incorrectly positioned hose can cause clutch faults and interfere with moving parts. Position the two gaskets (8) and tighten the screw (10) to a torque of 23 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Page 355 Handlebar unit: clutch lever...
Page 356 Handlebar unit: clutch lever...
Page 357 Handlebar unit: clutch lever...
Page 358: Gearchange Mechanism
Gearchange mechanism 9 -Gearchange mechanism 1 Bolt 2 Gearchange pedal 3 Screw 4 Rubber pad 5 Bush 6 Washer 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...
Page 359: Disassembly Of The Gearchange Control
Gearchange mechanism 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. Note 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).
Page 360 Gearchange mechanism In particular, apply threadlocker to the screw (16), the pivot bolt (1) and the screw (15) and then tighten them to the specified torque (Sect. 3 - 3, Frame torque settings). - the screws (15) and (16) to a torque of 10 Nm ±10%; - the pivot bolt (1) to a torque of 24 Nm ±10%.
Page 361: Fork - Steering Head: Front Fork
Fork - steering head: front fork 10.1 - Fork - steering head: front fork 1 Right fork leg assembly 2 Left fork leg assembly 3 Banjo bolt 4 Washer 5 Screw 6 Right inner tube assembly 7 Plug 8 Damper tube 9 Spring 10 Spacer 11 Joint...
Page 362: Removal Of The Front Forks
Fork - steering head: front fork 796 ABS HANDLEBAR AND CONTROLS 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. Removal of the front forks Before removing the front forks, it is first necessary to remove the following parts: Operations Section reference...
Page 363 Fork - steering head: front fork Unscrew the top cap (7). Remove the filler cap assembly (7). Fit the service tool part no. 88713.0957, engaging its pins (A) in the spring retainer holes, 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).
Page 364 Fork - steering head: front fork Push downwards to overcome the force of the spring and remove the spacer (C). Remove the service tool part 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 leg. Warning This movement generates pressure so that the oil will be rapidly expelled from the fork leg.
Page 365 Fork - steering head: front fork 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).
Page 366 Fork - steering head: front fork To separate the outer tube (18) from 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)
Page 367 Fork - steering head: front fork 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 leg. Aim the jet of oil into a previously prepared container and avoid contact with fork oil.
Page 368 Fork - steering head: front fork Important Take care not to damage the outer tube (18) or inner tube (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).
Page 369 Fork - steering head: front fork Service 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.
Page 370 Fork - steering head: front fork This distance should be 81 mm. Clean off any oil from spring (9) and spring retainer (12) before assembly. Note Install the spring (9), ensuring that the end with tighter coils is towards the bottom of the fork. Fit the following components: - spring (9);...
Page 371 Fork - steering head: front fork Inspection of the front fork left leg Place the spring on a flat surface and measure the free length (L). Service 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.
Page 372 Fork - steering head: front fork Note 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.
Page 373: Refitting The Front Forks
Fork - steering head: front fork Refitting the front forks Refit the fork legs, positioning them at the height shown in the figure relative to the upper surface of the bottom yoke. Position the legs (2) and (1). If they were removed, grease the thread and the underside of the screws (24) and (25) and place them in their seats.
Page 374: Fork - Steering Head: Steering
Fork - steering head: Steering 10.2 - Fork - steering head: Steering 1 Screw 2 Steering head 3 Screw 4 Lower U-bolt 5 Bearing 6 Bearing 7 Screw 8 Sealing ring 9 Nut 10 Spacer 11 Washer 12 Nut 13 Washer 14 Screw 15 Bottom yoke 16 Dowel...
Page 375: Adjusting The Steering Head Bearings
Fork - steering head: Steering HEADLIGHT 796 ABS HANDLEBAR AND CONTROLS 796 ABS HEADLIGHT 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. Adjusting the steering head bearings Note To adjust the steering bearing clearance, follow what is described in Sect.
Page 376: Removal Of The Steering Head Components
Fork - steering head: Steering Turn the front forks to the right until the spacer (A) is seated against the frame top tube. Turn the adjuster screw (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).
Page 377 Fork - steering head: Steering Note In the “ABS“ version the hose clip marked with an arrow is not present. Loosen the screw (3) securing the steering head (2) to the steering head nut (12). Remove the steering head (2). With the service tool no.
Page 378 Fork - steering head: Steering 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.
Page 379 Fork - steering head: Steering Reassembly of the steering head If the spacers (10) were removed from the steering head, lubricate with silicone spray. Seat the spacers (10) square in the bores (D) in the steering head, 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 steering head.
Page 380 Fork - steering head: Steering Locate the lower clamp (4) on the steering head. Fit the screws (7) complete with the washers (11) in the lower clamp (4). Insert the washers (11) on the screws (7) and start the nuts (9) in their threads. Tighten the nuts (9) to a torque of 45 Nm ±5% (Sect.
Page 381: Refitting The Steering Head Components
Fork - steering head: Steering Refitting the steering head components Important The steering head bearings (5) and (6) are identical but in no case may their components be swapped around during reassembly. Clean all contact surfaces and lubricate with the recommended grease. To fit the outer rings (C) of the bearings (5) and (6) to the steering head, use the service tool no.
Page 382 Fork - steering head: Steering Insert the washer (13), sealing ring (18) (with the rim facing upwards) and inner ring (L) of bottom bearing (6) onto the steering shaft after heating it for about 10 minutes to 120 °C. Insert the tool code 88713.1072 into the steering pin. Push the inner ring (L) on the sealing ring (18), manually pushing for at least 10-15 seconds.
Page 383 Fork - steering head: Steering Grease the nut (12). Tighten the steering shaft nut (12) by hand until it seats against the sealing ring (8). Fit service bush no. 88713.1058 to the steering shaft nut (12) and fit the torque wrench to the bush. Tighten the adjuster ring nut (12) to a torque of 30 Nm ±5% (Sect.
Page 384 Fork - steering head: Steering Operations Section reference Refit the fork legs 7 - 10.1, Refitting the front forks Reassembling the handlebar on the 7 - 8, Refitting the handlebar steering head Refit the front wheel 7 - 1, Refitting the front wheel Refit the front mudguard 5 - 4, Refitting the rear mudguard...
Page 385: Rear Shock Absorber Assembly
Rear shock absorber assembly 12 - Rear shock absorber assembly 1 Shock absorber 2 Screw 3 Shock absorber mounting 4 Nut 5 Screw 6 Nut Spare parts catalogue REAR SUSPENSION 796 ABS REAR SUSPENSION 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.
Page 386: Overhauling The Rear Shock Absorber
Rear shock absorber assembly Overhauling the rear shock absorber Before dismantling the shock absorber, measure the spring preload length (L). The same length must be restored on re- assembly. Disassembly of the rear shock absorber Remove the shock absorber mounting (3) while holding the screw (2) and unscrewing the nut (4).
Page 387 Rear shock absorber assembly Slacken off lock nut (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. Reassembly of the rear shock absorber Fit the spring into its seat in the shock absorber with the tapered end towards the lower mounting.
Page 388: Refitting The Rear Shock Absorber
Rear shock absorber assembly Refit the shock absorber mounting (3) inserting the screw (2) and screwing on the nut (4). Note Insert the screw (2) from the side on which the adjuster screw (C) is located. Tighten the nut (4) to a torque of 42 Nm ±5% (Sect. 3 - 3, Frame torque settings) while holding the screw (2).
Page 389 Rear shock absorber assembly Tighten the screw (5) and the nut to a torque of 42 Nm ±5% (Sect. 3 - 3, Frame torque settings). Refit the seat (Sect. 5 - 3, Refitting the seat).
Page 390: Rear Swingarm
Rear swingarm 13 - Rear swingarm 1 Swingarm pivot 2 Pin 3 Screw 4 Rear swingarm 5 Banjo bolt 6 Washer 7 Upper drive chain slider 8 Lower drive chain slider 9 Screw 10 Circlip 11 Vibration damper 12 Lower protection 13 Upper protection 14 Washer 15 O-ring...
Page 391: Removal Of The Rear Wheel Eccentric Hub And Rear Wheel Shaft
Rear swingarm 32 Pin 33 Screw 34 Screw 35 Rubber block* 36 Hose clip* 37 Spacer* 38 Hose clip* 39 Rubber block* 40 Spacer* Spare parts catalogue REAR WHEEL AXLE SWINGARM 796 ABS REAR WHEEL AXLE 796 ABS SWINGARM 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.
Page 392: Removal Of The Rear Brake Disc
Rear swingarm Loosen screws (24) and take the speed sensor cable (C) off the swingarm. Remove the washer (14) and the calliper mounting bracket (16) with the two O-rings (15). Remove the other washer (14). Withdraw the eccentric hub (17) from the chain side of the swingarm. Note The rear hub is a component particularly critical to the dynamic safety of the motorcycle.
Page 393: Refitting The Rear Brake Disc
Rear swingarm Undo and remove the four fixing screws (34) of the brake disc to the wheel shaft and remove the rear brake disc (26). If they are to be renewed, undo the screws (33) from the wheel shaft (27) and remove the locating pins (32). The brake disc must be perfectly clean, with no rust, oil, grease or other dirt and no deep scoring.
Page 394: Refitting The Rear Wheel Eccentric Hub And Rear Wheel Shaft
Rear swingarm Refitting the rear wheel eccentric hub and rear wheel shaft If the calliper bracket locating pin (2) was removed during disassembly, apply the recommended threadlocker upon reassembly, fit it on the swinging arm and tighten to a torque of 33 Nm ±5% (Sect. 3 - 3, Frame torque settings).
Page 395 Rear swingarm Fit the first washer (14) on the eccentric hub. Position the calliper mounting bracket (16) setting it as shown in the figure. Refit the other washer (14) and tighten the calliper mounting bracket (16) after installing circlip (19) in its groove (E) on hub, and setting it with its cutting edge outward.
Page 396 Rear swingarm Evenly apply the recommended grease to the thread (M) of the pin (27). Fit the rear wheel shaft (27) to hub fully home. Fit the inner bush (18) on wheel shaft (27), and position it so as the taper end is facing the shaft, as shown, then tighten the screws (3) to a torque of 31 Nm ±5% (Sect.
Page 397: Removal Of The Swingarm
Rear swingarm Fit the rear brake calliper (A) over the brake disc, aligning it with the holes in the calliper mounting bracket. Grease the threads and undersides of the heads of the screws (B). Tighten the screws (B) to a torque of 25 Nm ±5% (Sect. 3 - 3, Frame torque settings).
Page 398 Rear swingarm Remove the rear wheel eccentric hub as described in chapter “Removal of the rear wheel eccentric hub and rear wheel shaft” of this section. Free the rear brake hose and the speed sensor wiring from the lower chain slider (8) and from the upper protection (13) and lower protection (12) by unscrewing the screws (9).
Page 399 Rear swingarm Any abnormal movement is a sign of worn bearings that could cause instability when riding. To check the free play of the support bearings, refer to Sect. 7 - 1, Overhauling the front wheel bearings. Once the play in the swingarm bearings has been checked, the swingarm (4) may be removed from the motorcycle. Undo and remove the screws (9) to remove the upper chain slider (7) from the swingarm (4).
Page 400: Inspecting The Swingarm Pivot
Rear swingarm Inspecting the swingarm pivot Measure the swingarm pivot shaft (1) runout using a dial gauge: - place the pivot shaft (1) on two reference blocks of the same size; - rotate the shaft and move the gauge horizontally; - read off the runout.
Page 401: Refitting The Swingarm
