Ducati Monster 696 2009 Manual

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GENERAL SUMMARY

A - General

B - Information about the model

C - Technical data

D - Use and maintenance

E - Fairings

F - Controls - Devices

G - Wheels - Suspension - Brakes

H - Frame

L - Fuel/Exhaust System

M - Fuel injection - ignition system

N - Engine

P - Electrical system

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Table of Contents

Summary of Contents for Ducati Monster 696 2009

Page 1 GENERAL SUMMARY A - General B - Information about the model C - Technical data D - Use and maintenance E - Fairings F - Controls - Devices G - Wheels - Suspension - Brakes H - Frame L - Fuel/Exhaust System M - Fuel injection - ignition system N - Engine P - Electrical system...
Page 2 General summary Section A A - General 1 - How to use this manual Layout of the manual 2 - Symbols - Abbreviations - References Product specifications 3 - Hazardous Products - Warnings General safety rules General maintenance indications Section B B - Information about the model 1 - Identification data Identification data for the Monster 696 i.e.
Page 3 Adjusting the throttle and choke cables Adjusting the position of the gearchange and rear brake pedals Adjusting the rear shock absorber 5 - Diagnostic instruments Description of the Ducati Diagnostic System tester Tester power supply DDS tester Checking and adjusting timing belt tension...
Page 4 General summary Section E E - Fairings 1 - Headlight fairing - rear-view mirrors Removal of the rear-view mirrors Refitting the rearview mirrors Removal of the headlight fairing (696+) Refitting the headlight fairing (696+) 2 - Fairings Removal of the fuel tank fairings Refittings the fuel tank fairings 3 - Seat Removal of the seat...
Page 5 General summary Section G G - Wheels - Suspension - Brakes 1 - Front wheel Removal of the front wheel Overhauling the front wheel Refitting the front wheel 2 - Front fork Removal of the front forks Overhauling the front forks Refitting the front forks 3 - Hydraulic front brake Maintenance operations...
Page 6 General summary Section H H - Frame 1 - Handlebar Removal of the handlebar Refitting the handlebar 2 - Steering Adjusting the steering head bearings Steering angle adjustment Removal of the steering head components Refitting the steering head components 4 - Footrest brackets Removal of the footrest brackets Refitting the footrest brackets 5 - Stands...
Page 7 General summary 7 - Air intake Removal of the airbox Removal of the oil breather valve Refitting the oil breather valve Refitting the airbox 8 - Exhaust system Operating principle of the catalytic converter Removal of the exhaust system Refitting the exhaust system 10 - Evaporative emissions canister Evaporative emissions canister system (USA versions only) Removal of the evaporative emissions canister...
Page 8 General summary 4.1 - Cylinder head assemblies: checks and adjustments Checking and adjusting valve clearances Checking the engine timing 4.2 - Cylinder head assemblies: timing belt covers/timing system Removal of the timing belt covers Removal of the timing system assembly Disassembly and reassembly of the timing belt pulleys Refitting the timing system assembly Refitting the timing belt covers...
Page 9 General summary 7.1 - Gearbox assembly: gearchange mechanism Removal of the gearchange mechanism Disassembly of the gear selector mechanism Disassembly of the gear interlock plunger and pawl assembly Refitting the gear interlock plunger and pawl assembly Reassembly of the gearchange mechanism Refitting the gearchange mechanism 7.2 - Gearbox assembly: gearbox shafts Removal of the gearbox assembly...
Page 10 General summary Section P P - Electrical system 1 - Wiring diagram Key to wiring diagram Wiring colour codes Key to fusebox Routing of wiring on frame Plate A Plate B Plate C Plate D Plate E Plate F Plate G Plate H Plate J Plate K...
Page 11 General summary 7 - Instruments Instrument panel Instrument panel system Display settings and functions 8 - Immobilizer and transponder 9 - Diagnostic instruments Using a multimeter to check the electrical systems Monster 696/696+ - M.Y. 2009 - edition 00...
Page 13 A - General...
Page 14 section General 1 - How to use this manual Layout of the manual 2 - Symbols - Abbreviations - References Product specifications 3 - Hazardous Products - Warnings General safety rules General maintenance indications Monster 696/696+ - M.Y. 2009 - edition 00...
Page 15 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 16 Some of the sections of this manual are not present, since the motorcycle in question is not equipped with the relevant parts. Important The layout of the manual is designed in such a way as to be applicable to all the different models manufactured by Ducati Motor Holding.
Page 17 section General 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 18 section General Product specifications Symbols in the diagram show the type of threadlocker, sealant or lubricant to be used at the points indicated. The table below shows the symbols used and the specifications of the various products. Symbol Specifications Recommended product Engine oil (for specifications, see Sect.
Page 19 LOCK 11 Instant adhesive gel offering tensile/shear strength. Loctite 454 gel LOCK DUCATI liquid gasket. 942470014 Exhaust pipe paste. Self-sealing paste, hardens when Holts Firegum heated; resists temperatures exceeding 1000 °C. Spray used to protect electrical systems.
Page 20 section General 3 - Hazardous Products - Warnings General safety rules Carbon monoxide When a maintenance operation must be performed with the engine running, maker sure that the working area is well-ventilated. Never run the engine in an enclosed space. Warning Exhaust fumes contain carbon monoxide, which is a poisonous gas that can cause unconsciousness or even death if inhaled.
Page 21 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 operation since this information can highlight anomalies;...
Page 23 B - Information about the model...
Page 24 section Information about the model 1 - Identification data Identification data for the Monster 696 i.e. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 25 Information about the model 1 - Identification data Identification data for the Monster 696 i.e. Each Ducati motorcycle has two identification numbers -the frame number and the engine number - and an EC nameplate (A) (not present on the US version). ????
Page 26 Information about the model Data stamped on the frame Europe version 1 Manufacturer: Ducati Motor Holding 2 Type, same on all Monster models 3 Variant: - 00 Full power - 01 Power limited 4 Version 5 Year of manufacture (8=2008) 6 Manufacturing facility 7 Progressive serial No.
Page 27 Information about the model Data stamped on engine Europe version 1 Manufacturer: Ducati Motor Holding 2 Engine type 3 Progressive production No. Data stamped on engine Europe version ZDM 696A2*000001* Data stamped on engine US version 1 Engine type 2 Model year 3 Progressive production No.
Page 29 C - Technical data...
Page 30: Table Of Contents
section Technical data 1.1 - Technical specifications General Colours Transmission Timing system/valves Cylinder/Piston Gearbox Cooling system Front wheel Front suspension Rear wheel Rear suspension Hydraulic brakes Charging system/alternator Ignition system Fuel system Injection system Lights/instrument panel 1.2 - Dimensions 2 - Fuel, lubricants and other fluids 3 - Torque settings Frame torque settings Engine torque settings...
Page 31 section C 1.1 Technical data 1.1 - Technical specifications General Reference Technical specifications Motorcycle dimensions Total length 2058 mm Total width 784 mm Total height 1012 mm Wheelbase 1452 mm Height of handlebar grip from ground 960 mm Seat height 770 mm Front footrest height 334 mm...
Page 32: Colours
C 1.1 Technical data Colours Description Code Ducati Anniversary Red F_473.101 (PPG) Transparent 228.880 (PPG) Red frame with black wheels Matt black 291.501 (PPG) Transparent 228.880 (PPG) Matt black frame with black wheels Pearl white 490.019 (PPG) Transparent 228.880 (PPG)
Page 33: Cylinder/Piston
section C 1.1 Technical data Cylinder/Piston Reference Standard value Service limit Cylinder barrel Max. bore ovality 0.03 mm Max. bore taper 0.03 mm Nominal diameter 88 mm Class A 88.000 to 88.010 mm Class B 88.010 to 88.020 mm Class C 88.020 to 88.030 mm Piston-to-cylinder bore clearance 0.025 to 0.045 mm...
Page 34: Front Suspension
section C 1.1 Technical data Front suspension Reference Technical specifications Type SHOWA: 43 mm Ø upside-down hydraulic fork, non-adjustable Fork travel 120 mm Fork Not adjustable. Oil charge per leg 538±2.5 cm (per leg) Rear wheel Reference Standard value Service limit In the most worn part 2 mm Minimum tread depth...
Page 35: Hydraulic Brakes
section C 1.1 Technical data Hydraulic brakes Reference Standard value Service limit FRONT Brake disc Type Drilled dual disc Shim 4 mm 3.6 mm (min.) Flange material Steel Braking surface material Steel Diameter 320 mm Braking surface 44 cm (per disc) Brake caliper Make Brembo...
Page 36: Fuel System
section C 1.1 Technical data Fuel system Make Type Unleaded fuel 95-98 RON Throttle body Ø 45 mm Injectors per cylinder Holes per injector Injection system Make Type Electronic Control Unit Siemens Lights/instrument panel Reference Technical specifications Bulbs Front headlight (low beam/high beam) H7 (12 V - 55 W) Number plate light C5W (12 V - 5 W)
Page 37: Dimensions
section C 1.2 Technical data 1.2 - Dimensions 1452 2058 Monster 696/696+ - M.Y. 2009 - edition 00...
Page 38 section Technical data 2 - Fuel, lubricants and other fluids Fuel, lubricants and other fluids Type dm³ (litres) Fuel tank, including a reserve of 3.5 dm (litres) Unleaded fuel with an octane rating of at least 95-98 RON Sump and filter SHELL Advance Ultra 4 Front/rear brake and clutch circuits SHELL Advance Brake DOT 4...
Page 39: Torque Settings
section Technical data 3 - Torque settings Frame torque settings Part Thread/pitch (mm) Nm ±10% Tolerance Notes Headlight fairing Screw securing plexiglass to headlight fairing M4x0.7 Screw securing headlight fairing bracket to headlight M6x1 support Lower screws initial tightening Upper screws final tightening Lower screws final tightening Screw securing headlight fairing to bracket M5x0.8...
Page 40 section Technical data Part Thread/pitch (mm) Nm ±10% Tolerance Notes Electrical System Screws securing coil to battery support M5x0.8 RH/LH handlebar switch screw M5x0.8 Screw securing battery lead to battery terminal M6x1 Nut securing contactor cable to starter motor M6x1 GREASE D Nut securing battery leads/starter motor to contactor M6x1...
Page 41 section Technical data Part Thread/pitch (mm) Nm ±10% Tolerance Notes Handlebar clutch lever Handlebar clamp screw M8x1.25 GREASE B Sequence 1-2-3-4 Clutch bleed valve M6x1 Clutch hose connector M10x1 Clutch slave cylinder screw M6x1 Sequence 1-2-3-1 Throttle twistgrip retaining screw M6x1 Sequence 1 (UP)-2-1 Clutch master cylinder screw...
Page 42 section Technical data Part Thread/pitch (mm) Nm ±10% Tolerance Notes Fuel tank Screw securing fuel tank support brackets to fuel tank M6x1 Screw securing fuel pipe guide to fuel tank M5x0.8 Screw securing flange to fuel tank M5x0.8 Tank filler cap screw M5x0.8 Special screw (twin male thread) securing flange to M5x0.8...
Page 43 section Technical data Part Thread/pitch (mm) Nm ±10% Tolerance Notes Screws securing subframe joining plate to rear tile M6x1 assembly Screws securing exhaust support plate to fuel tank support plate Screw securing fuel tank to bracket on rear subframe M8x1.25 LOCK 1 Seat lock nut M22x1.5...
Page 44: Engine Torque Settings
section Technical data Engine torque settings Part Thread (mm) Min. Max. Notes Oil temperature sensor holder nut M30x1.5 LOCK 4 Camshaft timing belt pulley nut M15x1 GREASE A Oil temperature sensor M12x1.5 LOCK 4 Cylinder head nuts M10x1.5 Apply GREASE C to face Stage 1 under cylinder head and Stage 2...
Page 45 section Technical data Part Thread (mm) Min. Max. Notes Crankcase screw M8x1.25 Initial tightening Final tightening Crankcase drilled screw M8x1.25 Crankcase screw M6x1 Crankcase screw M6x1 Blow-by valve screw M6x1 Radial pick-up screw M6x1 Clutch side primary bearing retaining plate screw M6x1 LOCK 2 or THREE BOND 1324...
Page 46 section Technical data Part Thread (mm) Min. Max. Notes Wet clutch centre nut M25x1.5 GREASE B Oil filler plug M20x2.5 Oil way blanking plug M10x1 LOCK 5 or THREE BOND 1375B Oil pressure sensor M10x1 Dry clutch drum screws M8x1.25 LOCK 4 Clutch cover screw M6x1...
Page 47: Service Tools
section Technical data 4 - Service tools Parts catalogue WORKSHOP SERVICE TOOLS Specific tools for the engine Code no. Description 88700.5644 Socket wrench for camshaft pulley nut Torque wrench for tightening front sprocket 88713.2423 88713.2676 Wrench for tightening cylinder head nuts 88713.2103 Stand for cylinder head assembly 98112.0002...
Page 48 Technical data Code no. Description DDS (Ducati Diagnosis System) + 97900.0215 cylinder vacuum meter kit 88765.1581 Valve lift gauge 88765.2878 Spacer and fork feeler gauge 0.2/0.3 mm 88713.2783 Tool for fitting spring and closing rocker 88713.2009 Belt pulley timing tool 88713.2011...
Page 49 section Technical data Code no. Description 88713.1091 Plate for gear selector fork positioning 88713.1749 Puller for drive pulley and cover 88765.1297 TDC gauge 88713.2837 Rocker pin puller 88713.2556 Clutch drum holding tool 88713.2591 Clutch screw 88713.2036 Alternator holding tool for tightening nut Monster 696/696+ - M.Y.
Page 50 section Technical data Code no. Description 88713.2092 Primary drive gears puller 88713.3152 Tool for tightening timing belt roller nut 88713.2442 Oil seal installation tool 88713.2906 Oil filter cartridge wrench 88713.2282 Pulley holding tool 88713.1411 Oil seal installation tool Monster 696/696+ - M.Y. 2009 - edition 00...
Page 51: Specific Tools For The Frame
section Technical data Parts catalogue WORKSHOP SERVICE TOOLS Specific tools for the frame Code no. Description 677.4.003.1A Chain joining link 88713.1072 Drift to install half bearing in bottom yoke 88713.1344 Chain assembly tool 8000.70139 Front wheel axle wrench 88713.1096 Tool for forks overhaul - oil seal installation Monster 696/696+ - M.Y.
Page 52 section Technical data Code no. Description 88713.1058 Wrench for steering stem nut 88713.1062 Tool for installing steering head bearings 88713.1010 Exhaust gases pick-up connector 88713.3166 Wrench for tightening frame ring nut Monster 696/696+ - M.Y. 2009 - edition 00...
Page 53 D - Use and maintenance...
Page 54 Adjusting the throttle and choke cables Adjusting the position of the gearchange and rear brake pedals Adjusting the rear shock absorber 5 - Diagnostic instruments Description of the Ducati Diagnostic System tester Tester power supply DDS tester Checking and adjusting timing belt tension...
Page 55: Preliminary Checks
Throughout the running-in period, be careful to stick to the recommended maintenance schedule and periodic service intervals indicated in the warranty booklet. Failure to comply with these rules will release Ducati Motor Holding S.p.A. from any liability whatsoever for any engine damage or shorter engine life.
Page 56: Pre-Ride Checks
section Use and maintenance Pre-ride checks Warning Failure to carry out these checks before riding may result in damage to the motorcycle and serious injury to the rider. Before starting, check the following points: Fuel level in the tank Check the fuel level in the tank. Fill the tank if needed (Sect. C 2, Fuel, lubricants and other fluids). Engine oil level Check the oil level in the sump through the sight glass.
Page 57: Starting - Engine Warmup
section Use and maintenance 2 - Starting - Engine warmup Starting the engine Normal ambient temperature (between 10 °C/50 °F and 35 °C/95 °F) Turn the ignition switch to position (1). Check that both the green N light and the red light on the instrument panel come on (Sect.
Page 58 section Use and maintenance Warning The engine can be started with the sidestand down and the gearbox in neutral. When starting the engine with a gear engaged, pull in the clutch lever (in this case the sidestand must be in the raised position). Subsequently, move the cold start lever (2) gradually towards its vertical position as the engine warms up.
Page 59: Routine Maintenance Table
section Use and maintenance 3 - Routine maintenance table Programmed maintenance plan: operations to be carried out by the dealer List of operations with frequency km x1000 (distance or time interval*) miles x1000 22.5 37.5 Months • • • • •...
Page 60: Programmed Maintenance Plan: Operations To Be Carried Out By The Customer
section Use and maintenance Programmed maintenance plan: operations to be carried out by the customer List of operations with frequency km x1000 (distance or time interval *) miles x1000 Months • Check the engine oil level • Check the brake and clutch fluid levels •...
Page 61: Maintenance Operations
section Use and maintenance 4 - 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 62 section Use and maintenance Remove the oil sump filter cartridge (4) using service tool 88713.2906. Important Dispose of the used cartridge, do not attempt to reutilise it. Fit a new cartridge (4) using service tool 88713.2906: lubricate the seal with engine oil. Notes It is advisable to fill the filter cartridge (2) with engine oil before installing it: this enables the recommended oil level to be maintained without topping up.
Page 63 section Use and maintenance Remove the filler cap (2) and fill with oil of the recommended type (Sect. C 2, Fuel, lubricants and other fluids) up to the MAX line in the sight glass. Refit the filler cap (2). Run the engine at idle speed for a few minutes. Check for oil leaks.
Page 64: Checking Valve Clearances
section Use and maintenance Checking valve clearances Proceed as described in Sect. N 4.1, Checking and adjusting valve clearances. With the valve in the rest position, slide a feeler gauge between the opening rocker and the opening shim to measure the clearance.
Page 65: Adjusting The Valve Clearances
section Use and maintenance 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 0.20 mm Exhaust: Adjusting clearance...
Page 66: Changing And Cleaning The Air Filters
section Use and maintenance Changing and cleaning the air filters The air filter must be renewed at the intervals indicated in the “Routine maintenance table” (Sect. D 3). Raise the fuel tank (Sect. L 2, Removal of the fuel tank). Uncsrew the three screws (1) securing the filter cover (2).
Page 67: Changing The Brake Fluid
section Use and maintenance 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. Filling the front brake circuit Undo the screws (3) and remove the cover and membrane (1) from the front brake fluid reservoir (2).