Rear swingarm The maximum permissible end float is 0.1 mm. When a 0.10 mm feeler gauge or shim can only be 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 end float. Example: Measured end float Shims on left-hand side.
Page 402 Rear swingarm Refit the upper chain slider (7) to the swingarm starting the screws (9) in their thread. Tighten the screws (9) to a torque of 5 Nm ±10% (Sect. 3 - 3, Frame torque settings) in the mentioned sequence. Fasten the rear brake hose and the speed sensor wiring to swingarm (4) installing the lower chain slider (8), the upper protection (13) and lower protection (12), and starting the screws (9) in their thread.
Page 403 Rear swingarm Note In the ABS version place the hose clip (36) and the spacer (37) as shown in the figure. Note In the ABS version make sure that the speed sensor cable (A) is placed to the “right“ of the rib present inside the chain slider (8) or (13), as shown in the figure.
Page 404 Rear swingarm Operations Section reference Refit the footrests 7 - 15, Refitting the footrest brackets Refit the shock absorber to 7 - 12, Refitting the rear shock swinging arm absorber Refit the rear sprocket 7 - 14, Refitting the rear sprocket Refit the rear wheel 7 - 2, Refitting the rear wheel...
Page 405: Final Drive
Final drive 14 - Final drive 1 Screw 2 Sprocket stop plate 3 Front sprocket 4 Chain 5 Screw 6 Front sprocket cover 7 Rear sprocket (Z=39) 8 Nut 9 Washer 10 Nut 11 Rear sprocket flange 12 Cush drive bush 13 Bush 14 Bush 15 Spacer...
Page 406: Inspecting The Final Drive
Final drive 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. Inspecting the final drive To check the wear of the final drive, visually check the pinion (3) and sprocket (7). If the teeth are found to worn as shown in the figure (dotted line), the sprocket must be renewed.
Page 407 Final drive Remove the chain with the tool code 88713.1344. The tool is composed of a holder (A), punch (B), body (C) and two wrenches (D) and (E). Fit the link to be opened into the holder (A). Fit a punch (B) into the body (C) and manually unscrew the screw until the punch no longer protrudes. Fit the holder (A) and link into the body (C).
Page 408: Refitting The Front Sprocket
Final drive Refitting the front sprocket Check that the splines of the gearbox secondary shaft and the sprocket are in perfect condition. Hook the chain (4) onto the sprocket (3). Fit the sprocket on the gearbox secondary shaft (G), as shown in the figure, and push it past the groove (H). Insert the stop plate (2) on the gearbox secondary shaft (G) and turn it inward past the groove (H) until the plate (2) holes coincide with the threaded holes on the sprocket (3): position the retaining plate with the rounded edge facing the sprocket.
Page 409: Replacing Of The Rear Sprocket
Final drive Use wrenches (D) and (E) to turn the bolt clockwise until the punch (B) is seated against the chain plate. To complete reassembly, repeat the entire procedure with the second pin. Warning Carefully check the two pins: the figure shows the correct result of the procedure. Adjust the chain tension (Sect.
Page 410: Refitting The Rear Sprocket
Final drive Fully unscrew the nut (8) and remove the washer (9) and the flange (11) with the sprocket (7). Recover the spacer with collar (15). Using a mallet, tap the sprocket flange (11) with the cush drive bushes (12) off the sprocket (7). Refitting the rear sprocket Check the cush drive bushes (12) for signs of wear and, if necessary, remove from the sprocket flange and renew them.
Page 411: Washing The Chain
Final drive To refit nut (8) and clip (18) retaining the rear sprocket flange, follow the same specifications given for the wheel nut, in Sect. 7 - 2, Refitting the rear wheel. Operations Section reference Refit the rear wheel 7 - 2, Refitting the rear wheel Tension the chain 4 - 3,...
Page 412: Footrest Brackets
Footrest brackets 15 - Footrest brackets 1 Vibration damper 2 Washer 3 Screw 4 Pin 5 Ring 6 Spring 7 Right front footrest 8 Right footrest bracket 9 Ball 10 Plate 11 Screw 12 Spring 13 Right rear footrest 14 Left front footrest 15 Left footrest bracket 16 Left rear footrest 17 Washer...
Page 413: Removal Of The Footrest Brackets
Footrest brackets the exploded view diagram. Removal of the footrest brackets The following removal operations apply to both left and right footrests. To remove the right-hand footrest, unscrew the screws (A) while holding the nut (B) and remove the rear brake fluid reservoir (C).
Page 414 Footrest brackets 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). To 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).
Page 415: Refitting The Footrest Brackets
Footrest brackets The procedure is the same for the LH footrest. Note The footrest may also be removed with the footrest bracket installed on the motorcycle. Refitting the footrest brackets The refitting operations described below apply to both footrest brackets. To reassemble the 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.
Page 416 Footrest brackets Locate the spring (12), the plates (10), the ball (9) and RH rear footrest (13) between the lugs on the RH footrest bracket (8). Note Drilled plate (10) shall be installed with hole countersink (L) facing the rear footrest.
Page 417 Footrest brackets 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.
Page 418 Footrest brackets Smear the seats (N) of screws (11) and (18) with lubricant. Locate them in correspondence with the threaded holes in the frame and the crankcase. Important When refitting the LH footrest bracket (15), position the washers (2) in correspondence with the fixings on the engine crankcase.
Page 419 Footrest brackets Refit the brake master cylinder (E) tightening the screws (F) to a torque of 23 Nm ±10% (Sect. 3 - 3, Frame torque settings). Position the rear brake sensor (H) of main wiring harness onto plate (8) with copper washer (M) in-between. Insert the rear brake pushrod (G) in the rear brake master cylinder (E).
Page 420 Footrest brackets Fix the gearbox control unit to the crankcase, applying threadlocker to the screw (D) and tightening it to a torque of 10 Nm ±10% (Sect. 3 - 3, Frame torque settings). Refit rear brake reservoir (C) and tighten the screw (A) to a torque of 2 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Page 421: Stands
Stands 16 - Stands 1 Side stand 2 Screw 3 Support plate 4 Screw 5 Switch 6 Inner spring 7 Spring assembly 8 Plate 9 Pivot screw 10 Nut Spare parts catalogue STANDS 796 ABS STANDS 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.
Page 422 Stands Loosen the screw (B) and release the LH footrest bracket (C) from the engine block. Unscrew and remove the screw (A) securing the LH footrest bracket (C) to the engine. Unscrew the screw (2) securing the side stand bracket (3) to the engine and remove the complete side stand assembly. Disassembly of the side stand Unscrew the retaining screw (4) and remove the side stand switch (5).
Page 423: Refitting The Side Stand
Stands Grease the side stand leg (1) and fit it to the bracket (3). Secure it with the pivot screw (9) and the nut (10). Tighten the nut (11) to a torque of 20 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Page 424 Stands...
Page 425: Frame Inspection
Frame inspection 17 - Frame inspection 1 Frame 2 Clamp 3 Nut 4 Clearance adjuster 5 Nut 6 Banjo bolt 7 Rear subframe (right) 8 Plate 9 Screw 10 Rear subframe (left) 11 Nut 12 Screw 13 Pin 14 Special nut 15 Bracket 16 Spacer 17 Vibration damper mount...
Page 426 Frame inspection 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. Disassembly of structural components and the frame Before carrying out dimensional checks on the frame, you must remove all the superstructures fitted, referring to the removal procedures outlined in the sections of this manual.
Page 427 Frame inspection Removal of the frame...
Page 428 Frame inspection To separate the frame (1) from the rear subframe, unscrew the two special screws (6). On the 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).
Page 429 Frame inspection Loosen the clearance adjuster (4) with ring nut (5) until flush with the inner surface of frame bushes (C). Withdraw the pin (13) from the engine block to release the rear subframe. Apply the 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.
Page 430: Removal Of The Rear Subframe
Frame inspection Removal of the rear subframe Disconnect all the electrical parts connections from subframe (Sect. 6 - 1, Routing of wiring on frame), and remove the silencers (Sect. 8 - 8, Removal of the exhaust system). Remove the frame as specified in the previous paragraph “Removal of the frame”.
Page 431: Checking The Frame
Frame inspection Remove the cable (A) of exhaust valve motor (B) as explained in Sect. 8 - 8, Removal of the exhaust system. Unscrew the screws (9) securing the plate (8) and slide out the plate then separate the rear left-hand subframe from the right-hand side one.
Page 432: Reassembly Of The Rear Subframe
Frame inspection Reassembly of the rear subframe Check that the rubber mountings (A) are installed on the plate (8). Locate the plate (8) on the LH subframe (10) and on the RH subframe (12) and insert the screws (9). Tighten the screws (9) to the specified torque (Sect. 3 - 3, Frame torque settings), in the sequence: 1-2-3-4.
Page 433 Frame inspection Check that the rubber buffer (B), rubber bushes (17) and spacers (16) are installed on the bracket (15). Refit the bracket (15) to the rear subframe with screws (12). While holding the nuts (11), present only on the left-hand side, tighten the screws (12) to a torque of 22 Nm ±10% (Sect.
Page 434: Refitting The Rear Subframe
Frame inspection Refit the rear subframe to the crankcase (Sect. 9 - 1, Refitting the engine). Reconnect all the electrical parts connectors on subframe (Sect. 6 - 1, Routing of wiring on frame), and refit the silencers (Sect. 8 - 8, Removal of the exhaust system).
Page 435: Tail Light-Number Plate Holder And Locks
Tail light-number plate holder and locks 18 - Tail light-number plate holder and locks 1 Splashguard 2 Tail light 3 Number plate holder 4 Right turn signal 5 Left turn signal 6 Plate 7 Screw 8 Screw 9 Washer 10 Screw 11 Bracket 12 nut 13 Reflector...
Page 436: Removal Of The Tail Light-Protection-Number Plate Holder Assembly
Tail light-number plate holder and locks Spare parts catalogue NUMBER PLATE HOLDER - TAIL LIGHT FRAME 796 ABS NUMBER PLATE HOLDER - TAIL LIGHT 796 ABS FRAME 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.
Page 437 Tail light-number plate holder and locks Separate the number plate holder (3) from the spray guard (1) by unscrewing the screws (7). Disconnect the tail light wiring connector (B) from the tail light (2). Disconnect the connector for the rear right-hand turn indicator wiring (C) and rear left-hand turn indicator wiring (D) from the main wiring harness.
Page 438 Tail light-number plate holder and locks Unscrew the screws (22) and remove the tail light (2); recover the quick-release fasteners (23). Removal of the rear turn signals The following operations refer to the left side of the motorcycle, but apply also to the right side. Remove clamp (G) fastening the rear right-hand turn indicator wiring (F) and rear left-hand turn indicator wiring (E).
Page 439: Refitting The Tail Light-Protection-Number Plate Holder Assembly
Tail light-number plate holder and locks Refitting the tail light-protection-number plate holder assembly Refitting the rear turn signals The following operations refer to the left side of the motorcycle, but apply also to the right side. Insert wiring and left-hand turn indicator (5) into the mounting hole on number plate holder (3), positioned with the drain slot (H) facing down, as shown below.
Page 440 Tail light-number plate holder and locks Connect the rear turn indicator wiring connector to the right (C) and to the left (D) to the rear wiring and place them inside the specific splashguard (1) housings. Refit clamp (G) fastening the rear right-hand turn indicator wiring (F) and rear left-hand turn indicator wiring (E). Note Never fully tighten clamp (E), leave a slight gap allowing for the free sliding of the two cables, as shown.
Page 441 Tail light-number plate holder and locks Install the number plate holder (3) to the splashguard (1) then tighten the screws (7) to a torque of 3.5 Nm ±10% (Sect. 3 - 3, Frame torque settings). Place the latch (31) beneath the plate (24), at the “lowest“ position with respect to the slots on the plate, as shown in the figure.