Page 68 section Use and maintenance Operate the clutch lever two or three times until the circuit is pressurized. Hold the lever pulled in towards the handgrip. Loosen the bleed valve (4) to allow fluid to escape. Warning While filling the system, always keep the fluid level above the MIN mark to prevent the formation of air bubbles in the circuit. Allow the fluid to flow from the bleed valve (4) until it changes colour.
Page 69 section Use and maintenance Attach a length of transparent plastic tubing to the bleed valve (7) and insert the other end of the tubing in a container placed on the floor. Siphon off the fluid from the reservoir (5). Fill the reservoir (5) with new brake fluid up to the MAX mark. Operate the brake pedal two or three times to pressurize the circuit.
Page 70: Draining The Brake Circuit
section Use and maintenance Draining the brake circuit 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. Remove the cover (1) and membrane from the front brake fluid reservoir (2) and the cover (5) from the rear brake fluid reservoir (6).
Page 71 section Use and maintenance 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 caliper bleed valve (4) or rear caliper bleed valve (7) and immerse the other end of the tubing in a container on the floor containing old brake fluid.
Page 72: Filling The Brake System With Fluid
section Use and maintenance Filling the brake system with 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. Fill the reservoirs (2) and (5) with the recommended fluid (Sect.
Page 73 section Use and maintenance Connect the bleed tool to bleed valve (4) or (7). Notes Follow the manufacturer's instructions when using a commercial brake bleeding tool. Open the bleed valve (4) or (7) and pump with the bleeder. Make sure that the reservoir level does not fall below the MIN mark. Repeat the bleeding operation until the fluid flowing from the tube is completely free of air bubbles.
Page 74 section Use and maintenance Tighten the bleed valve (4) or (7) to the specified torque (Sect. C 3, Frame torque settings). Replace the dust cap. Top the fluid up to the correct level and refit cover (1) to reservoir (2) and tighten screws (3) and fit cap (5) to reservoir (6). Monster 696/696+ - M.Y.
Page 75: Changing The Clutch Fluid
section Use and maintenance Changing the clutch fluid Warning Clutch fluid will damage painted surfaces if spilled on them. In addition, it is very harmful in contact with the skin or with the eyes; in the event of accidental contact wash the affected area with abundant running water. Undo the screws (3) and remove the cover and membrane (1) from the clutch fluid reservoir (2).
Page 76 section Use and maintenance Allow the fluid to flow from the bleed valve (4) until it changes colour. Tighten the bleed valve (4) to the specified torque (Sect. C 3, Frame torque settings) and top up the reservoir fluid level. Monster 696/696+ - M.Y.
Page 77: Draining The Clutch Hydraulic Circuit
section Use and maintenance 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 event of accidental contact, wash the affected area with abundant running water. Remove the dust cap to expose the bleed valve (4).
Page 78 section Use and maintenance Withdraw the clutch slave cylinder assembly (6). Push in the internal piston to force out all the fluid from inside the cap. Refit the slave cylinder cap and tighten retaining screws (5) to the specified torque (Sect. C 3, Frame torque settings). Tighten the bleed valve to the specified torque (Sect.
Page 79: Filling The Clutch Circuit
section Use and maintenance Filling the clutch 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 event of accidental contact, wash the affected area with abundant running water. Fill the reservoir (2) with the recommended fluid (Sect.
Page 80 section Use and maintenance Fill up to 3 mm above the MIN level mark on the reservoir. Replace the membrane and the cover (1) on the reservoir (2) and tighten the screws (3). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 81: Adjusting The Steering Head Bearings
section Use and maintenance Adjusting the steering head bearings Excessive handlebar play or the forks shaking in the steering head indicate that the play in the steering head bearings requires adjustment. Proceed as follows. Unscrew the four screws (1), remove the two clamps (2) and remove the handlebar (3) from the steering head, positioning it out of the way so it does not hinder subsequent operations.
Page 82 section Use and maintenance Reposition the handlebar (3), fit the clamp (2) and tighten the four clamp screws (1) to the specified torque (Sect. C 3, Frame torque settings). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 83: Adjusting The Chain Tension
section Use and maintenance Adjusting the chain tension Tensioning the drive chain. Turn the rear wheel slowly to find the position at which the chain is at its most taut. With the motorcycle on its sidestand, press with a finger in the centre of the bottom run of the chain and measure the distance between the centres of chain link pins and the aluminium swingarm.
Page 84: Checking Brake Pad Wear And Changing Brake Pads
section Use and maintenance Checking brake pad wear and changing brake pads 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. Important On handing over the motorcycle after changing the brake pads, inform the customer that the front brake must be used gently for the first 100 km to allow the pads to bed in completely.
Page 85 section Use and maintenance Insert the new pads and clip (1). Slide in the pad retaining pin (4) and secure it in position with the cotter pin (3). Operate the brake lever repeatedly so that the pads are firmly bedded in against the disc by the force of the brake fluid. Check that the brake fluid level in the master cylinder reservoir is above the MIN mark.
Page 86 section Use and maintenance Insert the new pads and clip (3). Slide in the pad retaining pin (2) and secure it in position with the circlip (1). 1 mm Operate the brake pedal repeatedly so that the pads are bedded in against the disc by the force of the brake fluid. Check that the brake fluid level in the reservoir (4) is between the MIN and MAX marks.
Page 87: Adjusting The Throttle And Choke Cables
section Use and maintenance Adjusting the throttle and choke cables The throttle cable should have freeplay of 2 to 4 mm (measured in terms of rotation of the twistgrip rim) in all steering positions. If necessary, adjust the freeplay with the adjuster (1) located on the twistgrip. 2 ÷...
Page 88 section Use and maintenance Operate the control to check that the inner cable slides smoothly inside the outer cable: if you feel excessive resistance or stiffness, renew the cable. To lubricate throttle cable, undo the two screws (9) and remove the upper half of the twistgrip housing (8). Grease the end of the cable (10) and the race.
Page 89: Adjusting The Position Of The Gearchange And Rear Brake Pedals
section Use and maintenance Adjusting the position of the gearchange and rear brake pedals The position of the gearchange and rear brake pedals in relation to the footrests can be adjusted to suit the preferred riding position. To adjust the position of the gearchange pedal, proceed as follows. Restrain the tie-rod (1) and slacken the locknuts (2) and (3).
Page 90: Adjusting The Rear Shock Absorber
section Use and maintenance Adjusting the rear shock absorber Adjuster (1), located on the left-hand side at the point at which the top of the shock absorber is fixed to the rear sub-frame, controls rebound damping. Adjuster nuts (2) and (3), located at the bottom of the shock absorber, serve to adjust the preload of the outer spring. Turn the adjuster (1) clockwise to stiffen the damping H and anti-clockwise to soften it S.
Page 91 section Use and maintenance Important If the motorcycle is to be ridden with a pillion rider and luggage, we recommend setting the rear shock absorber spring preload to the maximum to ensure the best handling and proper ground clearance at all times. It may also be necessary to adjust the rebound damping accordingly.
Page 92: Diagnostic Instruments
Use and maintenance 5 - Diagnostic instruments 1 97900.0211 Basic DDS (Ducati Diagnosis System) 2 97900.0227 Power and diagnostic cable D607 3 97900.0222 Power and diagnostic cable 1060838 (Measurement Module) 4 97900.0218 Vacuum sensor 5 552.1.039.1A Pressure sensor 6 97900.0220 Pressure/vacuum pipe 7 97900.0221 Pipe fitting...
Page 93: Description Of The Ducati Diagnostic System Tester
Description of the Ducati Diagnostic System tester The Ducati Diagnostic System (DDS) is used for diagnosis of the injection-ignition system via a serial connection. The system is also equipped with functions to test various devices on the motorcycle. The DDS tester can be used to measure current and voltage on any electrical device, to perform tests on individual components and to measure pressure and temperature values.
Page 94 section Use and maintenance The display unit is equipped with two connection panels: one at the top of the instrument and one at the bottom. The top connection panel has 6 connection sockets with the following functions: - one VGA output (E); - one port for connection of the measurement module (F);...
Page 95: Tester Power Supply
section Use and maintenance Tester power supply The DDS tester (1) may be powered in any one of the following ways: - from the mains power supply: by connecting the mains adapter (14) to the power connection socket (N); - from the motorcycle: by connecting the specific cables (see paragraph “Connection to the motorcycle”); - from the tester's internal battery: the battery (Q) is housed in the top part of the tester.
Page 96 section Use and maintenance Connection to the motorcycle The tester requires a power supply of between 9 and 16 Volts DC. When using the tester, take care never to allow the power supply to fall below the minimum voltage: this situation could occur during engine starting and idling on motorcycles in which the battery is not in perfect working order.
Page 97 section Use and maintenance - connect the power and diagnostic cable (2) to the diagnostic connection socket (P) on the tester; then connect the battery socket adapter (8) to the connection socket (R) on the power and diagnostics cable (2) and to the motorcycle battery. Notes For connection of the various devices required for self-diagnostic procedures, consult the instruction handbook supplied with the tester.
Page 98: Dds Tester
section Use and maintenance DDS tester The main functions of the DDS tester 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 99 section Use and maintenance Take the measurement on section (23) of the horizontal belt as described in the paragraph “Measuring timing belt tension”. Turn the crankshaft through 270° in the direction of rotation of the engine (so that the piston of the vertical cylinder is at TDC of the power stroke) and repeat the procedure used for the horizontal cylinder, measuring the tension on section (22) of the vertical cylinder timing belt.
Page 100 section Use and maintenance Fix the mounting bracket of the belt tension sensor (15) using the timing belt cover bolt (21). Aim the central green LED of the sensor (15) at the mid-point of the belt run, with the reader parallel to the belt and at a distance of about 1 to 1.5 cm from it.
Page 101 section Use and maintenance Flick the belt lightly with your finger and read the frequency value (Hz) on the DDS tester. Notes Do not flick the belt several times repeatedly, as the minimum time necessary for the DDS tester to take a reading is 1 second. Correct tension values are as shown in Sect.
Page 102 section Use and maintenance Important Rotate the contact point (U) anti-clockwise to increase belt tension or clockwise to reduce it. 88713.1215 Re-check the timing belt tension. Repeat the above procedure until the correct belt tension is obtained. Then tighten the screws (24) and (25) to the specified torque (Sect. C 3, Engine torque settings). Monster 696/696+ - M.Y.
Page 103: Adjusting The Idle Speed
Adjusting the idle speed 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 part no. 88713.1010 to the outlets on the exhaust pipes, using the connection fittings (20).
Page 104 section Use and maintenance Warning If the engine is shut off before proceeding with adjustment of the CO level, wait three minutes after restarting for the enrichment phase to finish and for the lambda sensors to start working. If the ifle speed is high and cannot be corrected by adjusting the air bypass screws, check the seals under the throttle body, in particular check for cracks or other damage in the intake manifolds and thelatter are fimrly fixed to the engine, cuts in the pressure sensor pipes, etc.
Page 105 Connect the Measurement Module cable (3) to the Measurement Module connector on the DDS tester (see paragraph “Description of the Ducati Diagnostic System tester”). Connect the vacuum/pressure pipes (6) to the connectors (A) and (C) of cable (3) and connect the fittings (7) to the pipes.
Page 106 section Use and maintenance Open both bypass screws (21) by one turn from the fully closed position. Warning Press the “Reset” icon (G), then connect the sensors (4) and (5) to connectors (A) and (C) of the cable (3) and to the vacuum/ pressure pipes (6).
Page 107 section Use and maintenance To adjust the balance, turn the bypass screws (21) until the two lines on the graph coincide, if in graphic mode, or until identical numerical values are displayed, if in numerical mode. Correct balancing is obtained when the two lines of the graph are superimposed or when the two numerical values indicated are equal.
Page 108: Check The Engine Oil Pressure
section Use and maintenance Check the engine oil pressure Notes The on-screen icons used during this procedure are explained in a table at the end of this section. To measure the pressure of the lubrication circuit, use the engine oil pressure test point (21) as described below. Disconnect the wiring connector (A) and remove the pressure switch (21), taking care to recover the seal.
Page 109 section Use and maintenance Connect the pressure sensor (5) to the pipe (12) to transform the pressure signal into an electrical signal. Switch on the DDS tester (1); see paragraph “Tester power supply”. Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (B) on the DDS tester (1).
Page 110 section Use and maintenance On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “PressureTest” icon (D) followed by the “Start” icon (E). The letter A is displayed on the screen to indicate the connection socket of the Measurement Module cable (3). Monster 696/696+ - M.Y.
Page 111 section Use and maintenance Start the engine. The values may be displayed in three different ways: in one numerical form or in two graphic forms; to select the desired display type, press the “Value display” icon (F). 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.
Page 112 section Use and maintenance Remove the tool and refit the pressure switch (21) along with its seal. Tighten the pressure switch to the specified torque (Sect. C 3, Engine torque settings). Reconnect the electrical system connector (A) to the pressure switch. Disconnect the DDS tester.
Page 113: Cylinder Compression Test
section Use and maintenance Cylinder compression test Notes 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. Excessive or insufficient pressure, or an excessive difference between the two cylinders, will result in a reduction in engine performance and can lead to component failure.
Page 114 section Use and maintenance Connect the pressure sensor (5) to socket (A) of the cable (3). Notes Measure the compression on one cylinder at a time. On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “Cylinder Compression”...
Page 115 section Use and maintenance The letter A is displayed on the screen to indicate the connector of the Measurement Module cable (3). Open the throttles completely. Turn over the engine with the starter motor until the pressure stops rising. Check the pressure in each cylinder: - standard value: 11 to 12 bar;...
Page 116: Fuel Pressure Test
section Use and maintenance Fuel pressure test Notes The on-screen icons used during this procedure are explained in a table at the end of this section. Lift the fuel tank (Sect. L 2, Removal of the fuel tank). Remove the fuel feed hose (20). Take the fuel pressure pipe test (17) and connect one end (D) to the outlet fitting on the tank and the other end (E) to the fuel feed hose (20) in this way, the fuel pressure can be measured at the test outlet (F).
Page 117 section Use and maintenance Switch on the DDS tester (1); see paragraph “Tester power supply”. Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (E) on the DDS tester (1). Connect the pressure sensor (5) to socket (A) or (C) of the cable (3). On the DDS tester (1), select the “Measurement module”...
Page 118 section Use and maintenance The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C. 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”...
Page 119: Immobilizer Override Procedure
section Use and maintenance Immobilizer override procedure Notes 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 Sect.
Page 120 section Use and maintenance 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” to display a list of the bike’s systems that can be analysed. Select “Engine electronics”...
Page 121 section Use and maintenance Press the “Actuators” icon (C) to display the actuators and other components connected to the ECU. Select the option “Immobilizer Override” and then press the icon “Apply” (D). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 122 section Use and maintenance 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 123: Guided Diagnosis
section Use and maintenance Guided diagnosis Notes The on-screen icons used during this procedure are explained in a table at the end of this section. The DDS tester guides the operator step-by-step through the various diagnostic procedures, providing descriptions and documentation for motorcycle components, wiring diagrams for the electronic systems and information on the locations of specific components.
Page 124 section Use and maintenance 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” to display a list of the bike’s systems that can be analysed. Select “Engine electronics”...
Page 125 section Use and maintenance 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. If any errors are present, the symbol (D) will be displayed. To determine the type of errors present, press the “Errors”...
Page 126: Testing The Battery Charging System
section Use and maintenance Testing the battery charging system Notes 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 the alternator to produce sufficient current to charge the battery, power the injection/ignition system and all the electrical equipment on the motorcycle.