Page 442: Removal Of The Seat Release Mechanism
Tail light-number plate holder and locks Refit the tail light - number plate holder assembly to the rear subframe, inserting it as shown in the photo. Fit and tighten the four screws (25) to a tightening torque of 22 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Page 443 Tail light-number plate holder and locks previous paragraph. Separate the spray guard (1) from the number plate holder (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).
Page 444 Tail light-number plate holder and locks Fit the lock lever (29) inserting the lugs (C) in the slots (E) as shown in the figure. Start the nut (28) in its thread onto seat lock (27) and tighten it to a torque 3 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Page 445 Tail light-number plate holder and locks Refit the cable end fitting (B) in the lock lever (29) and end fitting (A) in the latch (31). Refit the splashguard (1) on the number plate holder (3) tightening the screws (7) to a torque of 3.5 Nm ±10% (Sect. 3 - Frame torque settings).
Page 446 Tail light-number plate holder and locks Unscrew the screws (16) and remove the plate (6). Note On the USA version, the plate (6) has a different design and there is a bracket with side reflectors (13). Refitting the number plate holder For the Australia version, set gravel guard (32) between splashguard (1) and number plate holder (6), and fit spacers with collar (34) in-between the two guards.
Page 447 Tail light-number plate holder and locks...
Page 448 8 - Impianto elettrico 08 - Impianto elettrico 2 - Fuel tank Removal of the fuel tank 4 Removal of the fuel tank filler cap 7 Refitting the filler cap 7 Removal of the fuel tank flange 8 Refitting the fuel tank flange 9 Refitting the fuel tank 10 6 - Throttle body Removal of the throttle body 20...
Page 449: Fuel Tank
Fuel tank 2 -Fuel tank 1 Fuel tank 2 Filler cap 3 Screw 4 Hose 5 Y-fitting 6 Breather hose 7 Hose 8 Rubber pad 9 LH bracket 10 Banjo bolt 11 Rubber pad 12 RH bracket 13 Banjo bolt 14 Washer 15 Rubber pad 16 Guide...
Page 450: Removal Of The Fuel Tank
Fuel tank 33 Washer 34 Heat shield 35 Set of locks Spare parts catalogue FUEL TANK FUEL SYSTEM 796 ABS FUEL TANK 796 ABS FUEL SYSTEM 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.
Page 451 Fuel tank 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 (G) from tank flange cover.
Page 452: Removal Of The Fuel Tank Filler Cap
Fuel tank Warning Before removing the flange cover (20), make sure the tank (1) is empty and position a rag to collect any spilt fuel. Raise the tank, remove the flange cover (20) by unscrewing the nuts (21) and disconnect the quick-release fittings (29) from the flange.
Page 453: Refitting The Filler Cap
Fuel tank Refitting the filler cap Position seal (32) in tank cap (2) as shown and reassemble following the removal procedure in the reverse sequence. In particular tighten the screws (3) to a tightening torque of 3 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Page 454: Refitting The Fuel Tank Flange
Fuel tank Refitting the fuel tank flange Insert the flange (23) in its housing in the fuel tank. Fit the four screws (28) with threadlocker and tighten them to a torque of 5 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Page 455 Fuel tank Refit the tank by engaging pins (H) on mounting brackets (9) and (12) into their seats on the frame. Smear the O-rings (L) installed on fuel hose couplings (29) with rubber lubricant. While holding the tank in the raised position, connect the quick–release fittings (29) of the fuel outlet hose (18) and return hose (19) to the flange: fit the fuel outlet hose (18), orienting it as shown in the figure, inserting the fitting (29) in its union in the flange (identified with the word “OUT”), until you feel a click;...
Page 456 Fuel tank Refit the cover (20) and start the two nuts (21) onto the two screws (22) then tighten the nuts to a torque of 3 Nm ±10% (Sect. 3 - 3, Frame torque settings). Note When installing cover (20), ensure hoses (18) and (19) and wiring (M) on flange stay inside the cover jut (N). Connect the fuel sensor (F) to the main wiring harness.
Page 457 Fuel tank Secure the tank to the frame with the screw (30) and the washer (31). Tighten the screw (30) to a torque of 10 Nm ±10% (Sect. 3 - 3, Frame torque settings). Secure the tank to the subframe with the screw (13) and the washer (14). Tighten the screw (14) to a torque of 10 Nm ±10% (Sect.
Page 458 Fuel tank Lay hoses into retainers (C) of cover (D) and fasten retainers. Position the hoses into cable grommet (B) and tighten the screw (A) to a torque of 10 Nm ±10% (Sect. 3 - 3, Frame torque settings). Refit the tank covers (Sect. 5 - 2, Refitting the fuel tank fairings).
Page 459 Fuel tank...
Page 460 Fuel tank Positions of the fuel hoses connecting the fuel tank to the throttle body...
Page 461 Fuel tank...
Page 462 Fuel tank...
Page 463: Throttle Body
Throttle body 6 -Throttle body 1 Fuel system assembly 2 Throttle position sensor 3 Clamp 4 Hose 5 Rubber pad 6 Heat shrink sleeve 7 Air temperature sensor 8 Clamp 9 Screw 10 Injector 11 Intake manifold 12 Aluminium gasket 13 Screw 14 O-ring 15 Nut...
Page 464: Removal Of The Throttle Body
Throttle body 33 Hose Spare parts catalogue INTAKE MANIFOLDS AIR INTAKE - OIL BREATHER 796 ABS INTAKE MANIFOLDS 796 ABS AIR INTAKE - OIL BREATHER Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but can be found in the exploded view diagram.
Page 465 Throttle body Disconnect the air pressure sensor (21) from the throttle body and detach connector (D) from the main wiring harness. Release the clip clamp (E) and remove the delivery and return hoses from the frame. Loosen the clips (17) securing the throttle body to the intake manifolds (11).
Page 466 Throttle body Disconnect the wiring connectors (F) connecting the main wiring loom 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. Undo the two screws (27) to remove the throttle position sensor (2) from the throttle body.
Page 467 Throttle body Refitting the injectors Lubricate the injector O-rings. Refit on injectors: fuel feed hose (28), fuel return hose (19) and injector connection hose (30), then tighten them using ties (8). Locate the washers (24) and tighten the screws (25). If the heat shrink sleeve (6) is to be renewed, slide it over hoses (28) and (29) and seat tight against the clamp (8), as shown in the photo.
Page 468: Refitting The Throttle Body
Throttle body Refitting the stepper motor Connect the hoses (G) to the throttle body. Locate the stepper motor (31) with its support on the throttle body, fitting the screws (32). Tighten the screws (32). Refitting the throttle body If the hoses (4) and (16) were removed, reconnect them to the throttle body with the clamps (3), positioning the hoses and clamps as shown in the figure.
Page 469 Throttle body 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). Note The end of the hose with the smaller diameter is to be connected to the throttle body. Take couplings fully home on throttle body, ensuring the mould parting lines (M) of couplings match with the right-hand edge of throttle body sockets (H), as shown below.
Page 470 Throttle body Locate the throttle body assembly (26) on the motorcycle. Fit the clamps (17) on the intake manifolds (11) and orient them as shown in the photos. Orient the throttle body (26) with the pulley facing the right-hand side (relative to the direction of travel) and insert it fully into the intake manifolds.
Page 471 Throttle body Install the air pressure sensor (21) to the throttle body, fit pressure sensor hoses to manifold and connect connector (D) to main wiring harness. Connect the connector (C) connecting the main wiring loom to the stepper motor (31). Connect the wiring connector (B) connecting the main wiring harness to the air temperature sensor (7).
Page 472 Throttle body Fasten the delivery and return hoses to the frame by means of the clip clamp (E). Operations Section reference Connect the throttle cable 7 - 8.1, Refitting the throttle twistgrip Refit the airbox 8 - 7, Refitting the airbox Refit the battery 6 - 2, Refitting the battery...
Page 473 Throttle body...
Page 474 Throttle body...
Page 475: Air Intake
Air intake 7 -Air intake 1 Clamp 2 Oil breather hose 3 Support (ABS) 4 Adapter 5 Clamp 6 Screw 7 Nut 8 Airbox cover 9 Air filter element 10 Support 11 Clamp 12 Hose 13 Screw 14 Breather valve 15 O-ring 16 Screw 17 Spacer...
Page 476: Removal Of The Airbox
Air intake Spare parts catalogue CRANKCASE HALVES AIR INTAKE - OIL BREATHER 796 ABS CRANKCASE HALVES 796 ABS AIR INTAKE - OIL BREATHER 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.
Page 477 Air intake Detach the tabs (B) and release the drain hose (12) from the cover (A) on the generator cover (Sect. 9 - 8, Removal of the generator cover). Disconnect the cables (C) of horizontal cylinder coil (D) and the vertical cylinder coil (E) from the respective spark plugs. Disconnect the coil connectors (F) from main wiring harness (Sect.
Page 478 Air intake Undo the screws (16), recover the spacers (17) and withdraw the airbox vertically upwards, taking care to recover the rubbers (19).
Page 479 Air intake Disassembly of the airbox Loosen the hose clamps (11) and (1) and remove the drain hose (12) and the oil breather hose (2) from the airbox. Remove the following electrical components A Control unit (Sect. 6 - 12, Electronic Control Unit (ECU));...
Page 480: Removal Of The Oil Breather Valve
Air intake For the remaining reassembly operations, reassemble following the removal procedure in the reverse sequence, and route wiring as shown in Sect. 6 - 1, Routing of wiring on frame. Removal of the oil breather valve Undo the screw (13) and remove the oil breather valve (14) from the crankcase half. Check the condition of O-rings (15) and renew them if necessary.
Page 481: Refitting The Airbox
Air intake Refitting the airbox Check that the rubber bushes (19) are present on the airbox. Check that clamps (G) are correctly positioned on intake manifolds (H), with the fixing screws oriented as shown in the figure. Locate the airbox assembly on the throttle body. ±...
Page 482 Air intake ± Tighten the clamps (G) of the couplings to a torque of 1.5 Nm 10% (Sect. 3 - 3, Frame torque settings).
Page 483 Air intake Connect the cables (C) of horizontal cylinder coil (D) and the vertical cylinder coil (E) from the respective spark plugs. Connect the coil connectors (F) from main wiring harness (Sect. 6 - 1, Routing of wiring on frame). In the ABS version refit the hose clip (3) to the vertical cylinder head cover and start the screws (31) in their thread with the spacers (4).
Page 484 Air intake Fasten the drain hose (12) to frame using the clamps and under cover (A) on generator cover (Sect. 9 - 8, Refitting the generator cover) then engage retainers (B). Operations Section reference Refit the battery 6 - 2, Refitting the battery Connect the starter motor/solenoid 6 - 3,...
Page 485 Air intake Positioning of the airbox drain hose...
Page 486 Air intake...
Page 487: Exhaust System
Exhaust system 8 -Exhaust system 1 Exhaust gasket 2 Lambda sensor 3 Horizontal cylinder head exhaust pipe 4 Vertical cylinder head exhaust pipe 5 Centre exhaust pipe 6 Lower bracket 7 Right-hand silencer 8 Left-hand silencer 9 Nut 10 Spring 11 Screw 12 RH heat shield 13 Horizontal heat shield...
Page 488: Operating Principle Of The Catalytic Converter
Exhaust system 33 LH heat shield 34 Washer 35 Guard 36 Cable 37 Exhaust valve motor 38 Washer 39 Clamp 40 Clamp 41 Spacer 42 Screw 43 Screw 44 Spacer 45 Circlip 46 Clip 47 Spacer 48 Washer Spare parts catalogue EXHAUST SYSTEM 796 ABS EXHAUST SYSTEM...
Page 489 Exhaust system While holding 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). Remove the left-hand side heat shield (33) loosening screws (26), (42) and (43); recover the spacers (25), (41) and (44) and the washers (34).
Page 490 Exhaust system Release the end fitting (A) of the cable (36) from the exhaust valve (B) and remove the circlip (45). Remove the cable (36) from the exhaust valve (B). Remove the clamps (39), (40) and disconnect the exhaust valve motor wiring (C). Unscrew the bolts (15) and remove the exhaust valve motor (37) from the rear number plate holder.