Page 127 section Use and maintenance On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “Ammeter” icon (F) followed by the “Start” icon. The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C.
Page 128 section Use and maintenance If the measured current is a positive quantity, this means that alternator is powering all the electrical equipment and charging the battery at the same time. If the current has a negative sign, this means that the charging system is not able to power the electrical loads and a significant amount of the current required must be supplied by the battery, which is therefore discharging.
Page 129: Icons Table
section Use and maintenance Icons table Symbol Description Confirm Exit Measurement module Belt tension Start/stop Menu 1 Select vehicle Select motorcycle Self-diagnosis Settings Apply Cylinder synchronisation Value display Reset Pressure test Cylinder compression Actuators Monster 696/696+ - M.Y. 2009 - edition 00...
Page 130 section Use and maintenance Symbol Description Guided diagnosis Select system Errors Ammeter clamp Monster 696/696+ - M.Y. 2009 - edition 00...
Page 131 E - Fairings...
Page 132 section Fairings 1 - Headlight fairing - rear-view mirrors Removal of the rear-view mirrors Refitting the rearview mirrors Removal of the headlight fairing (696+) Refitting the headlight fairing (696+) 2 - Fairings Removal of the fuel tank fairings Refittings the fuel tank fairings 3 - Seat Removal of the seat Refitting the seat...
Page 133: Headlight Fairing - Rear-View Mirrors
section Fairings 1 - Headlight fairing - rear-view mirrors 696+ 1 Rearview mirror 2 Screw 3 Upper clamp 4 Spring washer 5 Bracket 6 Nut 7 Screw 8 Headlight fairing 9 Screw 10 Windshield 11 Nut 12 Quick-release fastener 13 Screw 14 Washer Parts catalogue INSTRUMENT PANEL –...
Page 134: Removal Of The Rear-View Mirrors
section Fairings Removal of the rear-view mirrors Undo the screws (2), remove the rearview mirrors (1) and recover the washers (4). Refitting the rearview mirrors Insert the mirror (1) in the clamp (3) and fit the screw (2) with the washer (4). Tighten the screw (2) to the specified torque (Sect.
Page 135: Removal Of The Headlight Fairing (696+)
section Fairings Removal of the headlight fairing (696+) Counterhold the nuts (6) and unscrew the screws (9) from the headlight support and remove the headligt fairing (8) complete with the brackets (5). To remove the brackets (5), undo the screws (7), taking care not to lose the quick-release fasteners (12). 10 14 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).
Page 136: Refitting The Headlight Fairing (696+)
section Fairings 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). Refitting is the reverse of removal; tighten the retaining screws (13) to the specified torque (Sect. C 3, Frame torque settings). Refitting the headlight fairing (696+) Fit the brackets (5) to the headlight support, fitting the screws (9) and nuts (6).
Page 137 section 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 Special screw 10 Nylon washer 11 Screw 12 Screw Parts catalogue...
Page 138: Removal Of The Fuel Tank Fairings
section Fairings Removal of the fuel tank fairings Remove the seat (Sect. E 3, Removal of the seat). Unscrew the screws (7) and (12) securing the front tank cover (3) but do not remove the cover. Undo the screws (4) and (11) eand remove the RH tank cover (1) and LH tank cover (2) releasing the tabs (A) from the slots (B) in the rear cover (5): recover the nylon washers (10).
Page 139: Refittings The Fuel Tank Fairings
section Fairings Remove the front tank cover (3) and recover the spacers (6). Unscrew the special screws (9) and remove the rear tank cover (5). Refittings the fuel tank fairings Locate the rear cover (5) on the fuel tank and secure it in place with the special screws (9). Tighten the two upper special screws (9) to the specified torque (Sect.
Page 140 section Fairings Check that the four bushes (6) are installed on the front tank cover (3) with the larger diameter side facing upwards (as shown in the photo). Locate the front tank cover (3) on the fuel tank. Refit the right-hand tank cover (1), inserting the tabs (A) in the corresponding slots (B) in the rear cover (5). Insert the screws (11) complete with the nylon washers (10) and screws (11) in the RH tank cover (1) and LH tank cover (2).
Page 141 section Fairings Insert the screws (7) and (12) in the front tank cover (3). Tighten the screws (12) and (7) to the specified torque (Sect. C 3, Frame torque settings), starting with the front screw. Tighten the screws (4) and (11) to the specified torque (Sect. C 3, Frame torque settings). Monster 696/696+ - M.Y.
Page 142: Seat
section Fairings 3 - Seat 696+ 1 Seat 2 Helmet lock cable 3 Screw 4 Tool tray 5 Rubber 6 Special screw 7 Spacer 8 Rubber mounting 9 Elastic strap 10 Seat cover Parts catalogue SEAT 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 143: Removal Of The Seat
section Fairings Removal of the seat Insert the key in 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 from the frame. Disassembly of the seat On the 696+ version, unscrew the two special screws (6) and slide off the seat cover (10).
Page 144: Refitting The Seat
section Fairings Refitting the seat To refit the seat, engage the front end of the seat base in the lugs (B) on the fuel tank, then push down on the rear end of the seat until you hear the latch click into place. Removal of the tool tray Remove the seat as described in the paragraph “Removal of the seat”...
Page 145: Refitting The Tool Tray
section Fairings Refitting the tool tray Refit the tool tray (4), insert the screws (3) and tighten to the specified torque (Sect. C 3, Frame torque settings). Refit the seat as described in this section in the paragraph “Refitting the seat”. Monster 696/696+ - M.Y.
Page 146: Front Mudguard
section Fairings 4 - Front mudguard 1 Front mudguard 2 Washer 3 Rivet 4 Clip 5 Screw 6 Nylon washer Parts catalogue FUEL TANK (COVER) 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 147: Removal Of The Front Mudguard
section Fairings Removal of the front mudguard Disconnect the front brake hose (A) from the clip (4). Remove the retaining screws (5) and recover the nylon washers (6). LOCK Remove the front mudguard (1). Notes On USA versions, a reflector is mounted on the front mudguard (1). Notes The clip (4) is secured to the front mudguard by means of a shear rivet (3) with two washers (2).
Page 148: Refitting The Front Mudguard
section Fairings 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 braking. Apply threadlocker to the screws (5). Position the front mudguard (1) and refit the retaining screws (5) with the washers (6). Locate the front brake hose grommet (A) in the mudguard clip (4).
Page 149 F - Controls - Devices...
Page 150 section Controls - Devices 1 - Throttle and choke controls Adjusting the throttle and choke cables Removal of the throttle twistgrip Refitting the throttle twistgrip Removal of the choke cable Refitting the choke control 2 - Hydraulic clutch control Removal of the clutch master cylinder assembly Refitting the clutch master cylinder assembly Removal of the clutch slave cylinder Refitting the clutch slave cylinder...
Page 151: Throttle And Choke Controls
section Controls - Devices 1 - Throttle and choke controls 1 Grips 2 Choke control cable 3 Screw 4 Screw 5 Throttle twistgrip 6 Throttle cable 7 Spring 8 Throttle cable adjuster on handlebar 9 Plug 10 Throttle cable adjuster on throttle body 11 Choke cable adjuster on throttle body 12 Choke cable adjuster on handlebar 13 Cover...
Page 152: Adjusting The Throttle And Choke Cables
section Controls - Devices Adjusting the throttle and choke cables Read Sect. D 4, Adjusting the throttle and choke cables for instructions on throttle and choke cable adjustments. Removal of the throttle twistgrip Rotate the race on the throttle body linkage to free the end (D) of the inner cable from the race. Peel back the rubber sleeve (A), unscrew the lock nut (B) and unscrew the adjuster (10) from the race on the throttle body.
Page 153 section Controls - Devices Remove the throttle cable (6) from the motorcycle. Remove the end plug (9) from the handlebar. Loosen the two screws (3) fixing the throttle twistgrip to handlebar. Remove the throttle twistgrip (5) from the handlebar. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 154: Refitting The Throttle Twistgrip
section Controls - Devices 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. Apply the recommended grease to the throttle cable (6). Notes Refer to the figures at the end of the chapter for the correct routing of the starter control cable.
Page 155: Removal Of The Choke Cable
section Controls - Devices Removal of the choke cable Unscrew the choke cable retaining screw (E). Peel back the rubber sleeve (F), loosen the lock nut (G) and screw the adjuster (11) completely out of the bracket. Withdraw the choke cable (2) from the throttle body and recover the spring (7). Remove the left-hand handlebar switch (14) with the choke control by unscrewing the screws (H).
Page 156: Refitting The Choke Control
section Controls - Devices Refitting the choke control Notes The choke control is supplied as a replacement part complete with the adjusters and cable. Lubricate the choke cable (2). Insert the choke cable (2) in the left-hand handlebar switch and locate the inner cable end fitting (L) in its notch. Refit the left-hand switch (14) to the handlebar and tighten the screws (H) to the specified torque (Sect.
Page 157 section Controls - Devices Notes Refer to the figures on the next page for correct routing of the choke cable. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 158 section Controls - Devices Positioning of the throttle/choke cables Monster 696/696+ - M.Y. 2009 - edition 00...
Page 159 section Controls - Devices Monster 696/696+ - M.Y. 2009 - edition 00...
Page 160: Hydraulic Clutch Control
section Controls - Devices 2 - Hydraulic clutch control 1 Clutch master cylinder 12 Dust cap 2 Inspection plug (replacement part) 13 O-ring 3 Lever pivot pin 14 Clutch slave cylinder 4 Lever with grub screw 15 Screw 5 Fluid reservoir cover 16 Clutch pushrod 6 Clutch hose 17 O-ring...
Page 161: Removal Of The Clutch Master Cylinder Assembly
section Controls - Devices 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. Incorrect overhaul of this component could endanger rider safety. Maintenance operations of the master cylinder are limited to replacing the following parts: control lever, reservoir unit, and master cylinder fasteners.
Page 162: Refitting The Clutch Master Cylinder Assembly
section Controls - Devices Refitting the clutch master cylinder assembly Position the clutch master cylinder assembly (1) so that the line of the gasket (A) between the clamp and cylinder is aligned with the punch mark (B) on the handlebar. Tighten the retaining screws (7) to the specified torque (Sect.
Page 163 section Controls - Devices For the positioning of the clutch hose (6) and retaining clips, see the illustration at the end of this section. Locate the hose (6) as shown in the figure, then tighten down the banjo bolt (9) to the specified torque (Sect. C 3, Frame torque settings).
Page 164: Removal Of The Clutch Slave Cylinder
section Controls - Devices Removal of the clutch slave cylinder Warning The manufacturer of the clutch slave cylinder (14) advises against servicing of its internal parts due to the safety-critical nature of this component. Incorrect overhaul of these critical safety components can endanger rider and passenger safety. The only components that should be renewed are the complete clutch slave unit, the bleed valve, the seals and the complete clutch pushrod assembly.
Page 165: Refitting The Clutch Slave Cylinder
section Controls - Devices Refitting the clutch slave cylinder Grease and refit the clutch pushrod (16) with the two O-rings (17). Locate the slave cylinder unit (14) in the crankcase and tighten the screws (15) to the specified torque (Sect. C 3, Frame torque settings).
Page 166 section Controls - Devices Locate the two sealing washers (8) and tighten the banjo bolt (10) to the specified torque (Sect. C 3, Frame torque settings). Refit the bleed valve (11) and the dust cap (12). Refer to the diagram on the following page for correct positioning of the hose retaining clips (6). Operation Section reference Fill the clutch system with fluid...
Page 167 section Controls - Devices Positioning of the clutch hose Monster 696/696+ - M.Y. 2009 - edition 00...
Page 168 section Controls - Devices Monster 696/696+ - M.Y. 2009 - edition 00...
Page 169: Front Brake Control
section Controls - Devices 3 - Front brake control 1 Front brake master cylinder 2 Lever grub screw 3 Rubber mounting 4 Nut 5 Microswitch 6 Lever pivot pin 7 Caliper–master cylinder hose 8 Fluid reservoir cover 9 Inspection plug (replacement part) 10 Mounting clamp 11 Banjo bolt 12 Sealing washer...
Page 170: Removal Of The Front Brake Master Cylinder
section Controls - Devices Removal of the front brake master cylinder Warning The brake master cylinder manufacturer advises against servicing the brake master cylinder due to the safety critical nature of this component. Incorrect overhaul of these critical safety components can endanger rider and passenger safety. Maintenance operations on these units are limited to replacing the following parts: control lever, reservoir unit, reservoir fasteners and master cylinder fasteners.
Page 171: Refitting The Front Brake Master Cylinder
section Controls - Devices Refitting the front brake master cylinder Warning If incorrectly positioned, the hose can affect brake operation and foul moving parts. Position the hose as shown in the figure. Position the brake master cylinder assembly (1) so that the line of the gasket (A) between the clamp and cylinder is aligned with the punch mark (B) on the handlebar.
Page 172: Rear Brake Control
section Controls - Devices 4 - Rear brake control 1 Banjo bolt 14 Bush 2 Sealing washer 15 Fork 3 Rear brake hose 16 Hose 4 Hose clip 17 Rear brake master cylinder 5 Pin 18 Screw 6 Spring 19 Pushrod 7 Adjuster screw 20 Rubber boot 8 Rubber...
Page 173: Removal Of The Rear Brake Master Cylinder
section Controls - Devices Removal of the rear brake master cylinder Warning 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. Maintenance operations on these units are limited to replacing the following parts: control lever, reservoir unit, reservoir fasteners and master cylinder fasteners.
Page 174 section Controls - Devices Unscrew the pin (5) securing the rear brake pedal lever to the footrest bracket and remove the spring (6), the complete pedal lever (9) and the O-ring (24). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 175: Disassembly Of The Rear Brake Control
section Controls - Devices 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 176: Refitting The Rear Brake Master Cylinder
section Controls - Devices Refitting the rear brake master cylinder Lubricate the O-ring (24) eand install it on the pin (5). Lubricate also the other O-ring (24). Fit the spring (6) and the pedal pivot pin (5) to the footrest bracket, pushing the pivot pin fully home and positioning the spring (6) as shown in the figure.
Page 177 section Controls - Devices Locate the hoses (3) and (16) as shown in the figure, then tighten down the banjo bolt (1) to the specified torque (Sect. C 3, Frame torque settings). If the pushrod (19), clip (11) and clevis (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.
Page 178 section Controls - Devices Positioning of rear brake hose Monster 696/696+ - M.Y. 2009 - edition 00...
Page 179 section Controls - Devices Monster 696/696+ - M.Y. 2009 - edition 00...
Page 180 section Controls - Devices Monster 696/696+ - M.Y. 2009 - edition 00...
Page 181: Gearchange Mechanism
section Controls - Devices 5 - Gearchange mechanism 6 17 5 1 Pivot screw 2 Gearchange pedal 3 Screw 4 Rubber 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...
Page 182: Removal Of The Gearchange Mechanism
section Controls - Devices Removal of the gearchange mechanism Unscrew and remove the pivot screw (1) securing the gearchange pedal (2) and recover the washer (6) and the O-ring seals (17). Unscrew and remove the clamp screw (16) securing the gearchange lever (14) to the gear selector shaft. Withdraw the lever (14) complete with the gearchange control assembly.
Page 183: Disassembly Of The Gearchange Mechanism
section Controls - Devices Disassembly of the gearchange mechanism Refer to the exploded view at the beginning of this section for indications on disassembly and renewal of gearchange components. If the bush (5) inside the pedal (2) needs replacing, drive the new bush into place using a press. The bush must be seated 2 mm below the outer face of the pedal.
Page 184: Refitting The Gearchange Mechanism
section Controls - Devices Refitting the gearchange mechanism To refit the gearchange mechanism, reverse the operations of the removal procedure. Notes Fit new O-rings (17) on each reassembly. Apply threadlocker to the clamp bolt (16), pivot screw (1) and screw (15) and then tighten them to the specified torque (Sect.
Page 185 G - Wheels - Suspension - Brakes...
Page 186 section Wheels - Suspension - Brakes 1 - Front wheel Removal of the front wheel Overhauling the front wheel Refitting the front wheel 2 - Front fork Removal of the front forks Overhauling the front forks Refitting the front forks 3 - Hydraulic front brake Maintenance operations Removal of the front brake system...
Page 187: Front Wheel
section Wheels - Suspension - Brakes 1 - Front wheel 1 Nut 2 Screw 3 Spacer 4 Seal 5 Bearing 6 Inner spacer 7 Valve 8 Front wheel axle 9 Front wheel rim Parts catalogue FRONT FORKS 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 188 section Wheels - Suspension - Brakes Removal of the front wheel Support the bike so that the front wheel is raised from the ground. Remove the front brake caliper (B) by unscrewing the two screws (A) securing the caliper to the fork leg; do not disconnect the caliper from the hose.
Page 189 section Wheels - Suspension - Brakes Loosen and remove the nut (1) on left side of the axle. Loosen the axle clamp screws (2) on the ends of the fork legs. Working from the left side, use a plastic mallet to drive the wheel axle (8) out from the opposite side. Remove the wheel and recover the spacer (3) on the left-hand side.
Page 190: Overhauling The Front Wheel
section Wheels - Suspension - Brakes Overhauling the 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 191 section Wheels - Suspension - Brakes Notes Wheels must be rebalanced after repair, maintenance and overhaul operations. Overhauling the front wheel axle Check the wheel axle for straightness. Roll the axle on a reference surface and measure maximum distortion using a feeler gauge (see Sect. C 1.1, Front wheel). Maximum permissible distortion: 0.05 mm.
Page 192: Refitting The Front Wheel
section Wheels - Suspension - Brakes Refitting the front wheel When all the necessary inspections have been completed, refit the wheel as follows. Lubricate the shank and thread of the wheel axle (8). Insert the front wheel between the fork legs, installing the spacer (3) between the wheel hub and the left fork leg. Warning Position the front wheel, observing the arrow (G) marked on the rim showing the direction of rotation.
Page 193 section Wheels - Suspension - Brakes Fit service tool no. 8000.70139 on the wheel axle (8). Drive the axle (8) fully home into the wheel hub, inserting the locating peg of the service tool in the special notches at the bottom end of the fork.
Page 194 section Wheels - Suspension - Brakes Grease the threads and undersides of the heads of screws (A). Screw in the two screws (A) securing the brake caliper (B). Pre-tighten the screws (A) to the specified torque (Sect. C 3, Frame torque settings). Operate the front brake lever two or three times.
Page 195: Front Fork
section Wheels - Suspension - Brakes 2 - Front fork 1 Right fork leg assembly 14 Spring 2 Left fork leg assembly 15 Rubber bush 3 Special screw 16 O-ring 4 Washer 17 Complete damper 5 Screw 18 Outer tube 6 Right inner tube assembly 19 Left inner tube assembly 7 Plug...
Page 196: Removal Of The Front Forks
section Wheels - Suspension - Brakes Removal of the front forks Before removing the front forks, it is necessary to remove the following parts: Operation Section reference Removal of the front brake calipers G 3, Removal of the front brake system Removal of the front mudguard E 4, Removal of the front mudguard Removal of the front wheel...
Page 197: Overhauling The Front Forks
section Wheels - Suspension - Brakes Overhauling the front forks Notes It is advisable to loosen the top cap (7) when the fork is still fitted to the motorcycle. Notes The service tools required for front fork overhaul are listed in Sect. C 4, Specific tools for the frame. Disassembly of the front fork right leg Remove the top cap (7).
Page 198 section Wheels - Suspension - Brakes Fit the service tool code no. 88713.0957, engaging its pins (A) in the upper spacer, and secure in place with the screw (B). 88713.0957 Push the tool downwards to compress the spring and then fit the tool spacer (C) under the cartridge lock nut (13). Apply a wrench to the flats (D) and counterhold the lock nut to loosen the top cap (7).
Page 199 section Wheels - Suspension - Brakes Fit service tool no. 88713.0958 and screw it onto the damper rod. 88713.0958 Push downwards to overcome the force of the spring and remove the spacer (C). 88713.0958 Remove the service tool no. 88713.0957 and slide out the preload tube (12). Remove the spring (9) and pump the outer tube (18) and the damper (8) to expel the oil from the fork.
Page 200 section Wheels - Suspension - Brakes Clamp the inner tube (6) in a vice with soft-faced jaws. Unscrew the screw (3). Remove the adjuster screw (3) and recover the seal (4). Remove the complete damper assembly (8) and locating ring (10). Slide the dust seal (E) off the outer tube (18), prising it off with a screwdriver.
Page 201 section Wheels - Suspension - Brakes Important Take care not to damage the outer tube (18) or inner tube (6). 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).
Page 202 section Wheels - Suspension - Brakes Remove the top cap (7) complete with nut (13), rubber bush (15), bush (20), spring and complete damper asembly (17). Remove the spring (14) and pump the outer tube (18) to expel the oil from the fork leg. Warning This movement generates pressure so that the oil will be rapidly expelled from the fork.
Page 203 section Wheels - Suspension - Brakes Remove the circlip (F). 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 204 section Wheels - Suspension - Brakes Inspection of the front fork right 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 205 section Wheels - Suspension - Brakes Fit the seal (4) and tighten the adjuster screw (3). Hold the right fork leg assembly (2) in a vertical position and fill with fork oil, using 500±2.5 cc of the specific oil. Check the quantity of oil measuring the distance of the level from the end of the outer tube (18). This distance should be 81 mm.
Page 206 section Wheels - Suspension - Brakes Fit service tool 88713.0957 (previously used for removal) into the lateral hole of the upper spacer (12). Push the tool down and position the spacer (D) under the lock nut of the damper (8). Remove service tool no.
Page 207 section Wheels - Suspension - Brakes 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 208 section Wheels - Suspension - Brakes Reassembly of the front fork left leg Locate the outer tube (18) on the inner tube (19). Before reassembly, remove any oil from the spring (14). Notes Install the spring (14), ensuring that the end with tighter coils is towards the bottom of the fork. Hold the left fork leg assembly (2) in a vertical position and fill with fork oil, using 538±2.5 cc of the specific oil.
Page 209 section Wheels - Suspension - Brakes Monster 696/696+ - M.Y. 2009 - edition 00...
Page 210: Refitting The Front Forks
section Wheels - Suspension - Brakes 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). Tighten the clamp screws (24) and (25) securing the legs to the bottom yoke (22) and to the top yoke (25) to the specified torque (Sect.
Page 211: Hydraulic Front Brake
section Wheels - Suspension - Brakes 3 - Hydraulic front brake 1 Pad retaining pin and clip 12 Bracket 2 Screw 13 Brake disc 3 Right brake caliper 14 Screw 4 Sealing washer, thickness 1 15 Front brake hose 5 Bleed valve 16 Screw 6 Banjo bolt 17 Banjo bolt...
Page 212: Maintenance Operations
section Wheels - Suspension - Brakes 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. For maintenance instructions (brake pad wear check and renewal, brake fluid change, etc.) refer to Sect.
Page 213 section Wheels - Suspension - Brakes Remove the brake master cylinder (Sect. F 3, Removal of the front brake master cylinder). Unscrew the two retaining screws (2) securing the left front brake caliper (10) to the fork leg. Repeat the operation for the right brake caliper (3). Unscrew the banjo bolts (17) from both calipers and recover the sealing washers (4).
Page 214: Removal Of The Brake Discs
section Wheels - Suspension - Brakes Removal of the brake discs The front brake discs consist of an inner carrier, which is mounted to the wheel, and an outer rotor. Both parts must be changed together as a pair. Remove the front wheel (Sect. G 1, Removal of the front wheel). Unscrew the six screws (14) securing the brake disc to the wheel and remove the disc (13).
Page 215: Refitting The Front Brake System
section Wheels - Suspension - Brakes Refitting the front brake system Refitting the brake discs Before refitting the brake disc to the wheel, clean all contact surfaces thoroughly and apply threadlocker to the threads of retaining screws (14). Screw the six retaining screws (14) of front brake disc (13) into the front wheel in this sequence: 1-3-5-2-4-6. LOCK Tighten the screws to the specified torque (Sect.
Page 216 section Wheels - Suspension - Brakes Reconnect the hoses (8) and (15) to the front brake calipers (3) and (101) and tighten the bolts (17) to their specified torque (Sect. C 3, Frame torque settings). Notes Make sure that internal hose fitting (8) and external hose fitting (15) are installed to the RH brake caliper (10). Fit the RH caliper (10) over the disc.
Page 217 section Wheels - Suspension - Brakes Operate the front brake lever two or three times until the circuit is pressurized and force the pads against the brake disc. Hold the lever pulled in towards the grip and tighten the caliper screwts (2) to the specified torque (Sect. C 3, Frame torque settings).
Page 218: Rear Wheel
section Wheels - Suspension - Brakes 4 - Rear wheel 1 Nut 2 Pin 3 Slider 4 Screw 5 Bearing 6 Inner spacer 7 Valve 8 Wheel 9 Cush drive bush 10 Bearing 11 Brake disc 12 Screw 13 Ring Parts catalogue FRONT AND REAR WHEELS SWINGARM AND DRIVE CHAIN...
Page 219: Removal Of The Rear Wheel
section Wheels - Suspension - Brakes Removal of the rear wheel Unscrew the screws (B) to remove the brake caliper (A) from the mounting bracket, leaving it connected to the braking system. Place the bike on a service stand so that the rear wheel is clear of the ground. Unscrew and remove the whell retaining nut (1) on the right-hand side of the swingarm.
Page 220 section Wheels - Suspension - Brakes Push the wheel forward so as to be able to unhook the chain from the rear sprocket. Remove the rear wheel from the motorcycle, taking care not to hit the brake caliper mounting bracket, which is just resting on the swingarm, with the brake disc (11);...
Page 221: Overhauling The Rear Wheel
section Wheels - Suspension - Brakes Overhauling the rear wheel Remove the sprocket flange from the wheel (Sect. G 8, Removal of the rear sprocket). Refer to “Overhauling the front wheel”, Sect. G 1 for information on how to check the bearings (5) and (10) and the axle (2) and how to overhaul the rear wheel rim (7). Overhauling the rear brake disc Unscrew and remove the six screws (12) securing the brake disc (11) to the axle (2).
Page 222: Refitting The Rear Wheel
section Wheels - Suspension - Brakes Refitting the rear wheel Install the sprocket flange on the wheel (Sect. G 8, Refitting the rear sprocket). If the special screws of the (4) tensioner slides have been removed, apply grease to the threads and contact face of the nut and fit them to the swingarm.
Page 223 section Wheels - Suspension - Brakes Hook the chain onto the rear sprocket and introduce the wheel into the swingarm. During this operation, make sure that the spacer (10) remains in its seating. Insert the axle from the left-hand side of the swingarm, through the LH chain tensioner slider, the wheel hub, the hole on the caliper mounting bracket and the hole in the RH chain tensioner slider.
Page 224 section Wheels - Suspension - Brakes Refit the brake caliper (A) and tighten the screws (B) to the specified torque (Sect. C 3, Frame torque settings). Notes The gap between the sensor and the brake disc screw must be between 0.6 and 2.2 mm. Monster 696/696+ - M.Y.
Page 225: Rear Swingarm
section Wheels - Suspension - Brakes 5 - Rear swingarm 1 Drive chain slider 2 Screw 3 Special bolt 4 Circlip 5 Washer 6 Rubber bush 7 Rear swingarm 8 Nut 9 Ring 10 Rear wheel axle 11 Slider 12 Adjuster screw 13 Rear mudguard 14 Pin 15 Screw...
Page 226: Removal Of The Swingarm
section Wheels - Suspension - Brakes Removal of the swingarm Operation Section reference Remove the rear wheel G 4, Removal of the rear wheel Remove the final drive assembly G 8, Final drive Remove the rear brake caliper G 6, Removal of the rear brake system Remove the footrests H 4, Removal of the footrest brackets Remove the shock absorber from the...
Page 227 section Wheels - Suspension - Brakes Counterhold the nut (16) and loosen the screw (15) on the left side of the swingarm. Drive out the pivot shaft (18) using a suitable drift until the swingarm is free of the engine. Remove the swingarm (8) from the frame.
Page 228: Inspecting The Swingarm Pivot Shaft
section Wheels - Suspension - Brakes Inspecting the swingarm pivot shaft Measure the swingarm pivot shaft (18) runout using a dial gauge: - place the pivot shaft (18) on two reference blocks of the same size; - rotate the shaft and move the gauge horizontally; - read off the runout.
Page 229: Checking Swingarm Endfloat
section Wheels - Suspension - Brakes Checking swingarm endfloat The shim thicknesses (17) are to be determined on refitting the swingarm. Check the endfloat as follows: insert a 1.8 mm shim (17) on either side of the engine; hold the left arm of swingarm (8) against the engine and measure the clearance on the other side of engine using a feeler gauge or calibrated shims.
Page 230: Refitting The Swingarm
section Wheels - Suspension - Brakes Refitting the swingarm Grease both faces of the shim (17) you have selected after measuring endfloat (see paragraph “Checking swingarm endfloat” in this chapter). Locate the swingarm (8) on the engine interposing the selected shim (17) on the left-hand side. Grease the pivot shaft (18) and insert it from the left side of the swingarm together with circlip (5).
Page 231 section Wheels - Suspension - Brakes Refit the drive chain slider (1) to the swingarm with the screws (2) and hooking the tab (A) over the left-hand side of the swingarm as shown in the photo. Tighten the screws (2) to the specified torque (Sect. C 3, Frame torque settings). Operation Section reference Refit the shock absorber and tie-rod to rear...
Page 232: Hydraulic Rear Brake
section Wheels - Suspension - Brakes 6 - Hydraulic rear brake 1 Banjo bolt 2 Sealing washer 3 Rear brake caliper 4 Caliper mounting bracket 5 Screw 6 Rear brake hose 7 Spacer 8 Pin and clip 9 Dust cap 10 Bleed valve 11 Pair of brake pads 12 Screw...
Page 233: Removal Of The Rear Brake System
section Wheels - Suspension - Brakes Removal of the rear brake system 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.
Page 234 section Wheels - Suspension - Brakes Unscrew the screws (5) securing the rear brake caliper (3) to the caliper mounting bracket (10) and remove the caliper. Notes For the brake pad renewal procedure, refer to Sect. D 4, Checking brake pad wear and changing brake pads. To remove the speed sensor (13), undo the screw (12) securing it to the caliper mounting bracket, taking care not to damage the spacer (7).
Page 235: Refitting The Rear Brake System
section Wheels - Suspension - Brakes Refitting the rear brake system Relocate the caliper (10) on swingarm pin and on the pin (D). Refit the rear wheel (Sect. G 4, Refitting the rear wheel). If removed, locate the speed sensor (13) on the caliper mounting bracket with the spacer (7) and tighten the screw (12) to the specified torque (Sect.
Page 236 section Wheels - Suspension - Brakes Tighten the banjo bolts (1) to the specified torque (Sect. C 3, Frame torque settings). Locate the brake hose (6) on the swingarm and secure the clip (B) with the screw (A). Fit the rear brake caliper (3) over the brake disc, aligning it with the holes in the caliper mounting bracket. Grease the threads and undersides of the heads of the screws (5).
Page 237: Rear Suspension
section Wheels - Suspension - Brakes 7 - Rear suspension 1 Shock absorber 2 Screw 3 Shock absorber mounting 4 Nut 5 Screw 6 Nut Parts catalogue 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 238: Rear Suspension System
section Wheels - Suspension - Brakes Rear suspension system The rear suspension system uses a hydraulic monoshock absorber (1) with rebound and spring preload adjustment. The shock absorber is pivot-mounted to the swingarm at the lower end and to the rear subframe frame at the upper end. This system gives the motorcycle excellent stability.
Page 239: Overhauling The Rear Shock Absorber
section Wheels - Suspension - Brakes 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) by counterholding the screw (2) and unscrewing the nut (4). Slacken off locknut (A) and spring adjuster nut (B) with a pin wrench or special tool, and remove the spring.
Page 240 section Wheels - Suspension - Brakes Reassembly of the rear shock absorber Fit the spring into its seat in the shock absorber with the tapered end towards the lower mounting. Screw in the spring adjuster nut (B) to obtain the previously measured length (L). Notes One full turn of the adjuster nut changes the length of the spring by 1.5 mm.
Page 241: Refitting The Rear Suspension
section Wheels - Suspension - Brakes Refitting the rear suspension Lubricate the thread and underside of the head of the shock absorber screw. Insert the upper end of the shock absorber inthe hole in the rear sub frame and fit the nut (6). Orientate the rear shock absorber with the prelaod adjuster screw (C) as shown in the photo.
Page 242: Final Drive
section Wheels - Suspension - Brakes 8 - Final drive 1 Pin 2 Rear sprocket flange 3 Bush 4 Bearing 5 Rear sprocket (Z=48) 6 Nut 7 Circlip 8 Spacer 9 Chain 10 Screw 11 Sprocket retaining plate 12 Front sprocket 13 Front sprocket cover 14 Screw 15 Sprocket flange spacer...
Page 243: Inspecting The Final Drive
section Wheels - Suspension - Brakes Inspecting the final drive To check wear of the final drive, carry out a visual inspection of the front sprocket (12) and rear sprocket (5). If the teeth are found to worn as shown in the figure (dotted line), the sprocket must be renewed. Normal Worn Normal...
Page 244: Removal Of The Front Sprocket
section Wheels - Suspension - Brakes Removal of the front sprocket Undo the screws (14) and remove the sprocket cover (13). Slacken the chain (Sect. D 4, Adjusting the chain tension). Engage a low gear and unscrew the two screws (10) on the sprocket retaining plate (11). Remove the plate (11) from the gearbox output shaft.
Page 245: Refitting The Front Sprocket
section Wheels - Suspension - Brakes Refitting the front sprocket Check that the splines of the gearbox output shaft and the sprocket are in perfect condition. Hook the chain (9) onto the sprocket (12). Install the front sprocket on gearbox output shaft (B) as shown in the figure. Push the sprocket beyond the groove (A). Fit the sprocket retaining plate (11) to the gearbox output shaft (B) and turn it in the groove (A) until the holes in the plate (11) are aligned with the threaded holes in the sprocket (12): position the retaining plate with the rounded edge facing the sprocket.
Page 246: Removal Of The Rear Sprocket
section Wheels - Suspension - Brakes Removal of the rear sprocket Operation Section reference Slacken the chain D 4, Adjusting the chain tension Remove the rear wheel G 4, Removal of the rear wheel Slide the complete rear sprocket flange (2) off the rear wheel. Remove the sprocket flange spacer (15).
Page 247: Refitting The Rear Sprocket
section Wheels - Suspension - Brakes Refitting the rear sprocket If the bearings (4) were removed, to reinstall them, heat the sprocket flange (2) to a temperature of 180 to 200 °C. Immediately after heating the flange, install the two bearings (4) in the housing. Fit the circlip (7) in the groove in the sprocket flange, over the bearings.
Page 248 section Wheels - Suspension - Brakes Fit the rear sprocket flange (2) to the rear wheel hub. Make sure the pins (1) locate in the corresponding rubber cush drive bushes (G). Install the spacer (8) with the bevelled side facing the rear sprocket flange. Operation Section reference Refit the rear wheel...
Page 249 H - Frame...
Page 250 section Frame 1 - Handlebar Removal of the handlebar Refitting the handlebar 2 - Steering Adjusting the steering head bearings Steering angle adjustment Removal of the steering head components Refitting the steering head components 4 - Footrest brackets Removal of the footrest brackets Refitting the footrest brackets 5 - Stands Removal of the sidestand...