Page 491 Exhaust system Loosen the two nuts (20) and take central exhaust pipe (5) off the mounting bracket for tank and exhaust (E). Disconnect the two lambda sensors (2) from the main wiring harness (Sect. 6 - 1, Routing of wiring on frame).
Page 492 Exhaust system Loosen and remove the nuts (9) securing the exhaust pipe flanges to the cylinder heads. Remove the flanges from the cylinder heads. Slide out horizontal exhaust pipe (3) from horizontal head; recover 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.
Page 493: Refitting The Exhaust System
Exhaust system Refitting the exhaust system Renew the gaskets (1). Refit the horizontal exhaust pipe (3) and the vertical exhaust pipe (4) on the cylinder heads, starting the nuts (9) in their threads. To tighten the nuts (9) execute the following operations. Note The text “right“...
Page 494 Exhaust system Refit the bottom plate (6) fitting and tightening the screw (15) to a torque of 5 Nm ±10% (Sect. 3 - 3, Frame torque settings). 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).
Page 495 Exhaust system Refit the cable (36) on the exhaust valve motor (37) inserting the end fitting (D) in the pulley hole. Fix the cable (36) with the clip (46). Refit the cable (36) inserting the end fitting (A) on the exhaust valve (B) and secure it with the circlip (45). Adjust cable (36) on exhaust valve and exhaust valve motor as explained under Sect.
Page 496 Exhaust system Fasten wiring (C) to exhaust valve motor central body using the rubber clamp (39) and ensuring that the cables coming out of motor do not touch the metal sheet sharp edge. Connect the exhaust valve motor wiring (C) and fasten it with the clamp (40). Refit the protection (35), starting the screw (42) with washers (34) and the spacer (25).
Page 497 Exhaust system Connect the lambda sensors (2) to the main wiring harness (Sect. 6 - 1, Routing 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).
Page 498 Exhaust system Follow the same procedure to refit the RH silencer (7). Operations Section reference Refit the seat 5 - 3, Removal of the seat Refit the RH footrest bracket 7 - 15, Refitting the footrest brackets...
Page 499: Evaporative Emissions Canister
Evaporative emissions canister 10 - Evaporative emissions canister 1 Screw 2 Rubber pad 3 Spacer 4 LH air deflector 5 Hose 6 Plate 7 Spacer 8 Nut 9 Evaporative emissions canister 10 Hose clip 11 Hose clip 12 Filter/oil reservoir hose 13 Hose clip 14 Union/filter pipe 15 Hose clip...
Page 500: Evaporative Emissions Canister System (Usa Versions Only)
Evaporative emissions canister Evaporative emissions canister system (USA versions only) USA models are equipped with an additional system with an evaporative emissions canister that prevents fuel fumes from being discharged into the atmosphere. The hose (12) is connected to the evaporative emissions canister (9); when the fuel has been filtered, it is returned with the hose (14) to the intake manifolds via the hoses (16) and (14).
Page 501 Evaporative emissions canister Loosen the hose clamps (15) connecting the evaporative emissions canister (9) to the horizontal and vertical cylinders. Undo the screws (B) and remove the LH air deflector (4), taking care to release the clutch hose (C) from the clips.
Page 502: Refitting The Evaporative Emissions Canister
Evaporative emissions canister Remove the evaporative emissions canister (9) from the LH deflector (4) by releasing it from the plate (6). Refitting the evaporative emissions canister Refitting is the reverse of removal. In particular the plate (6) that supports the canister from the LH deflector (4) was removed, refit it with the corresponding elements, tightening the nuts (8) to a torque of 8 Nm ±10% (Sect.
Page 503 Evaporative emissions canister Operation Section reference Refit the fuel tank 8 - 2, Refitting the fuel tank Refit the tank covers 5 - 2, Refitting the fuel tank fairings Refit the seat 5 - 3, Refitting the seat Positioning the hoses, clamps and evaporative emissions canister...
Page 504 Evaporative emissions canister Positioning the hoses, clamps and evaporative emissions canister...
Page 505 Evaporative emissions canister Positioning the hoses, clamps and evaporative emissions canister...
Page 506 Evaporative emissions canister...
Page 507 9 - Impianto elettri-co 09 - Impianto elettrico 1 - Removal–refitting of the engine assembly Removal of the engine 5 Refitting the engine 7 2.1 - Lubrication system: oil pump Removal of the oil pump 10 Disassembly of the oil pump 11 Reassembly of the oil pump 12 Refitting the oil pump 13 2.2 - Lubrication system: oil cooler...
Page 508 9 - Impianto elettri-co Refitting the APTC clutch 107 6.2 - Clutch assembly: clutch cover Removal of the clutch cover 111 Disassembly of the clutch cover 112 Reassembly of the clutch cover 113 Refitting the clutch cover 114 6.3 - Clutch assembly: primary drive gears Removal of the primary drive gear 117 Refitting the primary drive gears and checking backlash 119 7.1 - Gearbox assembly: gearchange mechanism...
Page 509 9 - Impianto elettri-co...
Page 510: Removal-Refitting Of The Engine Assembly
Removal–refitting of the engine assembly 1 -Removal–refitting of the engine assembly 1 Engine 2 Bolt 3 Nut 4 Complete frame assembly 5 Swingarm pivot Spare parts catalogue FRAME SWINGARM 796 ABS FRAME 796 ABS SWINGARM 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.
Page 511 Removal–refitting of the engine assembly Remove the tank covers 5 - 2, Removal of the fuel tank fairings Remove the fuel tank 8 - 2, Removal of the fuel tank Remove the battery 6 - 2, Removal of the battery Remove the battery support 6 - 2, Battery support...
Page 512: Refitting The Engine
Removal–refitting of the engine assembly Refitting the engine Refitting is the reverse of removal. Important Position the correct shims between engine and swingarm (Sect. 7 - 13, Refitting the swingarm). Lubricate the nuts (3) of mounting bolts (2). ± Tighten the nuts (3) to a torque of 60 Nm 5% (Sect.
Page 513 Removal–refitting of the engine assembly Refit the oil cooler to the frame 9 - 2.2, Refitting the oil cooler Refit the throttle body 8 - 6, Refitting the throttle body Connect the throttle cable 7 - 8.1, Refitting the throttle twistgrip Refit the airbox 8 - 7,...
Page 514: Lubrication System: Oil Pump
Lubrication system: oil pump 2.1 -Lubrication system: oil pump 1 Complete oil pump assembly 2 O-ring 3 Circlip 4 O-ring 5 Pump body 6 Circlip 7 Reducer bush 8 Spring washer 9 Screw 10 Screw 11 Spring washer 12 Pump drive gear 13 Bush 14 By-pass plug 15 Locating bush...
Page 515: Disassembly Of The Oil Pump
Lubrication system: oil pump Operations Section reference Drain the engine oil 4 - 3, Changing the engine oil and filter cartridge Disconnect the oil pressure sensor 6 - 5, Checking the indicating devices Remove the clutch cover 9 - 6.2, Removal of the clutch cover Undo and remove the screws (9) and (10) securing the pump assembly.
Page 516: Reassembly Of The Oil Pump
Lubrication system: oil pump Remove the circlip (6), slide off the bush (13) and the circlip (3). Slide out the pump drive gear (12). Reassembly of the oil pump Fit on the oil pump the pump drive gear (12), the circlip (3) and the bush (13). Tighten the parts just fitted, inserting the circlip (6) in its seat.
Page 517 Lubrication system: oil pump Place the oil pump (1) on the crankcase and tighten the screws (9) to a torque of 26 Nm (Min. 23 Nm - Max. 29 Nm) and the screw (10) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm) (Sect. 3 - 3, Engine torque settings).
Page 518: Lubrication System: Oil Cooler
Lubrication system: oil cooler 2.2 -Lubrication system: oil cooler 1 Oil cooler 2 Vibration damper mount 3 Spacer 4 Screw 5 Oil return hose 6 Oil delivery hose 7 Nipple 8 Aluminium gasket 9 Screw 10 Guide 11 LH air deflector 12 Banjo bolt 13 Conveyor 14 RH air deflector...
Page 519 Lubrication system: oil cooler Drain the oil from the lubrication 4 - 3, Changing the engine oil and system filter cartridge Loosen the screws (12) and remove the deflectors (11) and (14) and conveyor (13). Loosen screw (9) to remove hoses from cable grommet (10). Release tabs (B) from cover (C). Loosen the nuts on the unions (A) and detach the supply (6) and return (5) pipes from the cooler.
Page 520 Lubrication system: oil cooler Loosen the nuts on the unions (D) and detach the supply (6) and return (5) pipes from the engine. You can now remove the nipples (7) for connecting the hoses to the engine. Check the condition of the aluminium sealing washers (8) and renew them if necessary. Loosen the screw (4) and recover the spacer (3) and the rubber mounting (2).
Page 521: Oil Cooler Inspection
Lubrication system: oil cooler Note The oil cooler can be removed complete with its hoses. Oil cooler inspection Visually inspect the oil cooler. Renew the cooler at any sign of damage or leaks. Refitting the oil cooler Note Lubricate the threads of the nipples (5) and (6) and union O-rings (E) with engine oil. Fit the vibration damper mounts (2) in the holes of the oil cooler mounting brackets.
Page 522 Lubrication system: oil cooler Locate the cooler (1) on the front subframe pins and secure it with the screw (4) tightened to a torque of 10 Nm ±10% (Sect. 3 - 3, Frame torque settings). Set the gaskets (8) in the nipples (7) and grease the pipe (5) and (6) O-rings with engine oil. Attach the unions (D) of hoses (5) and (6) to the nipples (7), finger-tightening the union nuts.
Page 523 Lubrication system: oil cooler Fit deflectors (11) and (14) as well as conveyor (13) then tighten the screws (12) to a torque of 5 Nm ±10% (Sect. 3 - Frame torque settings). Operations Section reference Fill the system with engine oil 4 - 3, Changing the engine oil and filter cartridge...
Page 524 Lubrication system: oil cooler...
Page 525: Cylinder Head Assemblies: Checks And Adjustments
Cylinder head assemblies: checks and adjustments 4.1 -Cylinder head assemblies: checks and adjustments 1 Closing shim 2 Camshaft 3 Opening shim 4 Valve Spare parts catalogue CYLINDER HEAD : TIMING SYSTEM VERTICAL CYLINDER HEAD HORIZONTAL CYLINDER HEAD 796 ABS CYLINDER HEAD : TIMING SYSTEM 796 ABS VERTICAL CYLINDER HEAD 796 ABS...
Page 526 Cylinder head assemblies: checks and adjustments Remove the oil cooler from the 9 - 2.2, Removal of the oil cooler frame Remove the valve covers 9 - 4.3, Removal of the valve covers Remove the timing belt covers 9 - 4.2, Removal of the timing belt covers Note...
Page 527 Cylinder head assemblies: checks and adjustments Checking the closing clearance (Sc) of the intake/exhaust valves To check the valve closing clearance, insert a feeler gauge between the closing rocker (D) and the shim (1): the closing clearance (Sc) corresponds to the thickness of the feeler gauge and should allow the free rotation of the shim without any significant play.
Page 528: Checking The Engine Timing
Cylinder head assemblies: checks and adjustments Checking valve lift Fit the gauge (C) 88765.1581 in correspondence with the fixing hole of the previously removed head valve cover, as shown in the figure. Reset the valve opening clearance when the camshaft is in its rest position by inserting the blade of a feeler gauge between the upper rocker arm and the opening shim.
Page 529 Cylinder head assemblies: checks and adjustments Remove the oil cooler from the 9 - 2.2, Removal of the oil cooler frame Remove the valve covers 9 - 4.3, Removal of the valve covers Remove the horizontal cylinder 8 - 8, Removal of the exhaust exhaust pipe system...
Page 530 Cylinder head assemblies: checks and adjustments intake valve of 1 mm on the gauge (C). Check the angular value with the prescribed one (Sect. 3 - 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.
Page 531: Cylinder Head Assemblies: Timing Belt Covers/Timing System
Cylinder head assemblies: timing belt covers/timing system 4.2 -Cylinder head assemblies: timing belt covers/timing system 1 Vertical cylinder timing belt cover 2 Horizontal cylinder timing belt cover 3 Screw 4 Screw 5 Spacer 6 Elastic stop ring 7 Washer 8 Outer timing belt driveshaft pulley 9 Horizontal cylinder timing belt 10 Intermediate spacer 11 Idler pulley assembly...
Page 532: Removal Of The Timing Belt Covers