Page 251: Handlebar
section Frame 1 - Handlebar 1 Upper clamp 2 Plug 3 Screw 4 Handlebar 5 Grips Parts catalogue 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.
Page 252 section Frame Removal of the handlebar Operation Section reference Remove the throttle twistgrip F 1, Removal of the throttle twistgrip Remove the right-hand and left-hand P 5, Checking the indicating devices handlebar switches Remove the front brake lever F 3, Removal of the front brake master cylinder Remove the clutch lever F 2, Removal of the clutch master cylinder...
Page 253: Refitting The Handlebar
section Frame Refitting the handlebar Position and orientate the handlebar (4) so that the punch marks (A) are equidistant from the lower clamp and aligned with the face of the clamp. Apply the recommended grease to the threads and undersides of the heads of screws (3). Important Position the clamps with the arrows (B) pointing towards the fuel tank.
Page 254: Steering
section Frame 2 - Steering 1 Screw 13 Washer 2 Top yoke 14 Screw 3 Screw 15 Bottom yoke 4 Lower clamp 16 Adjuster screw 5 Bearing 17 Nut 6 Bearing 18 Seal 7 Screw 19 Rubber mounting 8 Seal 20 Guide 9 Nut 21 Bracket...
Page 255: Adjusting The Steering Head Bearings
section Frame Adjusting the steering head bearings Notes See Sect. D 4, Adjusting the steering head bearings for adjustment of steering head bearing play. If the steering head bearings cannot be adjusted correctly, check the bearings (5) and (6) for wear and, if necessary, renew them as described in “Removal of the steering head components”...
Page 256: Steering Angle Adjustment
section Frame Steering angle adjustment Loosen the nuts (17) and adjuster screws (16) on both sides of the bottom yoke. Use a 6 to 6.5 mm spacer (A) fitted to the fork outer tube, or use a gauge. 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.
Page 257: Removal Of The Steering Head Components
section Frame Removal of the steering head components Operation Section reference Remove the headlight P 4, Renewal of the headlight Remove the handlebar H 1, Removal of the handlebar Remove the fork legs G 2, Removal of the front forks Notes All parts fitted to the top and bottom yokes, including the wiring and control cables, can remain on the motorcycle provided they do not hinder the following operations.
Page 258 section Frame Using a universal puller (see figure) remove the inner race (A) and the spacer (13) from the steering stem, taking care not to damage the seat. Important Once disturbed, the oil seals (8) and (18) and bearings (5) and (6) must not be refitted. Using a suitable drift, remove the outer bearing races (C) from the steering head.
Page 259 section Frame Unscrew the screws (23) and remove the guide (20). Recover the washers (22) and the headlight support bracket (21). Reassembly of the top yoke If the spacers (10) were removed from the top yoke, lubricate with silicone spray. Seat the spacers (10) square in the bores (D) in the top yoke, orienting them as shown in the figure.
Page 260 section Frame Fit the rubber mountings (19) on the headlight support brackets (21). Fit the headlight support brackets (21), the guide (20) and the washers (22) with the screws (23). Tighten the screws (23) to the specified torque (Sect. C 3, Frame torque settings). Locate the lower clamp (4) on the top yoke.
Page 261: Refitting The Steering Head Components
section Frame 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 races (C) of the bearings (5) and (6) to the steering head, use the service tool no. 88713.1062 and proceed as follows: heat the steering head to 150 °C;...
Page 262 section Frame Insert the washer (13), oil seal (18) (with the rim facing upwards) and inner race (A) of bottom bearing (6) onto the steering stem after heating it for about 10 minutes to 120 °C. Fit tool no. 88713.1072 into the steering stem. Keep the inner race (A) pressed against the dust seal (18) by hand for at least 15 seconds.
Page 263 section Frame Grease the nut (12). Tighten the steering stem nut (12) by hand until it seats against the oil seal (8). Fit service bush no. 88713.1058 to the steering stem nut (12) and fit the torque wrench to the bush. Tighten the steering stem nut (12) to the specified torque (Sect.
Page 264: Footrest Brackets
section Frame 4 - Footrest brackets Left-hand side Right-hand side 1 Rubber mounting 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...
Page 265: Removal Of The Footrest Brackets
section Frame 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 counterholding the nut (B) and remove the rear brake fluid reservoir (C). Before removing the left footrest bracket, unscrew the screw (D) securing the gearchange lever to the engine, but leave the gearchange assembly attached to the bracket.
Page 266 section Frame Remove the brake master cylinder (E) by unscrewing the two screws (F): slide the master cylinder (E) off the pushrod (G). Disconnect the rear brake sensor (H) from the main wiring harness. Remove the RH footrest bracket assembly (8). To separate the rear RH footrest (13) from the footrest bracket (8), remove the circlip (5) and drive out the pin (4) to release the footrest (13), the plates (10), the ball (9) and the spring (12).
Page 267 section Frame 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). The procedure is the same for the LH footrest. Notes The footrest may also be removed with the footrest bracket installed on the motorcycle.
Page 268: Refitting The Footrest Brackets
section Frame 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. Grease the pin (4) and insert it from the top, securing it on the other side with the circlip (5).
Page 269 section Frame Grease the pin (4) and insert it from the top, securing it on the other side with the circlip (5). Check the condition of the rubber bushes (1) installed on the footrest bracket. If they need to be renewed, orientate them as shown in the figure. Monster 696/696+ - M.Y.
Page 270 section Frame 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. Refit the brake master cylinder (E) and tighten the screws (F) to the specified torque (Sect. C 3, Frame torque settings). Reconnect the rear brake sensor (H) to the main wiring harness.
Page 271 section Frame Fix the gearchange control to the engine crankcase, applying threadlocker to the screw (D) and tightening it to the specified torque (Sect. C 3, Frame torque settings). Refit the rear brake reservoir (C), tightening the screw (A) to the specified torque (Sect. C 3, Frame torque settings). Monster 696/696+ - M.Y.
Page 272: Stands
section Frame 5 - Stands 1 Sidestand 2 Screw 3 Bracket 4 Screw 5 Switch 6 Inner spring 7 Spring assembly 8 Plate 9 Pivot screw 10 Nut Parts catalogue 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 273: Removal Of The Sidestand
section Frame Removal of the sidestand Unscrew and remove the screw (A) securing the LH footrest bracket (C) to the engine. Loosen the screw (B) and release the LH footrest bracket (C) from the engine block. Disconnect the wiring connector (5) of the sidestand switch (1) from the main wiring harness. Unscrew the screw (2) securing the sidestand bracket (3) to the engine and remove the complete sidestand assembly.
Page 274 section Frame Inspecting the sidestand Fit the sidestand leg to the bracket and check that there is no excessive play. Ensure that the ends of the sidestand are not bent with respect to the shank. A stand which shows signs of cracking must be renewed immediately. For details of how to test the switch (5), see Sect.
Page 275: Refitting The Sidestand
section Frame Refitting the sidestand Locate the sidestand bracket (3) between the engine and the LH footrest bracket (C) and fit the screw (2). Connect the connector (5) of the sidestand switch to the main wiring harness. For correct routing of the sidestand switch wiring, refer to the plates diagrams in Sect. P 1, Routing of wiring on frame. Fit the screw (A) in the footrest bracket (C).
Page 276: Frame Inspection
section Frame 6 - Frame inspection 1 Frame 2 Clamp 3 Nut 4 Clearance adjuster 5 Nut 6 Special screw 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 Rubber mounting...
Page 277: Disassembly Of Structural Components And The Frame
section Frame 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. The flow chart below illustrates the logical sequence in which the parts are to be removed from the motorcycle and gives a reference to the section of the manual in which the removal procedure is described.
Page 278 section Frame COMPLETE MOTORCYCLE HEADLIGHT FAIRING AND GEARSHIFT FOOTRESTS SEAT REARVIEW MIRRORS CONTROL FAIRINGS FUEL TANK HYDRAULIC SIDESTAND REAR RH AND LH BRAKE HANDLEBAR CONTROL SWITCHES P 3 - P 5 TAIL LIGHT BATTERY AIRBOX SUPPORT NUMBER PLATE ASSEMBLY HOLDER REAR BRAKING HYDRAULIC...
Page 279: Removal Of The Frame
section Frame Removal of the frame 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.
Page 280 section Frame If the ring nuts (5) with the clearance adjusters (4) were removed, proceed as follows. Grease the threads of the clerance adjuster (4) and the ring nuts (5) taking care not to get any grease on face (B) of the clearance adjuster (4).
Page 281 section Frame Monster 696/696+ - M.Y. 2009 - edition 00...
Page 282: Removal Of The Rear Subframe
section Frame Removal of the rear subframe Disconnect all the wiring connections of the electrical components mounted on the subframe (Sect. P 1, Routing of wiring on frame) and remove the silencers (Sect. L 8, Removal of the exhaust system). Remove the frame as indicated in the previous paragraph “Removal of the frame”.
Page 283 section Frame Disassembly of the rear subframe Counterhold the nuts (11), present only on the left-hand side of the rear subframe, unscrew the screws (12) and remove the bracket (15). Unscrew the screws (9) securing the plate (8) and separate the left subframe from the right subframe. Monster 696/696+ - M.Y.
Page 284: Checking The Frame
section Frame Checking the frame Check the dimensions of the frame against the dimensions shown here to determine whether it needs to be renewed. Important Badly damaged frames cannot be repaired, they must be renewed. Any work carried out on the frame can give rise to potential danger, infringing the requirements of EC directives concerning manufacturers' liability and general product safety.
Page 285: Reassembly Of The Rear Subframe
section Frame Reassembly of the rear subframe Check that the rubber mountings (A) are installed on the plate (8). Locate the plate (8) on the LH subframeo (10) and on the RH subframe (12) and insert the screws (9). Tighten the screws (9) to the specified torque (Sect. C 3, Frame torque settings) in the sequence: 1-2-3-4. Check that the rubber buffer (B), rubber bushes (17) and spacers (16) are installed on the bracket (15).
Page 286 section Frame Refit the bracket (15) to the rear subframe with screws (12). Counterhold the nuts (11), present only on the left-hand side of the rear subframe, and tighten the screws (12) to the specified torque (Sect. C 3, Frame torque settings), in the sequence: 5-6-7-8. Refit the rear subframe to the engine (Sect.
Page 287: Refitting The Rear Subframe
section Frame Refitting the rear subframe Locate the complete rear subframe assembly on the engine, apply the recommended grease to the threads of the pin (13) and the nut (3). Counterhold the pin (13) and tighten the nut (3) to the specified torque (Sect. C 3, Frame torque settings). Monster 696/696+ - M.Y.
Page 288: Tail Light-Number Plate Holder And Locks
section Frame 7 - Tail light-number plate holder and locks 8 17 11 21 1 Sprayguard 17 Plate 2 Tail light 18 Rubber mounting 3 Protection 19 Special screw 4 Right turn indicator 20 Screw 5 Left turn indicator 21 Nut 6 Plate 22 Screw 7 Screw...
Page 289: Removal Of The Tail Light-Protection-Number Plate Holder Assembly
section Frame Removal of the tail light-protection-number plate holder assembly Remove the seat (Sect. E 3, Removal of the seat). Disconnect the rear wiring harness connector (A) from the main wiring harness (Sect. P 1, Routing of wiring on frame). Unscrew the four screws (25) and and slide the tail light - number plate holder assembly off the rear subframe, as shown in the photo.
Page 290 section Frame Unscrew the screws (22) and remove the tail light (2); recover the quick-release fasteners (23). Removal of the rear turn indicators Separate the protection (3) from the spray guard (1) by unscrewing the screws (7). The following operations refer to the left side of the motorcycle, but apply also to the right side. Disconnect the turn indicator wiring from the main wiring harness.
Page 291 section Frame Refitting the rear turn indicators The following operations refer to the left side of the motorcycle, but apply also to the right side. Insert the wiring and left turn indicator (5) in the fixing hole in the protection (3). Position the plate (17).
Page 292: Refitting The Tail Light-Protection-Number Plate Holder Assembly
section Frame Refitting the tail light-protection-number plate holder assembly Fit the tail light (2) to the protection (3) and fit the screws (22). Tighten the screws (22) to the specified torque (Sect. C 3, Frame tightening torques). Refit the plate (24) to the tail light - number plate holder assembly, securing it with the four screws (10) and washers (9). While counterholding the special screws (19), tighten the screws (10) to the specified torque (Sect.
Page 293 section Frame Fit the four screws (25) and tighten to the specified torque (Sect. C 3, Frame tightening torques). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 294: Removal Of The Seat Release Mechanism
section Frame Removal of the seat release mechanism Remove the tail light - number plate holder assembly from the rear subframe and the plate (24) as described in the previous paragraph. Separate the spray guard (1) from the protection (3) by unscrewing the screws (7). Remove the end fitting (A) and release the lock cable (26) from the latch lever (31).
Page 295 section Frame Unscrew the nut (28), remove the lever (29) and withdraw the seat lock (27). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 296: Refitting The Seat Release Mechanism
section Frame Refitting the seat release mechanism Fit the seat lock (27) in the housing in the spray guard (1), inserting the lugs (C) in the slots (D) as shown in the figure. Fit the lock lever (29) inserting the lugs (C) in the slots (E) as shown in the figure. Fit the nut (28) on the seat lock (27) and tighten to the specified torque (Sect.
Page 297 section Frame Position the lock cable (26) on the spray guard (1), as shown in the figure. Refit the cable end fitting (B) in th elock lever (29) and end fitting (A) in the latch (31). Refit the spray guard (1) to the protection (3) and tighten the screws (7) to the specified torque (Sect. C 3, Frame tightening torques).
Page 298: Removal Of The Number Plate Holder
section Frame Removal of the number plate holder Unscrew the screws (16) and remove the plate (6). Notes 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 Refitting is the reverse of removal;...
Page 299 L - Fuel/Exhaust System...
Page 300 section Fuel/Exhaust System 2 - Fuel tank Removal of the fuel tank Removal of the fuel tank filler cap Refitting the filler cap Removal of the fuel tank flange Refitting the fuel tank flange Refitting the fuel tank 6 - Throttle body for pivoting fuel tank Removal of the throttle body Refitting the throttle body 7 - Air intake...
Page 301: Fuel Tank
section Fuel/Exhaust System 2 - Fuel tank 28 27 1 Fuel tank 17 Screw 2 Filler cap 18 Fuel outlet hose 3 Screw 19 Fuel return hose 4 Hose 20 Cover 5 Union 21 Nut 6 Hose 22 Special screw 7 Hose 23 Flange 8 Rubber...
Page 302 section Fuel/Exhaust System Removal of the fuel tank Remove the seat (Sect. E 3, Removal of the seat). Remove the fuel tank covers (Sect. E 2, Removal of the fuel tank fairings). Remove the breather hose cover (Sect. N 8, Removal of the alternator-side crankcase cover). Withdraw the breather hose (6) from the cover (A).
Page 303 section Fuel/Exhaust System Remove the screw (13) and recover the washer (14). Release the fuel hoses (18) and (19) from the clips (16). Detach the lambda sensor cable (C) from the tank flange cover. Warning Before removing the flange cover (20), make sure the tank (1) is empty and position a rag to collect any spilt fuel. Monster 696/696+ - M.Y.
Page 304 section Fuel/Exhaust System Raise the tank, remove the flange cover (20) by unscrewing the nuts (21) and disconnect the quick-release fittings (29) from the flange. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 305: Removal Of The Fuel Tank Filler Cap
section Fuel/Exhaust System Removal of the fuel tank filler cap To remove the fuel filler cap assembly from the fuel tank proceed as follows. Remove the fuel tank covers (Sect. E 2, Removal of the fuel tank fairings). Open the filler cap. Unscrew the outer screws (3) securing the ring nut to the filler cap recess.
Page 306: Removal Of The Fuel Tank Flange
section Fuel/Exhaust System Removal of the fuel tank flange Unscrew the screws (28) and (22) securing the fuel tank flange (23). Remove the flange (23) from the tank. Recover the O-ring (24). Using the appropriate commercial tool, undo the clips (26) next to the fuel filter (25). Remove the old filter from the connecting hoses and fit a new filter.
Page 307: Refitting The Fuel Tank Flange
section Fuel/Exhaust System Refitting the fuel tank flange Insert the flange (23) in its housing in the fuel tank. Fit the four screws (28) and tighten to the specified torque (Sect. C 3, Frame torque settings). Insert the two screws (22), positioning them so the ends with threadlocker are towards the flange and tighten them to the specified torque (Sect.
Page 308: Refitting The Fuel Tank
section Fuel/Exhaust System Refitting the fuel tank If the fuel tank has been disassembled into its component parts, reposition all the parts as shown in the exploded view. In particular: tighten the screws (10) and (17) to the specified torque (Sect. C 3, Frame torque settings). Refit the fuel tank inserting the pins (D) of the mounting brackets (9) and (12) in the correponding locations in the frame.
Page 309 section Fuel/Exhaust System While holding the tank in the raised position, connct 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 310 section Fuel/Exhaust System Connect the fuel sensor (B) to the main wiring harness. Locate the lambda sensor wire (C) on the tank flange cover and secure it with a cable tie. Fix the fuel tank to the subframe with the screw (13) and washer (14) and to the subframe with the screw (30) and washers (31). Tighten the screws (13) and (30) to the specified torque (Sect.
Page 311 section Fuel/Exhaust System Locate the fulr tank breather/drain hose (6) on the motorcycle and refit the breather hose cover (A) (Sect. N 8, Refitting the alternator-side crankcase cover). Refit the fuel tank covers (Sect. E 2, Refittings the fuel tank fairings). Monster 696/696+ - M.Y.