Cylinder head assemblies: timing belt covers/timing system Spare parts catalogue TIMING SYSTEM CYLINDER HEAD : TIMING SYSTEM 796 ABS TIMING SYSTEM 796 ABS CYLINDER HEAD : TIMING SYSTEM 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.
Page 533 Cylinder head assemblies: timing belt covers/timing system Repeat the above operations to remove the vertical cylinder timing belt (23). To remove the camshaft pulleys, install the tool 88713.3152 on the pulley to be removed to prevent its rotation, and using service socket 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).
Page 534 Cylinder head assemblies: timing belt covers/timing system Use the wrench of tool no. 88700.5644 to lock rotation of the timing belt driveshaft pulley on the crankcase and, using the socket combined with the tool, loosen the ring nut (6). Remove the nut (6), the washer (7) and the outer pulley (8). Remove the first tongue (24) located on the timing belt driveshaft.
Page 535: Disassembly And Reassembly Of The Timing Pulleys
Cylinder head assemblies: timing belt covers/timing system Disassembly and reassembly of the timing pulleys To disassemble pulley parts, loosen and remove the three screws (12), slide out washer (15) and remove pulley (16) from flange (17). To reassemble, fit the pulley (16) on the hub (17), aligning the timing mark (G) on the pulley with the timing mark (H) on the hub.
Page 536 Cylinder head assemblies: timing belt covers/timing system Fit one key (C) into the camshaft keyway. Important During reassembly, take care that the timing mark “B” 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.
Page 537 Cylinder head assemblies: timing belt covers/timing system Refitting the timing belt driveshaft pulleys Install the circlip (25) on the pulley side of the timing belt driveshaft. Drive it into its seat using the protective cap 88700.5749 and the relative drift. Install spacer (5) with the slot facing the crankcase.
Page 538 Cylinder head assemblies: timing belt covers/timing system Then fit the outer pulley (8), outer spacer (7) and ring nut (6). Important To prevent the nuts working loose and consequent serious engine damage, always use new self-locking nuts on all the timing belt pulleys on reassembly.
Page 539 Cylinder head assemblies: timing belt covers/timing system Position the crankshaft so that the piston of the horizontal cylinder is at TDC of its power stroke. This is achieved by aligning the timing mark (P) on the timing belt driveshaft pulley (8) with the reference notch (Q) on the clutch cover. Important Turn the timing belt driveshaft pulley with the spark plugs removed from the engine.
Page 540 Cylinder head assemblies: timing belt covers/timing system Restrain the camshafts of both cylinder heads by screwing tool no. 88713.2282 into the side covers. Turn the pulleys by hand until the end of the tool engages the slot on the camshaft. Fit the horizontal (9) and vertical (23) timing belt using your hands only and without altering the alignment of the pulleys.
Page 541 Cylinder head assemblies: timing belt covers/timing system Locate the tensioner pulleys (21) on the vertical and horizontal cylinders. Screw without tightening to the specified torque screw (27) and screw (20) so that the tensioners can turn. Check the timing belt tension and adjust if necessary as described in the paragraph “Measuring timing belt tension“...
Page 542 Cylinder head assemblies: timing belt covers/timing system Warning Whenever you renew any components of the timing system, it is good practice to also check the timing (Sect. 9 - 4.1, Cylinder head assemblies: checks and adjustments). Remove the side covers (E) of the tool part no. 88713.2282 and refit the screws (F), with the recommended threadlocker, with corresponding washer, tightening it to a torque of 3 Nm (Min.
Page 543: Refitting The Timing Belt Covers
Cylinder head assemblies: timing belt covers/timing system Before refitting the cover (C), check the condition of the O-ring and renew it if necessary. Refitting the timing belt covers Position the vertical timing belt cover (1) on the engine. Start the screw (4) in its thread on the cover. Locate the horizontal timing belt cover (2) on the engine.
Page 544: Cylinder Head Assemblies: Camshafts
Cylinder head assemblies: camshafts 4.3 -Cylinder head assemblies: camshafts 1 Screw 2 Vertical cylinder head inner timing belt cover 3 Sealing ring 4 Screw 5 Washer 6 Horizontal cylinder head inner timing belt cover 7 Screw 8 Valve cover 9 O-ring 10 Vertical cylinder head 11 Horizontal cylinder head 12 Stud bolt...
Page 545: Removal Of The Intake Manifolds
Cylinder head assemblies: camshafts INTAKE MANIFOLDS 796 ABS CYLINDER HEAD : TIMING SYSTEM 796 ABS VERTICAL CYLINDER HEAD 796 ABS HORIZONTAL CYLINDER HEAD 796 ABS INTAKE MANIFOLDS 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.
Page 546: Refitting The Intake Manifolds
Cylinder head assemblies: camshafts Refitting the intake manifolds Apply the recommended threadlocker to the stud bolts (12) and (13), install them on the cylinder heads and tighten them to a torque of 15 Nm (Min. 13 Nm - Max. 17 Nm) (Sect. 3 - 3, Engine torque settings).
Page 547: Removal Of The Side Covers
Cylinder head assemblies: camshafts Operations Section reference Refit the throttle body 8 - 6, Refitting the throttle body Connect the throttle cable 7 - 8.1, Refitting the throttle twistgrip Refit the airbox 8 - 7, Refitting the airbox Refit the ABS control unit 7 - 6, Refitting the ABS control unit Reconnect the HT leads...
Page 548 Cylinder head assemblies: camshafts Repeat the operation for the horizontal cylinder head (11). Note When removing the covers, take care not lose the tongues (15) located on camshafts (16) and (22). Unscrew the screws (21) of the cover (20) of the camshaft (16). Remove the camshaft end cap (20) from the cylinder head and recover the O-ring (19).
Page 549: Removal Of The Valve Covers
Cylinder head assemblies: camshafts Removal of the valve covers Operations Section reference Remove the seat 5 - 3, Removal of the seat Remove the tank covers 5 - 2, Removal of the fuel tank fairings Remove the fuel tank 8 - 2, Removal of the fuel tank Remove the oil cooler from the 9 - 2.2,...
Page 550 Cylinder head assemblies: camshafts Refitting the valve covers Always fit new O-rings (9) when refitting. Fix the valve covers (8) with the relative O-ring (9) to the cylinder head. Tighten the screws (7) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm) (Sect. C 3, Engine torque settings).
Page 551: Removal Of The Camshafts
Cylinder head assemblies: camshafts Refit the seat 5 - 3, Refitting the seat Removal of the camshafts Operations Section reference Remove the seat 5 - 3, Removal of the seat Remove the tank covers 5 - 2, Removal of the fuel tank fairings Remove the fuel tank 8 - 2,...
Page 552: Inspecting The Camshafts
Cylinder head assemblies: camshafts Inspecting the camshafts Check the cam contact surfaces for scratches, grooves, steps and waving. Worn cams are frequently the cause of poor timing, which leads to loss of engine power. Install the camshaft between two centres and check for distortion using a dial gauge: - service limit: 0.1 mm.
Page 553: Refitting The Camshafts
Cylinder head assemblies: camshafts Fit new oil seals at each engine overhaul. Insert the new oil seals squarely in their bores. Use suitable drifts. Lubricate the lip of oil seals after assembly. This operation must be performed very carefully. Refitting the camshafts If removed, install the sealing ring (3) in its seat on the cylinder head right-hand side, using a suitable tool.
Page 554: Refitting Side Covers
Cylinder head assemblies: camshafts If removed, reposition clip (A) onto opening rocker arm (B). Check the condition of the key (15) and its groove, and install it. Operations Section reference Refit the inner timing belt covers 9 - 4.3, Refitting side covers Refit the timing belt pulleys on the 9 - 4.2, Refitting the timing system...
Page 555 Cylinder head assemblies: camshafts Fasten the cover (20) using the screws (21), with the recommended threadlocker. Tighten the screws (21) to a torque of 10 Nm (Min. 9 Nm - Max. 10 Nm) (Sect. C 3, Engine torque settings). Note Take care not to dislodge the key (15) located on camshaft (16).
Page 556 Cylinder head assemblies: camshafts Operations Section reference Refit the camshaft and the timing 9 - 4.2, Refitting the timing system belt pulleys on the heads assembly Refit the timing belt covers 9 - 4.2, Refitting the timing belt covers Refit the horizontal cylinder 8 - 8, Refitting the exhaust system exhaust pipe...
Page 557: Cylinder Head Assemblies: Valves - Rocker Arms
Cylinder head assemblies: valves - rocker arms 4.4 -Cylinder head assemblies: valves - rocker arms 1 Clip 2 Shim 3 Opening rocker arm 4 Rocker arm shaft 5 O-ring 6 Valve opening shim 7 Half rings 8 Valve closing shim 9 Spring 10 Valve rubber 11 Exhaust valve guide...
Page 558: Removal Of The Cylinder Head Assembly
Cylinder head assemblies: valves - rocker arms 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. Removal of the cylinder head assembly Operations Section reference Remove the engine from the...
Page 559 Cylinder head assemblies: valves - rocker arms Screw tool 88713.2837 on the threaded end of the opening rocker arm shaft (4). Slide out the rocker arm shaft (4) and recover the opening rocker arm (3) and the two shims (2). Using a screwdriver, hold the closing rocker arm (18) in the valve open position: Slide the valve closing shim (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.
Page 560 Cylinder head assemblies: valves - rocker arms Repeat the procedure for the exhaust side. Attach the end of the spring (9) of the closing rocker arm (18) to the tool 88713.2783. Slide out the closing rocker arm shaft (4) using tool 88713.2837. Remove the rocker arm (18), the spring (9) and the service tool 88713.2783.
Page 561: Overhaul Of Cylinder Head Components
Cylinder head assemblies: valves - rocker arms 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. The cylinder barrel mating surface must be perfectly flat.
Page 562 Cylinder head assemblies: valves - rocker arms Checking the valves Check that the stem and the valve seat contact surface are in good condition. There must be no pitting, cracks, deformations or signs of wear. Warning The valves cannot be ground. Perform the following checks: measure the diameter of the valve stem (D) at various heights along the portion that runs in the valve guide.
Page 563 Cylinder head assemblies: valves - rocker arms Visually inspect the valve seats: there must no excessive hollowing and there must be no pitting or cracks. If a valve seat is slightly damaged, it may be lapped using the special 45° lapping tools, with subsequent grinding of the valves and leak test.
Page 564 Cylinder head assemblies: valves - rocker arms 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, smooth the connections between the ducts and the new seats and grind the valves.
Page 565 Cylinder head assemblies: valves - rocker arms Note When you change the valve guide, you must also change the valve. The intake valve guides are in cast iron while the exhaust ones are in bronze. Valve-valve guide clearance Assembly clearance: 0.03 to 0.06 mm. Maximum permissible wear limit: 0.08 mm.
Page 566: Refitting The Cylinder Head Assembly
Cylinder head assemblies: valves - rocker arms Rocker shaft–rocker bore clearance The assembly clearance must be 0.03 to 0.06 mm. Maximum 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).
Page 567 Cylinder head assemblies: valves - rocker arms Refitting of the rocker arms, shims and valves Fit the closing rocker arm (18) and relative spring (9) on service tool no. 88713.2783. Insert the tool-rocker-spring assembly in the cylinder head and fit shaft (4) with a new washer (5), duly lubricated. Important When assembling the rocker arm shafts (4) make sure that threaded hole is on the external side of the cylinder head.
Page 568 Cylinder head assemblies: valves - rocker arms Detach the spring (9) and remove the tool no. 88713.2783. Proceed in the same way for the exhaust side. Install the valve (17) and valves (16), first lubricating them with engine oil.