Page 312 section Fuel/Exhaust System Positioning of the fuel tank breathe/drain hoses Monster 696/696+ - M.Y. 2009 - edition 00...
Page 313 section Fuel/Exhaust System Monster 696/696+ - M.Y. 2009 - edition 00...
Page 314 section Fuel/Exhaust System Monster 696/696+ - M.Y. 2009 - edition 00...
Page 315 section Fuel/Exhaust System Positions of the fuel hoses connecting the fuel tank to the throttle body Monster 696/696+ - M.Y. 2009 - edition 00...
Page 316 section Fuel/Exhaust System Monster 696/696+ - M.Y. 2009 - edition 00...
Page 317: Throttle Body For Pivoting Fuel Tank
section Fuel/Exhaust System 6 - Throttle body for pivoting fuel tank 1 Fuel system assembly 16 Hose 2 Throttle position sensor 17 Clamp 3 Clamp 18 Washer 4 Hose 19 Union 5 Rubber 20 Gasket 6 Heat shrink sleeve 21 Pressure sensor 7 Air temperature sensor 22 Hose 8 Clamp...
Page 318: Removal Of The Throttle Body
section Fuel/Exhaust System Removal of the throttle body Operation Section reference Remove the fuel tank L 2, Removal of the fuel tank Remove the airbox L 7, Removal of the airbox Disconnect the throttle cable F 1, Removal of the throttle twistgrip Disconnect the choke cable F 1, Removal of the choke cable Disconnect the connector (A) connecting the main wiring harness to the throttle position sensor (2).
Page 319 section Fuel/Exhaust System Loosen the clips (17) securing the throttle body to the intake manifolds (11). Disconnect the wiring connectors (D) connecting the main wiring harness to the injectors (10). Remove the throttle body assembly (26) from the motorcycle. If necessary, slacken off the clamps (3) securing the throttle body to the hoses (4) and (16) and remove the hoses. Monster 696/696+ - M.Y.
Page 320 section Fuel/Exhaust System Undo the two screws (27) to remove the throttle position sensor (2) from the throttle body. Removal of the fuel injectors Undo the injector retaining clips (8) with the fuel feed hose (28), fuel return hose (29) and injector connection hose (30). Undo the screws (25) to remove the injectors from the throttle body, recovering the washers (24).
Page 321: Refitting The Throttle Body
section Fuel/Exhaust System Refitting the throttle body If the hoses (4) and (16) were removed, reconnect them to the throttle body with the hose clamps (3), positioning the hoses and clamps as shown in the figure. Notes The air temperature sensor (7) is installed on the intake hose of the vertical cylinder (16); to refit, refer to Sect. M 3, Air pressure sensor.
Page 322 section Fuel/Exhaust System 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 race facing the right-hand side (relative to the direction of travel) and insert it fully into the intake manifolds.
Page 323 section Fuel/Exhaust System Reconnect the wiring connectors (D) connecting the main wiring harness to the injectors (10). Install the air pressure sensor (21) on the throttle body, insert the tubes of the pressure sensor in the manifold and connect the wiring connector (C) to the main wiring harness.
Page 324 section Fuel/Exhaust System 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. Set the hot air blower to 150 °C. While holding the pipes curved, apply heat to “shrink” the sleeve, holding the blower approximately 15 mm from the sleeve.
Page 325 section Fuel/Exhaust System Positioning the injector connection pipe Monster 696/696+ - M.Y. 2009 - edition 00...
Page 326: Air Intake
section Fuel/Exhaust System 7 - Air intake 1 Clamp 2 Oil breather hose 3 Bush 4 Cap 5 Pin 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 327: Removal Of The Airbox
section Fuel/Exhaust System Removal of the airbox Operation Section reference Remove the fuel tank L 2, Removal of the fuel tank Remove the battery P 2, Battery support Remove the ECU connector M 3, Removal of the electronic control unit Connect the starter motor/contactor cable P 3, Removal of the starter motor Loosen the hose clamps (1) and disconnect the oil breather hose (2).
Page 328 section Fuel/Exhaust System Disconnect the HT leads (A) of the horizontal cylinder head coil (B) and vertical cylinder head coil (C) from the respective spark plugs. Disconnect the coil wiring connectors (D) from the main wiring harness (Sect. P 1, Routing of wiring on frame). Loosen the clamps (E) of the hoses (F).
Page 329 section Fuel/Exhaust System Undo the screws (16), recover the spacers (17) and withdraw the air filter vertically upwards, taking care to recover the rubbers (19). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 330 section Fuel/Exhaust System 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 ECU (Sect. M 3, Electronic Control Unit (ECU)); B Starter contactor (Sect.
Page 331: Removal Of The Oil Breather Valve
section Fuel/Exhaust System 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. Refitting the oil breather valve Lubricate the two O-rings (15) with engine oil.
Page 332: Refitting The Airbox
section Fuel/Exhaust System Refitting the airbox Check that the rubber bushes (19) are present on the airbox. Check that clamps (E) are correctly positioned on intake manifolds (F), with the fixing screws positioned as shown in the figure. “V” cylinder “O”...
Page 333 section Fuel/Exhaust System Locate the airbox assembly on the throttle body. Fit screws (16) with the spacers (17) to the airbox and tighten to the specified torque (Sect. C 3, Frame torque settings). Tighten the hose clamps (E) on the hoses (G) to the specified torque (Sect. C 3, Frame torque settings). Monster 696/696+ - M.Y.
Page 334 section Fuel/Exhaust System Reconnect the HT leads (A) of the horizontal cylinder head coil (B) and vertical cylinder head coil (C) to the respective spark plugs. Connect the coil wiring connectors (D) to the main wiring harness (Sect. P 1, Routing of wiring on frame). Refit the oil breather hose (2) with the clamp (1) on the breather valve and tighten the clamp (1) to the specified torque (Sect.
Page 335 section Fuel/Exhaust System Secure the drain hose (12) with ties to the frame and under the cover (V) on the alternator–side crankcase cover (Sect. N 8, Refitting the alternator-side crankcase cover). Operation Section reference Refit the battery P 2, Refitting the battery Connect the starter motor/contactor cable P 3, Refitting the starter motor Connect the ECU connector M 3, Refitting the electronic control unit...
Page 336 section Fuel/Exhaust System Positioning of the blow-by hose Monster 696/696+ - M.Y. 2009 - edition 00...
Page 337 section Fuel/Exhaust System Monster 696/696+ - M.Y. 2009 - edition 00...
Page 338 section Fuel/Exhaust System Positioning of the airbox drain hose Monster 696/696+ - M.Y. 2009 - edition 00...
Page 339: Exhaust System
section Fuel/Exhaust System 8 - Exhaust system 1 Exhaust gasket 18 Plug 2 Lambda sensor 19 Sealing washer 3 Horizontal cylinder head exhaust pipe 20 Special nut 4 Vertical cylinder head exhaust pipe 21 Right-hand bracket 5 Centre exhaust pipe 22 Left-hand bracket 6 Lower bracket 23 Bush...
Page 340: Operating Principle Of The Catalytic Converter
section Fuel/Exhaust System Operating principle of the catalytic converter This model is fitted with “three-way” catalytic converters. Catalytic converters are fitted to the exhaust system in order to eliminate the noxious substances found in exhaust fumes, namely CO (carbon monoxide), HC (unburnt hydrocarbons) and NOx (nitric oxide).
Page 341: Removal Of The Exhaust System
section Fuel/Exhaust System Removal of the exhaust system Operation Section reference Remove the RH footrest bracket H 4, Removal of the footrest brackets Remove the retaining spring (10) of the LH silencer (8) from the centre exhaust pipe (5). While counterholding the nut (31), unscrew the retaining screw (30) and remove the LH silencer (8) from the motorcycle. Recover the spacer (23) and the rubber bushes (24).
Page 342 section Fuel/Exhaust System Remove the LH heat shield (33) by unscrewing the retaining screws (26) and recover the spacers (25) and the washers (34). Follow the same procedure to remove the RH silencer (7). Unscrew the two nuts (20) and release the centre exhaust pipe (5) from the fuel tank support bracket and exhaust (A). Disconnect the two lambda sensors (2) from the main wiring harness (Sect.
Page 343 section Fuel/Exhaust System Unscrew the clamp (16) and separate the centre exhaust pipe (5) from the horizontal cylinder exhaust pipe (3) and the vertical cylinder exhaust pipe (4). Loosen and remove the nuts (9) securing the exhaust pipe flanges to the cylinder heads. Monster 696/696+ - M.Y.
Page 344 section Fuel/Exhaust System Remove the flanges from the cylinder heads. Remove the horizontal cylinder exhaust pipe (3) from the horizontal cylinder head, recovering the gasket (1). Remove the vertical exhaust pipe (4) from the vertical cylinder head, recovering the gasket (1). Important Block off the exhaust ports on the head to prevent foreign matter from entering the combustion chamber.
Page 345: Refitting The Exhaust System
section Fuel/Exhaust System Refitting the exhaust system Renew the gaskets (1). Refit the horizontal cylinder exhaust pipe (3) and the vertical cylinder exhaust pipe (4) to the respective cylinder heads. Tighten the flange nuts (9) to the specified torque (Sect. C 3, Frame torque settings). Check that the quick-release fasteners (32) are installed on the horizontal cylinder exhaust pipe (3).
Page 346 section Fuel/Exhaust System Fit the vertical cylinder exhaust pipe (3) to the engine and tighten the screw (15) to the specified torque (Sect. C 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 347 section Fuel/Exhaust System Fix the centre exhaust pipe (5) to the fuel tank support bracket (A) by screwing on the nuts (20) and tightening them to the specified torque (Sect. C 3, Frame torque settings). Connect the lambda sensors (2) to the main wiring harness (Sect. P 1, Routing of wiring on frame). Connect the silencer (8) to the centre exhaust pipe (5) and locate the springs (10).
Page 348 section Fuel/Exhaust System Check that the quick-release fasteners (32) are installed on the LH silencer (8). Refit the LH heat shield (33) securing it with the retaining screws (26), the spacers (25) and the washers (34). Tighten the screws (26) to the specified torque (Sect. C 3, Frame torque settings). Follow the same procedure to refit the RH silencer (7).
Page 349: Evaporative Emissions Canister
section L 10 Fuel/Exhaust System 10 - Evaporative emissions canister 1 Screw 11 Hose clip 2 Rubber 12 Filter/oil reservoir hose 3 Spacer 13 Hose clip 4 LH air deflector 14 Union/filter pipe 5 Hose 15 Hose clip 6 Plate 16 Hose 7 Spacer 17 Union...
Page 350: Evaporative Emissions Canister System (Usa Versions Only)
section L 10 Fuel/Exhaust System 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 canister (9); when the fuel has been filtered, it is returned with the hose (14) to the intake manifolds via the hoses (16) and (21).
Page 351: Removal Of The Evaporative Emissions Canister
section L 10 Fuel/Exhaust System Removal of the evaporative emissions canister Operation Section reference Raise the fuel tank L 2, Removal of the fuel tank Remove the tank covers E 2, Removal of the fuel tank fairings Disconnect the hose (12) connecting the evaporative emissions canister (9) to the fuel filler cap. Release the hose (12) dfrom the drain hose (20) by removing the strap (A).
Page 352 section L 10 Fuel/Exhaust System Undo the screws (B) and remove the LH air deflector (4), taking care to release the clutch hose (C) from the clips. Remove the canister (9) from the LH deflector (4) by releasing it from the plate (6). Monster 696/696+ - M.Y.
Page 353: Refitting The Evaporative Emissions Canister
section L 10 Fuel/Exhaust System Refitting the evaporative emissions canister To refit the canister, reverse the steps of the removal procedure, taking care to tighten the screws (B) to the specified torque (Sect. C 3, Frame torque settings). Operation Section reference Refit the fuel tank L 2, Refitting the fuel tank Refit the tank covers...
Page 354 section L 10 Fuel/Exhaust System Positioning the hoses, clamps and canister filter Monster 696/696+ - M.Y. 2009 - edition 00...
Page 355 section L 10 Fuel/Exhaust System Positioning the hoses, clamps and canister filter Monster 696/696+ - M.Y. 2009 - edition 00...
Page 356 section L 10 Fuel/Exhaust System Positioning the hoses, clamps and canister filter Monster 696/696+ - M.Y. 2009 - edition 00...
Page 357 section L 10 Fuel/Exhaust System Monster 696/696+ - M.Y. 2009 - edition 00...
Page 359 M - Fuel injection-ignition system...
Page 360 section Fuel injection-ignition system 1 - Description of the system General information on the fuel injection-ignition system Fuel circuit Air circuit Operating phases 2 - Fuel injection-ignition system 3 - System components Electronic Control Unit (ECU) Fuel injectors Lambda sensor Air pressure sensor Temperature sensor Spark plug...
Page 361: Description Of The System
section Fuel injection-ignition system 1 - Description of the system General information on the fuel injection-ignition system The integrated electronic control system, with ignition and injection both controlled by the same control unit, ensures optimal engine performance and output, thus reducing fuel consumption and harmful exhaust emissions. This system ensures an accurately metered air-fuel ratio and optimal management of ignition advance.
Page 362 section Fuel injection-ignition system rich mixture lean mixture NO x Ideal ratio Siemens M3C fuel injection-ignition system The Marelli injection-ignition system is the Alfa/N type, in which the engine speed and throttle position are used as the 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 363 section Fuel injection-ignition system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 364 section Fuel injection-ignition system Fuel circuit Fuel from the tank is pumped into the fuel feed line (OUT) and then to the injectors, by means of a pump located on a flange installed at the bottom of the fuel tank. The flange also incorporates the pressure regulator that controls the fuel feed pressure and keeps it constant at a higher value than the negative pressure generated by the engine.
Page 365: Air Circuit
section Fuel injection-ignition system Air circuit The air circuit is composed of two intake manifolds (A), the throttle body (B) and an airbox (C) located over the throttle body. The engine control system (ignition and injection) relies on several sensors which adjust the mixture according to the air pressure and temperature and the engine load.
Page 366 section Fuel injection-ignition system The two lambda sensors (4) and (14), installed respectively in the horizontal and vertical cylinder exhaust pipes, provide information that is used by the ECU tocontrol the air-fuel mixture. There is a throttle position sensor (12) fitted on the spindle of the rear cylinder throttle. This device sends the ECU a signal that is an indirect indication of the quantity of air aspirated by the engine (indirect measurement of engine load).
Page 367: Operating Phases
section Fuel injection-ignition system Operating phases Normal operation When the engine is warm, the unit calculates injection time and the ignition advance using the values stored in the respective maps, in accordance with the RPM and throttle position. The calculated quantity of fuel is fed to each cylinder through the injectors in one single sequential delivery.
Page 368 section Fuel injection-ignition system 2 - Fuel injection-ignition system The electrical components of the fuel injection-ignition system are listed below: the reference next to each component is that shown in the diagram in Sect. P 1, Key to wiring diagram. Key to fuel injection–ignition system diagram 3) Horizontal cylinder spark plug 4) Vertical cylinder spark plug...
Page 369: System Components
section Fuel injection-ignition system 3 - 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 (misures the barometric pressure and the engine load in Speed Density mode) - Air temperature sensor (measures intake air temperature)
Page 370 section Fuel injection-ignition system Refitting the electronic control unit Fix the ECU (1) to the airbox with the fours screws (3) and reconnect the wiring connector (2). Tighten the screws (3) to the specified torque (Sect. C 3, Engine torque settings). The connector (2) is 48 PIN connector.
Page 371: Fuel Injectors
section Fuel injection-ignition system Fuel injectors The injectors (1) deliver the correct quantity of fuel required for optimal engine operation. 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.
Page 372 section Fuel injection-ignition system Positioning of the HT leads Monster 696/696+ - M.Y. 2009 - edition 00...
Page 373: Lambda Sensor
section Fuel injection-ignition system Lambda sensor The Lambda sensor, positioned on the exhaust pipe, transmits information to the ECU on the amount of oxygen present in the exhaust fumes. With this information the ECU can maintain optimal control over the fuel-air mixture. The outer surface of the sensor element in zirconium dioxide is in direct contact with the exhaust gas, while the inner surface is in contact with the atmosphere.
Page 374 section Fuel injection-ignition system To remove the lambda sensors (1) unscrew them from the horizontal and vertical cylinder exhaust pipes. When refitting the sensors, tighten them to the specified torque (Sect. C 3, Frame torque settings). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 375: Air Pressure Sensor
section Fuel injection-ignition system Air pressure sensor This sensor is powered by the ECU and it supplies information concerning the absolute air pressure in an area of the motorcycle that is not subject to turbulence. The electronic signals thus obtained are transmitted to the ECU, where they are used to make corrections in accordance with the pressure reading.
Page 376: Temperature Sensor
section Fuel injection-ignition system 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 377: Spark Plug
section Fuel injection-ignition system Spark plug Clean the area around the spark plug bores with a compressed air jet before removing the spark plugs themselves. Remove the spark plug caps (1) from the spark plugs in both cylinder heads and remove the two spark plugs, making sure that no dirt or other objects enter the combustion chamber.
Page 378 section Fuel injection-ignition system Coil An inductive discharge ignition system is used. Coil operation is governed by the M3C electronic control unit, which calculates the ignition advance. The power module (integrated in the electronic control unit) also guarantees constant energy coil charge, by adjusting the dwell time.
Page 379 section Fuel injection-ignition system Positioning of the HT leads Monster 696/696+ - M.Y. 2009 - edition 00...
Page 380: Throttle Position Sensor (Tps)