Page 569 Cylinder head assemblies: valves - rocker arms Temporarily fit the camshaft (C). Using a screwdriver, hold the closing rocker arm (18) in the valve open position: Fit the closing shim (8) on the valve stem (17) with the larger diameter side facing the rocker arm. Position the two half rings (7) on the valve stem.
Page 570 Cylinder head assemblies: valves - rocker arms Reposition the screwdriver, and compress the spring as much as possible while holding the valve, the shim and the half rings in the valve closed position. Release the closing rocker (18) with a rapid motion, so that the half rings seat in the shim.
Page 571 Cylinder head assemblies: valves - rocker arms Refit the camshaft end caps (Sect. 9 - 4.3, Refitting side covers). Refit the timing belt pulleys (Sect. 9 - 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 tolerance limits (Sect.
Page 572: Refitting The Cylinder Heads
Cylinder head assemblies: valves - rocker arms Refitting the cylinder heads Warning To prevent oil leaks past the contact area between cylinders and crankcase, each time the head is removed, cylinder and piston must be removed as well to clean the mating faces of crankcase and cylinder and restore the spoiled gaskets and O-rings and apply again liquid sealant (Sect.
Page 573 Cylinder head assemblies: valves - rocker arms Refit the engine to the frame 9 - 1, Refitting the engine...
Page 574: Cylinder/Piston Assemblies
Cylinder/piston assemblies 5 -Cylinder/piston assemblies 1 Pin 2 Circlip 3 Gudgeon pin 4 Vertical cylinder 5 Piston rings 6 Cylinder-crankcase gasket 7 Pin 8 Horizontal cylinder 9 Piston 10 Centring bush 11 Cylinder-head gasket 12 Cylinder temperature sensor Spare parts catalogue CYLINDERS - PISTONS 796 ABS CYLINDERS - PISTONS...
Page 575 Cylinder/piston assemblies covers Remove the timing belts and the 9 - 4.2, Removal of the timing timing belt pulleys system assembly Remove the cylinder heads from 9 - 4.4, Removal of the cylinder the engine head assembly Remove the dowel (7), bushes (10) and head gasket (11) from their seats on the cylinder barrel. Use the tool no.
Page 576: Overhaul Of The Cylinder Barrel/Piston Components
Cylinder/piston assemblies 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 out on the piston, carefully withdraw it from the cylinder.
Page 577 Cylinder/piston assemblies Check that the walls of the cylinder bore are perfectly smooth. Measure the cylinder bore diameter (D) at three different heights and in two directions offset by 90°, thereby determining the assembly clearance, taper, and ovality (see specified values in Section 3 - 1.1, Cylinder/Piston).
Page 578 Cylinder/piston assemblies 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 piston diameter. The pistons must always be renewed as a pair. Piston-cylinder clearance The pistons are marked with a letter (punched into the piston crown) that indicates the size class to which they belong.
Page 579 Cylinder/piston assemblies Overhauling the piston rings The piston rings must not show any signs of scuffing or scoring. Replacement pistons are supplied complete with piston rings and gudgeon pin. Piston ring-to-groove clearance The maximum permissible wear limit is 0.15 mm for the top segment (1st) and 0.10 mm for the others (2nd and oil scraper ring).
Page 580 Cylinder/piston assemblies Note The piston rings must always be installed with markings facing upwards. 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. Note If you fit a new gudgeon pin, you must also change the connecting rod small end bush.
Page 581 Cylinder/piston assemblies 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.
Page 582 Cylinder/piston assemblies oil). Position the cylinder with the smallest valve pockets facing the exhaust port. Remove any deposits and degrease the contact surfaces of the crankcase half and the cylinders. Check that pin (1) is installed on the crankcase. Apply a bead of liquid gasket to the mating surfaces of gasket (6): the exact configuration of the bead of liquid gasket varies according to whether the gasket is for the (6) for the vertical cylinder (V) and the horizontal cylinder (O).
Page 583 Cylinder/piston assemblies Using service tool no. 88700.5644, bring the small end of the connecting rod small end up to near TDC. Fit the piston– cylinder assembly on the crankcase studs. Push the connecting rod small end into the piston close to the gudgeon pin (3) bore. Lubricate and insert the gudgeon pin.
Page 584 Cylinder/piston assemblies 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 until it seats against the crankcase. Important Position the locating dowel (7), head gasket (11) and centring bushes (10).
Page 585: Clutch Assembly: Aptc Wet Clutch
Clutch assembly: APTC wet clutch 6.1 -Clutch assembly: APTC wet clutch 1 Screw 2 Collar 3 Clutch lifter 4 Clutch spring 5 Pressure plate 6 Bearing 7 Clutch plates 8 Nut 9 Lock washer 10 Clutch centre 11 Shim washer 12 Spring 13 Hub Spare parts catalogue...
Page 586: Removal Of The Aptc Clutch
Clutch assembly: APTC wet clutch without compromising the feel of the lever to the rider (servo-assisted). The APTC system consists essentially of a splined coupling between the two parts of the clutch drum. This coupling exploits the axial component of driving torque (bike accelerating) or reverse-acting torque (clutch disengaged) to produce servo-assistance in the former case and prevent rear wheel slip in the latter.
Page 587 Clutch assembly: APTC wet clutch Unscrew the retaining screws (1) and remove the collars (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).
Page 588: Disassembly Of The Clutch Hub-Plates-Centre Assembly
Clutch assembly: APTC wet clutch 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. Remove the spacer (11) from the clutch drum (A). Disassembly of the clutch hub-plates-centre assembly Unscrew the three tools 88713.2591.
Page 589: Overhaul And Inspection Of The Aptc Clutch Components
Clutch assembly: APTC wet clutch Overhaul and inspection of the APTC clutch components Clearance between the clutch drum and friction plates Insert a friction plate (C) in the clutch drum (A) and measure the clearance (S) with a feeler gauge. Clearance “S”...
Page 590: Reassembly Of The Clutch Hub-Plates-Centre Assembly
Clutch assembly: APTC wet clutch Place the plate on a flat surface and check the amount of deformation with a feeler gauge. Max flatness error: 0.2 mm. Overhaul of the pressure plate Check the condition of bearing (6): renew the bearing if the play is excessive. Check the contact surfaces of the last friction plate;...
Page 591 Clutch assembly: APTC wet clutch 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).
Page 592: Refitting The Aptc Clutch
Clutch assembly: APTC wet clutch Refitting the APTC clutch Locate the spacer (11) on the drum (A). Position the hub-plates-drum assembly (B) inside the drum (A). Note Place the last clutch plate (M) offset with respect to the others. Locate the lock washer (9) on the primary shaft, seating it against the clutch assembly. Apply the recommended grease to the contact face of the nut (8) and to thread of the primary shaft, then fit the nut to the input shaft and tighten by hand.
Page 593 Clutch assembly: APTC wet clutch Install the pressure plate (5) on the clutch assembly (B) aligning the three tools 88713.2591 with the three indents (N) in the pressure plate. Check that the two codes (P) stamped on the hub (13) and the pressure plate (5) are aligned. In each cavity, fit a spring (4) and a cap (2).
Page 594 Clutch assembly: APTC wet clutch...
Page 595: Clutch Assembly: Clutch Cover
Clutch assembly: clutch cover 6.2 -Clutch assembly: clutch cover 1 Clutch-side crankcase cover 2 Screw 3 Screw 4 Oil level sight glass 5 Screw 6 Panel (BLACK) 7 O-ring 8 Bush 9 Sealing ring 10 Shim washer 11 Circlip 12 O-ring 13 Locating bush 14 Sealing washer, thickness 2 15 Plug...
Page 596: Disassembly Of The Clutch Cover
Clutch assembly: clutch cover Removal of the clutch cover Operations Section reference Drain the engine oil 4 - 3, Changing the engine oil and filter cartridge Disconnect the oil pressure 6 - 5, Checking the indicating devices sensor Unscrew the screws (2), (3) and (5) securing the clutch-side crankcase cover (1). Tap around the edge of the cover with a plastic mallet to detach it from the crankcase half.
Page 597 Clutch assembly: clutch cover 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 sealing ring (9). The drilled bush (8) is mounted to the cover by a forced interference fit. Remove it using a suitable puller. Inspect the sealing ring (9) and renew it if necessary.
Page 598 Clutch assembly: clutch cover If the bush has been replaced, fully seat the new bush (8) in the slot in the cover using a suitable drift and a press. If the sealing ring (9) needs to be renewed, fit the new seal into the crankcase cover, positioning it so the side without a spring is facing the circlip (11).
Page 599 Clean 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.
Page 600: Clutch Assembly: Primary Drive Gears
Clutch assembly: primary drive gears 6.3 -Clutch assembly: primary drive gears 1 Clutch drum/Primary drive gears 2 Inner ring 3 Inner bearing 4 Spacer 5 Threaded ringnut 6 Lock washer Spare parts catalogue CLUTCH CONNECTING RODS 796 ABS CLUTCH 796 ABS CONNECTING RODS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in...
Page 601 Clutch assembly: primary drive gears Remove the clutch assembly 9 - 6.1, Removal of the APTC clutch Remove the oil pump 9 - 2.1, Removal of the oil pump Withdraw the clutch drum (1) complete with roller bearings (3) and the driven gear of the primary gear pair (A). Remove the circlip (2) and the internal spacer (4).
Page 602: Refitting The Primary Drive Gears And Checking Backlash
Clutch assembly: primary drive gears 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. Refitting the primary drive gears and checking backlash Fully degrease the crankshaft splined end and the corresponding spline on the primary drive gear.
Page 603 Clutch assembly: primary drive gears 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 primary shaft. Fix a dial gauge to the engine crankcase, positioning the stylus against a gear tooth.
Page 604 Clutch assembly: primary drive gears 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). Operations Section reference Refit the complete clutch 9 - 6.1, Refitting the APTC clutch...
Page 605: Gearbox Assembly: Gearchange Mechanism
Gearbox assembly: gearchange mechanism 7.1 -Gearbox assembly: gearchange mechanism 1 Return spring 2 Washer 3 Banjo bolt 4 Gear pawl assembly 5 Interlock plunger holder 6 Sealing washer 7 Detent ball spring 8 Ball 9 Circlip 10 Selector claw return spring 11 Shim washer 12 Circlip 13 Nut...
Page 606: Removal Of The Gear Selector Lever
Gearbox assembly: gearchange mechanism 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. Removal of the gear selector lever Operations Section reference Drain the engine oil 4 - 3, Changing the engine oil and...
Page 607 Gearbox assembly: gearchange mechanism Reassembly of the gear selector lever If the components of the gearchange mechanism were dismantled 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).
Page 608 Gearbox assembly: gearchange mechanism Ensure that the shaft with lever (16) is positioned correctly relative to stop plate (23). The edges of the plate must be equidistant from the pin of the lever; to adjust the position, loosen the lock nut (13) and turn eccentric pin (15). Position the spring (10) between the shaft (16) and the fork (14).
Page 609: Disassembly Of Gear Interlock Plunger And Pawl Assembly
Gearbox assembly: gearchange mechanism Disassembly of gear interlock plunger and pawl assembly Operations Section reference Drain the engine oil 4 - 3, Changing the engine oil and filter cartridge Disconnect the oil pressure 6 - 5, Checking the indicating devices sensor Remove the clutch cover 9 - 6.2,...
Page 610: Refitting The Pawl Assembly And The Gear Interlock Plunger
Gearbox assembly: gearchange mechanism Unscrew the clutch-side crankcase screw (3) and remove the pawl (4), the washer (2) and the spring (1). Refitting the pawl assembly and the gear interlock plunger On the special screw (3), fit the 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 half, and the spring (1), positioning it so that the hook end (A) is facing the gear pawl lever.
Page 611: Refitting The Gear Selector Lever
Gearbox assembly: gearchange mechanism Apply grease and then fit the ball (8), the spring (7), and the seal (6) into the interlock plunger (5) and tighten the interlock plunger assembly into the crankcase. Tighten the interlock plunger to a torque of 30 Nm (Min. 27 Nm - Max. 33 Nm) (Sect. 3 - 3, Engine torque settings) and screw in the interlock plunger into the crankcase.
Page 612 Gearbox assembly: gearchange mechanism Insert the screws (18) and (20) with the spacer (19). Temporarily fit gear change lever (or a service lever) and sprocket and shift to neutral gear. Place the tool 88713.3334 on the gear claw. Place the tool inserting the pushrod (A) into the tool hole, block the pin (B) of the tool in the gear claw pressing with the hand in the point (C) towards the right.
Page 613 Gearbox assembly: gearchange mechanism Operations Section reference Refit the flywheel/generator 9 - 8, Refitting the flywheel- assembly and generator cover alternator assembly Refit the front sprocket cover 7 - 14, Refitting the front sprocket Refit the clutch transmission unit 7 - 8.2, Refitting the clutch transmission unit Refit the gearchange control...
Page 614: Gearbox Assembly: Gearbox Shafts
Gearbox assembly: gearbox shafts 7.2 -Gearbox assembly: gearbox shafts 1 Shim, thickness 1 2 Gearbox primary shaft 3 Shim, thickness 0.5 4 Needle roller bearing 5 5 th speed driving gear 6 Splined washer, thickness 0.5 7 Circlip 8 3 rd - 4 th speed driving gear 9 6 th speed driving gear 10 2 nd speed driving gear 11 Shim, thickness 1.8...
Page 615: Removal Of The Gearbox Assembly
Gearbox assembly: gearbox shafts 29 5 th , 6 th speed selector fork 30 Selector fork shaft 31 Shim, thickness 1 32 Needle roller retaining circlip Spare parts catalogue GEARCHANGE CONTROL GEARBOX 796 ABS GEARCHANGE CONTROL 796 ABS GEARBOX 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.
Page 616: Disassembly Of The Gearbox Shafts
Gearbox assembly: gearbox shafts Remove the gearbox primary (2) and secondary (25) shafts complete with gears, taking care to recover the spacers on the ends of the shafts. If the bearing inner rings (A) are left on the shafts, slide them off the ends of the gearbox primary (2) and secondary (25) shafts (Sect.
Page 617 Gearbox assembly: gearbox shafts 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).
Page 618 Gearbox assembly: gearbox shafts 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).
Page 619 Gearbox assembly: gearbox shafts 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).
Page 620 Gearbox assembly: gearbox shafts Withdraw the roller cage (4) and the shim (3). All the components have thus been removed from gearbox secondary shaft (25). Disassembly of the gearbox primary shaft Remove the chain-side shim washer (11) and the clutch-side shim washer (1) from the primary shaft.
Page 621 Gearbox assembly: gearbox shafts 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). Remove the sixth speed driving gear (9) with its roller cage (4).
Page 622 Gearbox assembly: gearbox shafts Withdraw the third and fourth speed driving gear (8). Remove the circlip (7) and the splined washer (6).
Page 623: Overhaul Of The Gearbox
Gearbox assembly: gearbox shafts Remove the fifth speed driving gear (5) with the roller cage (4). Slide the shim (3) off the primary shaft (2). Overhaul of the gearbox Check the condition of the front coupling dogs of the gears. They must be in perfect condition and with no sign of wear on the edges of the teeth.
Page 624: Inspection Of The Gear Selector Forks
Gearbox assembly: gearbox shafts 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.
Page 625: Inspection Of The Gear Selector Drum
Gearbox assembly: gearbox shafts Inspection of the gear selector drum Use a gauge to measure the clearance between fork pin and the slot on the selector drum. If the service limit is exceeded, determine which part must be replaced by comparing these dimensions with those of new components (Sect.
Page 626 Gearbox assembly: gearbox shafts Figure 2 shows all the parts to be installed on the gearbox secondary shaft (25), with calculated end shims (15) and (26) (Sect. 9 - 9.2, Shimming the shafts). Reassemble the gears on the gearbox shafts by reversing the disassembly procedure. Take particular care when installing the idler gears.
Page 627 Gearbox assembly: gearbox shafts 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 type) and then open it slightly to make it easier to slide on to the shaft.
Page 628 Gearbox assembly: gearbox shafts Fit another needle roller cage (4) using the method already described. Fit the 4 th speed gear (21). Fit another safety washer (6) and another circlip (7) into the shaft. Seat the circlip using the drift used previously.
Page 629 Gearbox assembly: gearbox shafts Reassembly of the gearbox To reassemble the gearbox components, please proceed as indicated in Sect. 9 - 9.2 regarding the “Reassembly of the crankcase halves”. As a final practical 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).
Page 630 Gearbox assembly: gearbox shafts Refit the generator cover 9 - 8, Refitting the generator cover Refit the lubrication system 9 - 2.1, Refitting the oil pump Refit the clutch assembly 9 - 6.1, Refitting the APTC clutch Refit the clutch cover 9 - 6.2, Refitting the clutch cover Refit the engine to the frame...
Page 631: Flywheel - Alternator
Flywheel - alternator 8 -Flywheel - alternator 1 Front sprocket cover 2 Pick-up sensor inspection plug 3 Sealing ring 4 O-ring 5 Cover 6 Screw 7 Washer 8 Spacer 9 Cable guide bracket 10 Screw 11 Screw 12 Screw 13 Flange 14 Screw 15 Washer 16 Flywheel...
Page 632 Flywheel - alternator 33 Belleville washer 34 Flanged nut 35 Screw 36 Aluminium gasket Spare parts catalogue ALTERNATOR-SIDE CRANKCASE COVER ELECTRIC STARTING AND IGNITION AIR INTAKE - OIL BREATHER 796 ABS ALTERNATOR-SIDE CRANKCASE COVER 796 ABS ELECTRIC STARTING AND IGNITION 796 ABS AIR INTAKE - OIL BREATHER Important...
Page 633: Disassembly Of The Generator Cover
Flywheel - alternator Fix service tool no. 88713.1749 to the holes left vacant by the two bolts (6) you have just removed. Turn the tool shaft slowly to separate the cover (28) from the LH crankcase half. Disassembly of the generator cover Undo the three stator retaining screws (24) and the two screws (31) securing the cable guide bracket (30) from inside the generator cover.
Page 634: Removal Of The Flywheel/Alternator Assembly
Flywheel - alternator Removal of the flywheel/alternator assembly Use service tool no. 88713.2036 fixed to the M10 side stand fixing holes (D). Secure the tool to the flywheel with 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.
Page 635: Checking The Flywheel/Alternator Assembly
Flywheel - alternator Important Examine the inner race (18), needle roller bearing (19) and internal washer (17) for wear. Note The hole in the inner race (18) allows the passage of oil for lubrication of needle roller bearing (19). Checking the flywheel/alternator assembly Examine the inner part of alternator rotor (23) for signs of damage.
Page 636 Flywheel - alternator Reassembly of the flywheel-alternator assembly Install the starter clutch (21) in the flange (13) and take it fully home. Important Orient the flange with the round edge side (A) facing the starter clutch. Seat the flange (13) with the starter clutch in the flywheel (16), aligning the flange locating hole (B) with the flywheel locating hole (C).
Page 637 Flywheel - alternator Install the rotor (23) on the flywheel (16), aligning the flywheel locating hole (E) with the rotor locating hole (D). Apply threadlocker to the rotor-flywheel fixing screws (25) and start them in their threads. Tighten the screws (25) to a torque of 13 Nm (Min. 11 Nm - Max. 15 Nm) (Sect. 3- 3, Engine torque settings).
Page 638 Flywheel - alternator Lubricate the race (P) of the driven gear (20) with engine oil. Install the driven gear (20) on the starter clutch, ensuring it is properly seated. Note To facilitate the introduction operation, turn the driven gear in the direction indicated by the “green“ arrow. Check that the driven gear can rotate freely in the direction of the green arrow but not in the direction of the red arrow.
Page 639 Flywheel - alternator Refitting the flywheel-alternator assembly Fit the washer (17), duly lubricated, the needle roller bearing (19), and the inner ring (18) to the crankshaft. Make sure the inner ring is centred on the washer. Fit the previously assembled flywheel-rotor-driven gear on the crankshaft, taking care not to alter the position of inner ring (18) with respect to the washer (17).
Page 640: Reassembly Of The Generator Cover
Flywheel - alternator Restrain the rotation of the flywheel with the holding tool 88713.2036. Important Tighten the nut (34) to a torque of 270 Nm (Min. 256 Nm - Max. 284 Nm) (Sect. 3 - 3, Engine torque settings). Remove all traces of Loctite from the threads of the nut (34) and the crankshaft (A). Reassembly of the generator cover Fit the stator (32) to the generator cover, routing the cable through the notch in the cover.
Page 641 Remove any scale and grease from the mating surfaces of the left-hand crankcase half and the generator cover. Fit the two locating bushes (29). Spread a continuous uniform bead of DUCATI liquid gasket on the mating surface of the cover (28), ensuring continuity around the holes for the retaining screws and locating bushes.
Page 642 Flywheel - alternator Install under the screw (12), in correspondence with the starter motor, the spacer (8), the cable guide (9), the washer (38) and install the cover (1) under screw (11) in correspondence with the alternator lead: for instructions on the positioning of the wiring under the cover (1) see below.
Page 643 Flywheel - alternator Offer the cover (1) up to the generator cover and position the fuel tank breather hose (T) and the airbox drain hose (U), the side stand cable (R), generator 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).
Page 644 Flywheel - alternator Damp the sealing ring (3) with alcohol and install it in the generator cover, in correspondence with the gearchange shaft (Sect. 7 - 9, Refitting the gearchange mechanism) by means of the suitable drift 88713.1411. Make sure that the O-ring (4) is installed in the cover (5). Apply threadlocker to the screws (6).
Page 645 Flywheel - alternator Operations Section reference Refit the sprocket cover 7 - 14, Refitting the front sprocket Refit the clutch transmission unit 7 - 8.2, Refitting the clutch transmission unit Refit the gearchange control 7 - 9, Refitting the gearchange mechanism Top up the engine oil 4 - 3,...
Page 646 Flywheel - alternator...
Page 647 Flywheel - alternator...
Page 648: Crankcase Assembly: External Components
Crankcase assembly: external components 9.1 -Crankcase assembly: external components 1 Key 2 Timing gear pair 3 Lock washer 4 Hexagonal nut 5 Key 6 Sealing washer 7 Plug 8 Aluminium gasket 9 Plug 10 Breather valve 11 O-ring 12 Cylinder head stud 13 Locating dowel 14 Nipple 15 Plug...
Page 649: Removing Outer Components
Crankcase assembly: external components 33 O-ring 34 Pick-up sensor 35 Grub screw 36 Bush 37 Sealing washer 38 Ball 39 Spring Spare parts catalogue TIMING SYSTEM FILTERS AND OIL PUMP CRANKCASE HALVES ELECTRIC STARTING AND IGNITION GEARCHANGE CONTROL 796 ABS TIMING SYSTEM 796 ABS FILTERS AND OIL PUMP...
Page 650 Crankcase assembly: external components Loosen and remove the two nipples (14) from the clutch-side crankcase and recover the gaskets (8). Unscrew and remove the oil filter cartridge (Sect. 4 - 3, Changing the engine oil and filter cartridge). Unscrew and remove the oil filter support nipple (17). Remove the mesh filter (18) with its seal from the clutch-side crankcase half as described in Section 4 - 3, Changing the engine oil and filter...
Page 651 Crankcase assembly: external components Remove the drain plug (9) with its seal (29). Remove the neutral switch (19) with seal (20). Remove the cylinder head studs (12) with the aid of the appropriate tool. To remove the engine sensor (34), unscrew the screw (31) and recover the washer (32).
Page 652: Refitting The External Components
Crankcase assembly: external components Check the condition of O-rings (33) on crankcase and renew them if necessary. Remove the bush (36) and recover the seal (37), the spring (39) and the ball (38). Refitting the external components Check the condition of O-rings (11) and renew if necessary. Install the oil vapour breather valve (10) in the crankcase along with O-rings (11), previously lubricated.