section Fuel injection-ignition system 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. Notes To check this component, use the DDS tester following the instructions given in the paragraph “Guided diagnosis”...
Page 381: Rpm/Timing Sensor
section Fuel injection-ignition system Rpm/timing sensor This sensor is of the inductive type: it faces the timing gear and is capable of “reading”the 44 teeth and the 2 gaps (each equivalent to 2 teeth) positioned 180° apart. The signal coming from the pickup on the camshaft gear is used by the ECU to determine the engine speed and as a timing reference point.
Page 382: Main And Injection Relays
section Fuel injection-ignition system Main and injection relays The relay (1) is positioned alongside the ECU and fixed to the airbox. To remove the relay, raise the fuel tank (Sect. L 2, Removal of the fuel tank). Disconnect the relay 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 383 N - Engine...
Page 384 section Engine 1 - Removal–refitting of the engine assembly Removal of the engine Refitting the engine 2.1 - Lubrication system: oil pump Removal of the oil pump Disassembly of the oil pump Reassembly of the oil pump Refitting the oil pump 4.1 - Cylinder head assemblies: checks and adjustments Checking and adjusting valve clearances Checking the engine timing...
Page 385 section Engine Reassembly of the clutch-side crankcase cover Refitting the clutch-side crankcase cover 6.3 - Clutch assembly: primary drive gears Removal of the primary drive gears Refitting the primary drive gears and checking backlash 7.1 - Gearbox assembly: gearchange mechanism Removal of the gearchange mechanism Disassembly of the gear selector mechanism Disassembly of the gear interlock plunger and pawl assembly...
Page 386: Removal-Refitting Of The Engine Assembly
section Engine 1 - Removal–refitting of the engine assembly 1 Engine 2 Bolt 3 Nut 4 Complete frame assembly 5 Swingarm pivot shaft Parts catalogue FRAME SWINGARM AND DRIVE CHAIN 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 387 section Engine Removal of the engine In order to remove engine you must first remove a series of other components from the motorcycle. Most of these removal procedures are described in the relative sections of this manual. The following flow chart illustrates the logical sequence in which the parts are to be removed from the motorcycle and a reference to the section where the removal procedure is described.
Page 388 section Engine Place a stand under the engine. Unscrew and remove the nuts (3) on the right-hand side of the frame in correspondence with front and rear mounting bolts (2) securing the engine (1). Remove the swingarm from the engine (1) by withdrawing the swingarm pivot shaft (5) (Sect. G 5, Removal of the swingarm). Withdraw the complete engine block (1) from the frame (4).
Page 389: Refitting The Engine
section Engine Refitting the engine Refitting is the reverse of removal. Important Position the correct shims between the engine and the swingarm (Sect. G 5, Refitting the swingarm). Lubricate the nuts (3) of mounting bolts (2). Tighten the nuts (3) to the specified torque (Sect. C 3, Engine torque settings). Monster 696/696+ - M.Y.
Page 390: Lubrication System: Oil Pump
section N 2.1 Engine 2.1 - Lubrication system: oil pump 1 Oil pump complete with gear 2 O-ring 3 By-pass plug 4 O-ring 5 By-pass valve 6 Locating bush 7 Reducer bush 8 Spring washer 9 Screw 10 Screw 11 Spring washer 12 By-pass spring Parts catalogue FILTERS AND OIL PUMP...
Page 391: Removal Of The Oil Pump
section N 2.1 Engine Removal of the oil pump Operation Section reference Remove the clutch-side crankcase cover N 6.2, Removal of the clutch-side crankcase cover Undo and remove the screws (9) and (10) securing the pump assembly. Remove the oil pump assembly (1) and extract the O-rings (2) and (4) from the crankcase half together with two locating bushes (6).
Page 392: Disassembly Of The Oil Pump
section N 2.1 Engine Disassembly of the oil pump Hold the oil pump (1) in a vice taking care not to damage the drive gear (A). Warning Make sure that vice jaws are faced with soft material. Remove the plug (3) and extract the spring (12) and by-pass valve (5). Check the condition of the above components.
Page 393: Refitting The Oil Pump
section N 2.1 Engine Refitting the oil pump Position the locating bushes (6) and the O-rings (2) and (4) in correspondence with the crankcase lubrication oilways. Position the oil pump (1) on the crankcase and tighten the screws (9) and (10) to the specified torque (Sect. C 3, Engine torque settings).
Page 394: Cylinder Head Assemblies: Checks And Adjustments
section N 4.1 Engine 4.1 - Cylinder head assemblies: checks and adjustments 1 Closing shim 2 Camshaft 3 Opening shim 4 Valve Parts catalogue CYLINDER HEAD: TIMING SYSTEM VERTICAL CYLINDER HEAD HORIZONTAL CYLINDER HEAD 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 395: Checking And Adjusting Valve Clearances
section N 4.1 Engine Checking and adjusting valve clearances Operation Section reference Remove the valve covers N 4.3, Removal of the valve covers Remove the timing belt covers N 4.2, Removal of the timing belt covers Notes For clarity, the figures show the engine block removed from the frame. Remove the inspection cover (A) and install service tool no.
Page 396 section N 4.1 Engine Checking the opening clearance (Sa) of the intake/exhaust valves To check the valve opening clearance (Sa), insert the blade of a feeler gauge between the opening rocker (C) and the shim (3). Notes While inserting the blade of the feeler gauge to check the clearance, apply gentle leverage to overcome the force of the closing rocker spring and thus eliminate any play in the rocker mechanism: then check that the shim can rotate freely.
Page 397 section N 4.1 Engine Checking the closing clearance (Sc) of the intake/exhaust valves To check the valve closing clearance, insert the blade of a feeler gauge between the closing rocker (C) 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 398 section N 4.1 Engine Checking valve lift Fit the gauge (C) 88765.1581 in correspondence with the fixing hole of the previously removed cylinder head valve cover, as shown in the photo. Reset the valve opening clearance when the camshaft is in its rest position by fitting a feeler gauge between the upper rocker arm and opening shim.
Page 399: Checking The Engine Timing
section N 4.1 Engine Checking the engine timing Operation Section reference Remove the timing belt covers N 4.2, Removal of the timing belt covers Remove the valve covers N 4.3, Removal of the valve covers Notes Engine timing should be checked after changing parts such as camshafts, valves or timing belt rollers or when overhauling badly worn engines.
Page 400 section N 4.1 Engine Turn the degree wheel (G) counterclockwise until the dial gauge (C) on the exhaust side shows a lift of 1 mm. Check that the angular displacement reading on the degree wheel (G) is as specified (Sect. C 1.1, Timing system/valves). 88765.1581 88713.0123 Continue to rotate in the same direction until you obtain a 1 mm lift on the intake side.
Page 401: Cylinder Head Assemblies: Timing Belt Covers/Timing System
section N 4.2 Engine 4.2 - Cylinder head assemblies: timing belt covers/timing system 1 Vertical cylinder timing belt cover 15 Special washer 2 Horizontal cylinder timing belt cover 16 Camshaft pulley 3 Screw 17 Flange 4 Screw 18 Screw 5 Spacer 19 Screw 6 Elastic-stop ring 20 Screw...
Page 402: Removal Of The Timing Belt Covers
section N 4.2 Engine Removal of the timing belt covers Operation Section reference Remove the fuel tank L 2, Removal of the fuel tank Remove the hoizontal cylinder exhaust pipe L 8, Removal of the exhaust system Unscrew the screw (4) and screws (3) and remove the horizontal timing belt cover (2). Unscrew the screw (4) and remove the vertical timing belt outer cover (1).
Page 403: Removal Of The Timing System Assembly
section N 4.2 Engine Removal of the timing system assembly Loosen the positioning screw (20) of the tensioner pulley (21) of the horizontal cylinder timing belt. Loosen the screw (27) securing the tensioner pulley of the horizontal cylinder timing belt and move the tensioner pulley (21) to the rest position.
Page 404 section N 4.2 Engine To remove the camshaft pulleys, install the tool 88713.3152 on the pulley to be removed to prevent its rotation, and using service scoket no. 88700.5644 inserted in a torque wrench or ratchet arm, loosen the pulley retaining nut (13). 88713.3152 88700.5644 Remove the nut (13), washer (14) and pulley (16).
Page 405 section N 4.2 Engine Use the wrench of tool no. 88700.5644 to lock rotation of the drive roller on the crankcase and, using the socket combined with the tool, loosen the nut (6). Remove the nut (6), the washer (7) and the outer pulley (8). 88700.5644 Remove the first Woodruff key (24) located on the timing belt driveshaft.
Page 406 section N 4.2 Engine Remove the secondt Woodruff key (26) located on the timing belt driveshaft. Remove the spacer (5) and the circlip (25). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 407: Disassembly And Reassembly Of The Timing Belt Pulleys
section N 4.2 Engine Disassembly and reassembly of the timing belt pulleys To disassemble the pulleys, loosen and remove the three screws (12), slide of the washer and (15) and remove the pulley (16) from the flange (17). To reassemble, fit the pulley (16) on the hub (17), aligning the timing mark (G) on the pulley with the timing mark on the (H) on the hub.
Page 408: Refitting The Timing System Assembly
section N 4.2 Engine Refitting the timing system assembly Refitting the camshaft timing pulleys Check that the keyway on the end of camshaft is in good condition and without burrs. Fit one key (C) into the camshaft keyway. Important During reassembly, take care that the timing mark “D” on the spacer flange is aligned with the mark “A” on the pulley and washer.
Page 409 section N 4.2 Engine Insert tool no. 88713.3152 in the belt pulleys to prevent their rotation. Apply a smear of grease to the thread and underside of the ringnut (13), and fit the washer (14) and the ringnut. Important Always fit new nuts on reassembly. Using the socket of service tool no.
Page 410 section N 4.2 Engine 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. 88700.5749 Fit the spacer (5) with the slot facing the crankcase. Locate on the timing belt drievshaft, the first Woodruff key (26), the inner pulley (22) the intermediate spacer (10) and the second Woodruff key (24).
Page 411 section N 4.2 Engine Then fit the outer pulley (8) the outer spacer (7) lock 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. Notes Apply a thin coating of grease to the thread and underside of the nut (6).
Page 412 section N 4.2 Engine 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 (A) on the timing belt driveshaft pulley (8) with the reference notch (D) on the crankcase cover. Important Turn the timing belt driveshaft pulley with the spark plugs removed from the engine.
Page 413 section N 4.2 Engine Remove the srew (F) from the inner timing belt cover (E) and recover the washer. Restrain the camshafts of both cylinder heads by screwing tool no. 88713.2282 into the camshaft end caps. 88713.2282 Turn the pulleys by hand until the end of the tool engages the slot in the camshaft. Monster 696/696+ - M.Y.
Page 414 section N 4.2 Engine Fit the horizontal (9) and vertical (23) timing belts using your hands only and without altering the alignment of the pulleys. Locate the tensioner pulleys (21) on the vertical and horizontal cylinders. Screw in, but do not tighten at this point, the screws (27) and (20), so that the tensioner pulleys can rotate.
Page 415 section N 4.2 Engine Check the timing belt tension and adjust if necessary as described in the paragraph “Measuring timing belt tension” (Sect. D 5). Warning Check the tension values on sections of belts (M) and (N) shown in the figure. Vertical Idler Tensioner...
Page 416 section N 4.2 Engine Warning Whenever you renew any components of the timing system, it is good practice to also check the timing (Sect. N 4.1, Cylinder head assemblies: checks and adjustments). Remove the service tools no. 88713.2282 from the camshaft end caps (E) and refit the screws (F) with the washers, tightening them to the specified torque (Sect.
Page 417 section N 4.2 Engine Refit the inspection cover (C) in the alternator-side crankcase cover, inserting the two screws (D). Tighten the screws to the specified torque (Sect. C 3, Engine torque settings). Notes Before refitting the cover (C), check the condition of the O-ring and renew it if necessary. Monster 696/696+ - M.Y.
Page 418: Refitting The Timing Belt Covers
section N 4.2 Engine Refitting the timing belt covers Position the vertical timing belt cover (1) on the engine. Fit the cover retaining screws (4) and tighten to the specified torque (Sect. C 3, Engine torque settings). Locate the horizontal timing belt cover (2) on the engine. Tighten the screws (4) and (3) to the specified torque (Sect.
Page 419: Cylinder Head Assemblies: Camshafts
section N 4.3 Engine 4.3 - Cylinder head assemblies: camshafts 24 23 1 Screw 13 Stud bolt 2 Vertical cylinder head inner timing belt cover 14 Nut 3 Seal 15 Key 4 Screw 16 Camshaft-vertical cylinder head 5 Washer 17 Intake manifold 6 Horizontal cylinder head inner timing belt cover 18 Screw 7 Screw...
Page 420: Removal Of The Intake Manifolds
section N 4.3 Engine Removal of the intake manifolds Operation Section reference Remove the throttle body L 6, Removal of the throttle body Notes The procedure can also be carried out with the engine installed in the frame. For clarity, the photos show the engine removed from the frame.
Page 421: Refitting The Intake Manifolds
section N 4.3 Engine Refitting the intake manifolds Apply the recommended threadlocker to the studs (12) and (13), install them in the cylinder heads and tighten them to the specified torque (Sect. C 3, Engine torque settings). LOCK LOCK Locate the intake manifolds (17) and secure with the nuts (14). Tighten the nuts (14) to the specified torque (Sect.
Page 422: Removal Of The Inner Timing Belt Covers
section N 4.3 Engine Removal of the inner timing belt covers Operation Section reference Remove the camshaft timing pulleys N 4.2, Removal of the timing system assembly Notes For clarity, the figures show the cylinder head removed from engine. Remove the retaining screws (18) and (1) and remove the inner timing belt cover (2) from the vertical cylinder head (10). Repeat the operation for the horizontal cylinder head (11).
Page 423 section N 4.3 Engine Unscrew the screws (21) of the end cap (20) of the camshaft (16). Remove the camshaft end cap (20) from the cylinder head and recover the O-ring (19). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 424: Removal Of The Valve Covers
section N 4.3 Engine Removal of the valve covers Undo the retaining screws (7) of valve covers (8) and remove the covers with relative O-rings (9). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 425: Refitting The Valve Covers
section N 4.3 Engine Refitting the valve covers Always fit new O-rings (9) when refitting the valve covers. Fix the valve covers (8) with the relative O-ring (9) to the cylinder head. Tighten the screws (7) to the specified torque (Sect. C 3, Engine torque settings). Monster 696/696+ - M.Y.
Page 426: Removal Of The Camshafts
section N 4.3 Engine Removal of the camshafts Operation Section reference Remove the timing belt covers and the N 4.2, Removal of the timing belt covers timing belts Remove the camshaft timing pulleys N 4.2, Removal of the timing system assembly Notes This operation can be carried out with the rocker arms installed in the cylinder head.
Page 427 section N 4.3 Engine Withdraw the camshaft (16) from its housing. Remove the oil seal (3) from the cylinder head. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 428: Inspecting The Camshafts
section N 4.3 Engine 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 429: Refitting The Camshafts
section N 4.3 Engine Refitting the camshafts If removed, install the oil seal (3) in the bore on the right-hand side of the cylinder head using a suitable drift. Important If the rockers arms are already installed in the cylinder head (Sect. N 4.4, Refitting the rocker arms, shims and valves), insert the camshaft (16) carefully rotating it as you go, so that the camshaft lobes do not foul the rocker arms.
Page 430 section N 4.3 Engine Apply graphite oil to the seats of the camshaft so that it is lubricated also during the initial revs of the engine. Insert the camshaft (16) from the left-hand side of the cylinder head. If previously removed, relocate the spring (A) of the opening rocker arm (B). Monster 696/696+ - M.Y.
Page 431 section N 4.3 Engine Check the condition of the Woodruff key (15) and its groove, and install it. Operation Section reference Refit the inner timing belt covers N 4.3, Refitting the camshaft end caps Refit the camshaft timing pulleys to the N 4.2, Refitting the timing system cylinder heads assembly...
Page 432: Refitting The Camshaft End Caps
section N 4.3 Engine Refitting the camshaft end caps Lubricate the new O-rings (19) with the recommended grease and fit on the end cap (20). Fit the end cap (20) on the left-hand side of the cylinder head. Secure the end cap (20) with the screws (21). Tighten the screws (21) to the specified torque (Sect.
Page 433 section N 4.3 Engine Locate the inner timing belt cover (2) of the vertical cylinder head (10) on the left-hand side of the cylinder head and insert the retaining screws (1) and (18). Tighten the screws (18) and (1) to the specified torque (Sect. C 3, Engine torque settings). Repeat the above operations for the other cylinder head (11).
Page 434: Cylinder Head Assemblies: Valves - Rocker Arms
section N 4.4 Engine 4.4 - Cylinder head assemblies: valves - rocker arms 1 Clip 11 Exhaust valve guide 2 Shim 12 Washer 3 Opening rocker arm 13 Intake valve guide 4 Rocker arm shaft 14 Intake valve seat 5 O-ring 15 Exhaust valve seat 6 Valve opening shim 16 Exhaust valve...
Page 435: Removal Of The Cylinder Head Assembly
section N 4.4 Engine Removal of the cylinder head assembly Operation Section reference Remove the engine from the frame N 1, Removal of the engine Remove the timing belt covers and the N 4.2, Removal of the timing belt covers timing belts Removal of the cylinder heads Notes...
Page 436: Removal Of The Rocker Arms, Shims And Valves
section N 4.4 Engine Remove the head assembly from the engine by lifting it off the engine stud bolts. Remove the cylinder head gaskets (C). Removal of the rocker arms, shims and valves Operation Section reference Remove the valve covers N 4.3, Removal of the valve covers Remove the camshaft end caps N 4.3, Removal of the inner timing belt covers...