Page 653 Crankcase assembly: external components Fit the seals (8) on the nipples (14). Apply prescribed threadlocker on the plugs (14). Tighten the nipples (14) to a torque of 32 Nm (Min. 29 Nm - Max. 35 Nm) (Sect. 3 - 3, Engine torque settings).
Page 654 Crankcase assembly: external components Fit the exhaust plug (9) with the corresponding gasket (29) and tighten it to a torque of 20 Nm (Min. 18 Nm - Max. 22 (Sect. 3 - 3, Engine torque settings), after applying the recommended threadlocker. Refit the neutral switch (19) and the corresponding seal (20) and tighten it to a torque of 10 Nm (Min.
Page 655 Crankcase assembly: external components Install the stud screws (12) on the crankcases, applying threadlocker and tightening them to a torque of 30 Nm (Min. 28 Nm - Max. 32 Nm) (Sect. 3 - 3, Engine torque settings). Use a tool similar to the one shown. Make sure that the O-rings (33) are fitted on the crankcase.
Page 656 Crankcase assembly: external components If removed, apply prescribed threadlocker on the dowel (35), tighten the dowel to a torque of 15 Nm (Min. 13 Nm - Max. 17 Nm) (Sect. 3 - 3, Engine torque settings), insert the gasket (16) on the service plug (15): the seal must be oriented so that the square edge faces the clutch-side crankcase half.
Page 657: Removal Of The Timing Gears
Crankcase assembly: external components Operations Section reference Refit the cylinder barrel/piston 9 - 5, Refitting the cylinder/piston assemblies assembly Refit the cylinder heads 9 - 4.4, Refitting the cylinder head assembly Refit the timing belts 9 - 4.2, Refitting the timing system assembly Refit the timing belt covers 9 - 4.2,...
Page 658: Refitting The Timing Gears
Crankcase assembly: external components Remove the nut (4), the washer (3) and the timing driven gear (B). Refitting the timing gears Before refitting, check the wear on the timing gear pair (2) and renew if necessary. Important The timing gears (2) must always be renewed as a pair. Check that the key (1) is correctly fitted on the timing belt driveshaft and that key (5) is correctly fitted on the crankshaft.
Page 659: Removal Of The Starter Motor Idler Gear
Crankcase assembly: external components the nut from working loose. Operations Section reference Refit the flywheel/alternator 9 - 8, Refitting the flywheel- assembly alternator assembly Refit the generator cover 9 - 8, Refitting the generator cover Refit the sprocket cover 7 - 14, Refitting the front sprocket Refit the clutch transmission unit 7 - 8.2,...
Page 660: Refitting The Starter Motor Gear
Crankcase assembly: external components Refitting the starter motor gear Refitting is the reverse of removal. Note Apply threadlocker to the screw (26) and tighten the screw to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm) (Sect. 3 - 3, Engine torque settings).
Page 661: Crankcase Assembly: Crankcase Halves
Crankcase assembly: crankcase halves 9.2 -Crankcase assembly: crankcase halves 1 Circlip 2 Timing belt driveshaft 3 Alternator crankcase half 4 Bearing 5 O-ring 6 Circlip 7 Bearing 8 Screw 9 Retaining plate 10 Bearing 11 Sealing ring 12 Bearing 13 Sealing ring 14 Bearing 15 Bearing 16 Clutch-side crankcase half...
Page 662 Crankcase assembly: crankcase halves TIMING SYSTEM CRANKCASE HALVES 796 ABS TIMING SYSTEM 796 ABS CRANKCASE HALVES 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. Separation of the crankcase halves Operations Section reference...
Page 663 Crankcase assembly: crankcase halves Unscrew the two screws (22) from clutch-side crankcase, near the vertical cylinder. Reuse the generator cover or a service cover with puller 88713.1749 fitted. Secure cover to crankcase half with some of the original screws and begin separation by turning the central pin of the tool. Tap the end of the gearbox secondary shaft with a plastic mallet to separate the crankcase halves.
Page 664: Overhaul Of The Crankcase Halves
Crankcase assembly: crankcase halves Remove gearbox shafts and gear selector drum from the crankcase halves (Sect. 9 - 7.2, Removal of the gearbox assembly). Drive out the crankshaft (C) using a plastic mallet, taking care not to lose the shims (D). Remove the timing belt driveshaft (2).
Page 665 Crankcase assembly: crankcase halves At each overhaul it is recommended to renew also the oil sealing ring (11) on the outside of bearing (10) as well as oil sealing ring (20) on the outside of bearing (21). In the event of renewal of needle roller bearings (27) and oil seals (28) on the swingarm pivot, lubricate the seats of the bearings and the lips of the oil seals with the recommended grease.
Page 666 Crankcase assembly: crankcase halves Check the condition of locating bushes (19). If apparently distorted or loose in their seats, change them using proper tools. When the locating bushes (19) are hard to remove from casing, use a left-hand tap to force bushes out. Important The bushes (19) must always be renewed when they have been removed using the above procedure.
Page 667: Reassembly Of The Crankcase Halves
Crankcase assembly: crankcase halves designed for bearing combined loading (radial-axial loads). Bearings of this type can bear thrust loads in one direction only. In fact, under the action of a radial load inside the bearing, an axial force is created that must be counterbalanced by an axial force acting in the opposite direction; that is why these bearings are generally fitted back to back in pairs.
Page 668: Shimming The Shafts
Crankcase assembly: crankcase halves - gearbox secondary shaft bearing (15): apply grease to the bearing rollers. Fit the inner race (A) removed previously from the bearing. Apply grease to the inner ring; - the primary shaft bearing (14), secured with screws (18) and retaining spacer (17): apply the recommended threadlocker to the screws (18) and tighten them to a torque of 10 Nm (Min.
Page 669 Crankcase assembly: crankcase halves To calculate the thickness of each shim note that: SA=SA1+SA2 where “SA1” and “SA2” represent the shims for the clutch-side crankcase half 1 and the alternator-side crankcase half 2. Considering the alignment of the shaft, this gives: SA1=LA1+0.15-LA/2;...
Page 670 Crankcase assembly: crankcase halves Position a dial gauge (B) with magnetic stand on a support plate fixed to the crankcase. Bring the stylus into contact with the end of the crankshaft and set the dial gauge to zero in this position. Place a lever (C) between crankcase and crank web of the crankshaft pushing towards dial gauge.
Page 671 Crankcase assembly: crankcase halves Gearbox primary shaft Gearbox secondary shaft 3.15 Shimming the gearbox selector drum The following thickness spacers are supplied as spare parts. Position Clutch side (mm) Chain side (mm) Gear control drum Reassembly of the crankcase halves If it was removed, apply the recommended threadlocker to the dowel (24) and tighten it to a torque of 15 Nm (Min.
Page 672 Crankcase assembly: crankcase halves Mesh the gearbox shafts and install them on the clutch-side crankcase half with the calculated shims. Insert the 1ª- 4ª e 2ª- 3ª speed selector forks (B) in their respective channels in the driven gears of the secondary shaft. Note The two selector forks are identical.
Page 673 Apply a uniform and continuous bead of DUCATI liquid gasket to the mating surfaces of the crankcase halves, going around all the holes as shown in the figure.
Page 674 Crankcase assembly: crankcase halves Bring the crankcase halves (3) and (16) together, tapping with a rubber mallet in the area of the shafts if necessary. Prepare the crankcase screws and insert them in the alternator-side crankcase half (3); note that the screws are of different lengths.
Page 675 Crankcase assembly: crankcase halves Check that the crankshaft can be turned with a certain amount of interference with the main bearings (the crankshaft should have a pre-load of 0.15 to 0.20 mm); check also that all the parts you have fitted are free to rotate or move correctly.
Page 676 Crankcase assembly: crankcase halves Refit the timing covers 9 - 4.2, Refitting the timing belt covers Refit the starter motor 6 - 3, Refitting the starter motor Refit the starter motor idler gear 9 - 9.1, Refitting the starter motor gear Refit the flywheel/alternator 9 - 8,...
Page 677: Crankcase Assembly: Crankshaft/Connecting Rods Assembly
Crankcase assembly: crankshaft/connecting rods assembly 9.3 -Crankcase assembly: crankshaft/connecting rods assembly 1 Crankshaft 2 Drilled grub screw 3 Plug 4 Grub screw 5 Connecting rod assembly 6 Bush 7 Half bearing 8 Banjo bolt 9 Shim washer 10 Key Spare parts catalogue CONNECTING RODS 796 ABS CONNECTING RODS...
Page 678: Disassembly Of The Crankshaft/Connecting Rods Assembly
Crankcase assembly: crankshaft/connecting rods assembly assembly Remove the oil pump 9 - 2.1, Removal of the oil pump Remove the primary gear 9 - 6.3, Removal of the primary drive gear Remove the alternator-side 9 - 8, Removal of the generator crankcase cover cover Remove the flywheel/alternator...
Page 679 Crankcase assembly: crankshaft/connecting rods assembly the value must be H-h less than 0.02 mm; otherwise, renew the connecting rod. The cylinder head diameter must be within the specified values (Sect. 3 - 1.1, Cylinder/Piston). It is preferable to use crankshafts and connecting rods of the same size class. Renewal of the connecting rod bearings It is good practice to renew the bearings (7) each time the engine is overhauled.
Page 680 Crankcase assembly: crankshaft/connecting rods assembly 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. Crankshaft overhaul The main bearing and big-end journals should not be scored or grooved.
Page 681 Crankcase assembly: crankshaft/connecting rods assembly Use a hot air gun that can reach 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 682 Crankcase assembly: crankshaft/connecting rods assembly Apply the recommended threadlocker to the threads of plugs (3), (4) and (2) and refit them. Tighten the plugs (2) and (4) to a torque of 13 Nm (Min. 11 Nm - Max. 15 Nm) and the plug (2) to a torque of 15 Nm (Min.
Page 683: Reassembly Of The Connecting Rods
Crankcase assembly: crankshaft/connecting rods assembly Reassembly of the connecting rods Before starting, check that the crankshaft main bearing journals and big-end journals are free of burrs or evident signs of machining: if necessary, clean the surfaces with very fine emery cloth and oil. Check that the grooves are in perfect condition with no signs of forcing.
Page 684: Refitting The Crankshaft/Connecting Rod Assembly
Crankcase assembly: crankshaft/connecting rods assembly Fit the spacer (H) of the tool 88713.2878 between the connecting rods and take up residual axial clearance with 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.
Page 685 Crankcase assembly: crankshaft/connecting rods assembly Operations Section reference Reassemble the engine crankcase 9 - 9.2, Reassembly of the halves crankcase halves Refit the mesh filter 4 - 3, Changing the engine oil and filter cartridge Refit the cylinder barrel/piston 9 - 5, Refitting the cylinder/piston assemblies assembly...

Ducati Monster 796 Workshop Manual

Table of Contents

03 - Technical Data 1.1 - Technical Specifications

2 Fuel, Lubricants and Other Fluids

3 Torque Settings

4 Service Tools

04 - Impianto Elettrico

1 Vehicle Pre-Delivery

2 Routine Maintenance Table

3 Maintenance Operations

05 - Impianto Elettrico

1 Headlight Fairing - Rear-View Mirrors

2 Fairings

3 Seat

4 Front and Rear Mudguard

07 - Impianto Elettrico

1 Front Wheel

2 Rear Wheel

3 Front Brake Control

6 System Components

7 ABS Components Maintenance

9 Gearchange Mechanism

12 Rear Shock Absorber Assembly

13 Rear Swingarm

14 Final Drive

15 Footrest Brackets

16 Stands

17 Frame Inspection

18 Tail Light-Number Plate Holder and Locks

08 - Impianto Elettrico

2 Fuel Tank

6 Throttle Body

7 Air Intake

8 Exhaust System

10 Evaporative Emissions Canister

09 - Impianto Elettrico

1 Removal-Refitting of the Engine Assembly

5 Cylinder/Piston Assemblies

8 Flywheel - Alternator

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Summary of Contents for Ducati Monster 796