Page 437 section N 4.4 Engine Screw service tool 88713.2837 to the threaded end of the opening rocker shaft (4). Withdraw the rocker shaft (4) and recover the opening rocker arm (3) and the two shims (2). 88713.2837 Remove the camshaft (Sect. N 4.3, Removal of the camshafts). Monster 696/696+ - M.Y.
Page 438 section N 4.4 Engine Using two screwdrivers, 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 439 section N 4.4 Engine Attach the end of the spring (9) of the closing rocker arm (18) to the tool 88713.2783. Remove the closing rocker arm shaft (4) using service tool 88713.2837. Remove the rocker arm (18), the spring (9) and service tool 88713.2783. 88713.2837 88713.2783 88713.2783...
Page 440: Overhaul Of Cylinder Head Components
section N 4.4 Engine Overhaul of cylinder head components Overhaul of the cylinder heads Remove any carbon deposits from the combustion chamber and its ducts. Check for cracking and inspect the sealing surfaces for scoring, ridges or other damage. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 441 section N 4.4 Engine The cylinder barrel mating surface must be perfectly flat. If this is not the case, spread diamond dressing compound (6 to 12 micron thickness) on a reference surface and slide the cylinder head on the surface as shown in the figure until a flat finish is obtained.
Page 442 section N 4.4 Engine 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 443 section N 4.4 Engine If a valve seat is only slightly damaged, it may be lapped using the special 45° lapping tools, with subsequent grinding of the valve into its seats. If the valve seats are excessively damaged, fit oversize seats. Replacement seats are available with 0.03 and 0.06 mm oversized outside diameters.
Page 444 section N 4.4 Engine Renewal of the valve seat Remove the worn seats by grinding out the rings. Take great care not to damage the valve seat housing in the cylinder head. Check the diameter of cylinder head bores and choose the oversized valve seat that will give an interference fit of 0.11 to 0.16 mm.
Page 445 section N 4.4 Engine Valve–seat contact surfaces Use Prussian blue or a mixture of minium and oil to check that the contact surface (W) between valve and seat is 1.0 to 1.5 mm. Maximum permissible limit: 2.0 mm. Grind the seat if the dimension measured is greater than above limit. Fill the intake and exhaust ducts with fuel to check for leaks;...
Page 446 section N 4.4 Engine Renewal of the valve guides To renew the valve guides (11) and (13), proceed as follows. Heat up the cylinder head gradually and evenly up to 200 °C. Drive out the valve guide using a suitable drift (see drawing). Allow the cylinder head to cool down and check the condition of the seat.
Page 447 section N 4.4 Engine Overhauling the rocker arms Check for signs of wear, grooves or chrome flaking off. Check the condition of the rocker arm bore and shaft. nominal diameter of rocker arm bore: 10.040 to 10.062 mm. nominal diameter of rocker arm shaft: 10.001 to 10.010 mm.
Page 448 section N 4.4 Engine 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). Checking the rocker arm springs Carefully examine the springs (9) of the closing rocker arms (18).
Page 449: Refitting The Cylinder Head Assembly
section N 4.4 Engine Refitting the cylinder head assembly To refit the cylinder head reverse the steps of the removal procedure; pay particular attention to those operations mentioned specifically. It is very important that all the components are carefully cleaned. If removed, fit new valve guide seal rings (10), lubricate with engine oil and insert from the spring side with tool part no.
Page 450: Refitting The Rocker Arms, Shims And Valves
section N 4.4 Engine Refitting the rocker arms, shims and valves Fit the closing rocker arm (18) and relative spring (9) on service tool no. 88713.2783. Insstall the service tool – rocker arm –spring assembly in the cylinder head and insert the shaft (4) with a new seal ring (5), suitably lubricated.
Page 451 section N 4.4 Engine Proceed in the same way for the exhaust side. Install the valve (17) and valves (16), first lubricating them with engine oil. Provisionally install the camshaft (C). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 452 section N 4.4 Engine Using two screwdrivers, hold the closing rocker (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. Remove the screwdriver and position the closing rocker arm (18) in the rest position.
Page 453 section N 4.4 Engine Once the specified clearance has been obtained, remove the camshaft (C), lubricate it with graphite oil and reinstall it in the cylinder head. Insert the rocker arm shaft (4) with the threaded hole on the external side of the cylinder head: the seal (5) should be renewed on installation;...
Page 454: Refitting The Cylinder Heads
section N 4.4 Engine Fit the side clip (1) on the shaft (4) of the opening rocker arm (3) between the two spacers (2). Operation Section reference Refit the valve covers N 4.3, Refitting the valve covers Refitting the cylinder heads Warning In order to prevent oil leaks developing between the cylinder barrel and the crankcase, every time the cylinder head is removed, it is essential to remove also the cylinder barrel/piston in order to be able to clean the crankcase and cylinder barrel, to renew,...
Page 455 section N 4.4 Engine Fit the cylinder head onto the studs and lower it down onto the cylinder barrel. Fit the special washers (12) over the stud bolts with the square edged face towards the cylinder head and the flat face towards the inside.
Page 456: Cylinder/Piston Assemblies
section Engine 5 - Cylinder/piston assemblies 1 Pin 2 Circlip 3 Gudgeon pin 4 Vertical cylinder 5 Piston rings 6 Cylinder-crankcase gasket 7 Dowel 8 Horizontal cylinder 9 Piston 10 Centring bush 11 Cylinder head gasket 12 Cylinder temperature sensor Parts catalogue CYLINDERS - PISTONS Important...
Page 457: Removal Of The Cylinder/Piston Assembly
section Engine Removal of the cylinder/piston assembly Operation Section reference Remove the cylinder heads from the N 4.4, Refitting the cylinder head engine assembly Remove the dowel (7), bushes (10) and head gasket (11) from their seats on the cylinder barrel. Use service tool no.
Page 458 section Engine Since insertion of piston in the barrel is a difficult operation to perform at the time of reassembly, remove the piston together with the barrel as an assembly as described below. Close the opening in the engine crankcase with a rag or soft paper to prevent foreign material or solid combustion residue from falling in.
Page 459 section Engine To remove the vertical cylinder-piston assembly, proceed as described above for the horizontal cylinder. Remove cylinder-crankcase gaskets (6) from the cylinder barrel. Important Mark the pistons to show from which cylinder they were removed: V= Vertical - H= Horizontal. Monster 696/696+ - M.Y.
Page 460: Overhaul Of The Cylinder Barrel/Piston Components
section Engine Overhaul of the cylinder barrel/piston components Overhauling the cylinder 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 Sect.
Page 461 section Engine Overhaul of the piston Clean the piston crown and piston ring grooves, removing any carbon deposits. Inspect the piston and check its dimensions carefully: there must be no signs of scuffing, scoring, cracks, or other damage. Check the piston diameter. The pistons must always be renewed as a pair.
Page 462 section Engine Piston-cylinder clearance The pistons are marked with a letter (punched into the piston crown) that indicates the size class to which they belong. Always match cylinders with pistons from the same size class. For the values, refer to Sect. C 1.1, Cylinder/Piston. Overhauling the gudgeon pins Gudgeon pins must be perfectly smooth without signs of scoring, steps, or blueing due to overheating.
Page 463 section Engine Piston ring-to-groove clearance The maximum permissible wear limit is 0.15 mm for the top compression ring (1 ) and 0.10 mm for the others (2 and oil control ring). compression ring MARK compression ring MARK Oil control ring MARK Notes The piston rings must always be installed with markings facing upwards.
Page 464 section Engine Gudgeon pin-piston clearance Measure the diameter of the gudgeon pin bore in the piston. Measure the diameter of the gudgeon pin. Maximum wear limit: 0.025 mm. Notes If you fit a new gudgeon pin, you must also change the connecting rod small end bush. Monster 696/696+ - M.Y.
Page 465 section Engine Piston ring-to-bore clearance It is essential that the measurement be performed with the piston ring (A) positioned perfectly square in the cylinder. For this reason, the piston (9) should be inserted in the cylinder without piston rings fitted and then place the piston ring to be checked on top of the piston.
Page 466: Refitting The Cylinder/Piston Assembly
section Engine Refitting the cylinder/piston assembly If a new cylinder/piston assembly is to be fitted, make sure that the piston and cylinder are of the same size class. The letter indicating the cylinder size class is stamped on the cylinder-head mating face; the piston size class letter is stamped on the crown in between the two recesses.
Page 467 section Engine Apply a bead of liquid gasket to the contact faces of the 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 468 section Engine Using service tool no. 88700.5644, bring the small end of the connecting rod up to near TDC. Fit the piston–cylinder assembly on the crankcase studs. 88700.5644 Push the connecting rod small end into the piston close to the gudgeon pin (3) bore. Lubricate and insert the gudgeon pin. The gudgeon pin must slide smoothly in the connecting rod small end bush and in the piston (9).
Page 469 section Engine Important Locate the locating dowel (7), head gasket (11) and centring bushes (10). Repeat the procedure for the other cylinder. Operation Section reference Refit the cylinder heads N 4.4, Refitting the cylinder heads Monster 696/696+ - M.Y. 2009 - edition 00...
Page 470: Clutch Assembly: Aptc Wet Clutch
section N 6.1 Engine 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 12 Spring 13 Hub Parts catalogue CLUTCH...
Page 471: Description Of The Aptc Clutch Assembly
section N 6.1 Engine Description of the APTC clutch assembly The APTC system with servo-assisted torque and anti-wheel slip on braking. The advantages of this system are: - prevents the unwelcome effects of excessive engine braking during hard downshifting, thus making for smoother, cleaner cornering (no rear wheel slip);...
Page 472: Removal Of The Aptc Clutch
section N 6.1 Engine Removal of the APTC clutch Operation Section reference Drain the engine oil D 4, Changing the engine oil and filter cartridge Remove the clutch-side crankcase cover N 6.2, Removal of the clutch-side crankcase cover Screw the three tools 88713.2591 into the relative bores in the hub. 88713.2591 Unscrew the retaining screws (1) and remove the collars (2) and the clutch springs (4).
Page 473 section N 6.1 Engine Hold the clutch drum with the service tool no. 88713.2556 and unscrew the nut (8). 88713.2556 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.
Page 474: Disassembly Of The Clutch Hub-Plates-Centre Assembly
section N 6.1 Engine Remove the spacer (11) from the clutch drum (A). Disassembly of the clutch hub-plates-centre assembly Unscrew the three tools 88713.2591. Withdraw the hub (13) and the plates (7) from the clutch centre (10). Recover the three springs (12). Remove the clutch plates (7) from the hub (13).
Page 475: Overhaul And Inspection Of The Aptc Clutch Components
section N 6.1 Engine 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. The clearance “S” must not exceed 0.6 mm. If it does, renew the plates and, if necessary, the clutch drum.
Page 476 section N 6.1 Engine 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; if excessively scored, use a reference plate and diamond lapping paste (6-12 microns thick) and rub the friction plate on it to obtain a smooth, uniform surface.
Page 477: Reassembly Of The Clutch Hub-Plates-Centre Assembly
section N 6.1 Engine Reassembly of the clutch hub-plates-centre assembly Install the three springs (12) on the pin (E) on the drum (10). Install the clutch plates (7) in the hub (13) starting with one of the 11 friction plates (F) and alternate with the 10 driven plates (G). Install the clutch plate assembly (7) with hub (13) in the drum (10).
Page 478 section N 6.1 Engine Insert the three tools 88713.2591 to fix the hub (13) to the clutch centre (10). Screw in the three tools 88713.2591 by hand, pressing down on the clutch plates with the hub (13), so as to overcome the resistance of the springs.
Page 479: Refitting The Aptc Clutch
section N 6.1 Engine Refitting the APTC clutch Locate the spacer (11) on the drum (A). Position the hub-plates-drum assembly (B) inside the drum (A). Notes Position the last friction plate (M) so that it is offset relative to others. Locate the lock washer (9) on the gearbox input shaft, seating it against the clutch assembly.
Page 480 section N 6.1 Engine Apply the recommended grease to the contact face of the nut (8) and to thread of the gearbox input shaft, then fit the nut to the input shaft and tighten by hand. Restrain the clutch drum with tool part no. 88713.2556 when tightening nut (8). Tighten the nut (8) to the specified torque (Sect.
Page 481 section N 6.1 Engine 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). Tighten the screws (1) to the specified torque (Sect. C 3, Engine torque settings), working in a crosswise pattern. Unscrew and remove the service tools 88713.2591.
Page 482: Clutch Assembly: Clutch-Side Crankcase Cover
section N 6.2 Engine 6.2 - Clutch assembly: clutch-side crankcase cover 8 9 10 11 1 Clutch-side crankcase cover 11 Circlip 2 Screw 12 O-ring 3 Screw 13 Locating bush 4 Oil level sight glass 14 Sealing washer, thickness 2 5 Screw 15 Plug 6 Panel (BLACK)
Page 483: Removal Of The Clutch-Side Crankcase Cover
section N 6.2 Engine Removal of the clutch-side crankcase cover Operation Section reference Drain the engine oil D 4, Changing the engine oil and filter cartridge Disconnect the oil pressure P 5, Checking the front and rear brake light sensor switches, neutral light switch, oil pressure switch and clutch switch Unscrew the screws (2), (3) and (5) securing the clutch-side crankcase cover (1).
Page 484: Disassembly Of The Clutch-Side Crankcase Cover
section N 6.2 Engine Disassembly of the clutch-side crankcase cover Remove the plug (15) from the cover and the relative O-ring (7), the engine oil pressure switch (16) and its seal (14). Unscrew the screw (20) securing the inner cover (17). Remove the inner cover (17) and sound-proofing panel (6).
Page 485: Reassembly Of The Clutch-Side Crankcase Cover
section N 6.2 Engine Reassembly of the clutch-side crankcase cover Fit the plug (15) and the seal (7). Install the pressure switch (16) with its seal (14). 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 oil seal (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 486 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. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 487 section N 6.2 Engine Fit the cover assembly (1) to the crankcase half and insert the retaining bolts. Tighten the screws (2), (3) and (5) to the specified torque (Sect. C 3, Engine torque settings) in a crosswise pattern. Operation Section reference Connect the oil pressure sensor P 5, Checking the front and rear brake light...
Page 488 section N 6.3 Engine 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 Parts catalogue CLUTCH 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 the exploded view diagram.
Page 489: Removal Of The Primary Drive Gears
section N 6.3 Engine Removal of the primary drive gears Operation Section reference Drain the engine oil D 4, Changing the engine oil and filter cartridge Remove the clutch-side crankcase cover N 6.2, Removal of the clutch-side crankcase cover Remove the clutch assembly N 6.1, Removal of the APTC clutch Remove the oil pump N 2.1, Removal of the oil pump...
Page 490 section N 6.3 Engine Restrain the primary driving gear (B) using service wrench no. 88713.2423 and unscrew the threaded nut (5) securing the pinion. Remove the nut (5) and lockwasher (6). 88713.2423 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.
Page 491: Refitting The Primary Drive Gears And Checking Backlash
section N 6.3 Engine Refitting the primary drive gears and checking backlash Fully degrease the crankshaft splined end and the corresponding spline on the primary drive gear. Check that the key (C) and internal spacer (D) are in position on the crankshaft. Fit the driving gear (B) onto the crankshaft with the oil pump drive sprocket facing the crankcase.
Page 492 section N 6.3 Engine After checking the backlash, restrain the driving gear (B) with service wrench no. 88713.2423 and tighten the nut (5) to the specified torque (Sect. C 3, Engine torque settings). Stake the lock washer (6) onto the nut (5). 88713.2423 Monster 696/696+ - M.Y.
Page 493 section N 6.3 Engine Refit the oil pump and check the backlash between the oil pump gear and primary drive gear on the crankshaft (Sect. N 2.1, Refitting the oil pump). Thoroughly degrease the mating surfaces of the clutch drum (1), the internal bearing (3) and the bush (2). Fit the internal spacer (4) to the input shaft with its flat side facing outwards.
Page 494: Gearbox Assembly: Gearchange Mechanism
section N 7.1 Engine 7.1 - Gearbox assembly: gearchange mechanism 24 23 1 Return spring 14 Selector drum control fork 2 Washer 15 Gearchange lever pin 3 Special screw 16 Shaft with gearchange lever arm 4 Gear pawl assembly 17 Gearchange lever arm return spring 5 Interlock plunger holder 18 Screw 6 Sealing washer...
Page 495: Removal Of The Gearchange Mechanism
section N 7.1 Engine Removal of the gearchange mechanism Operation Section reference Remove the alternator-side crankcase N 8, Flywheel - alternator cover and flywheel/alternator assembly Remove the clutch drum N 6.3, Removal of the primary drive gears Undo and remove the gear selector mechanism (25) retaining screws (18) and (20). Remove screws (18) and (20), washers (19) and (21) and withdraw the gear selector mechnaism complete with the gear lever shaft, spring and stop plate.
Page 496: Disassembly Of The Gear Selector Mechanism
section N 7.1 Engine Disassembly of the gear selector mechanism If it is necessary to renew any components, disassemble the gearchange mechanism as shown in the exploded view. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 497: Disassembly Of The Gear Interlock Plunger And Pawl Assembly
section N 7.1 Engine Disassembly of the gear interlock plunger and pawl assembly Unscrew the interlock plunger screw (5) and remove seal (6), spring (7) and detent ball (8). Unscrew the clutch-side crankcase screw (3) and remove the pawl (4), washer (2) and spring (1). Monster 696/696+ - M.Y.
Page 498: Refitting The Gear Interlock Plunger And Pawl Assembly
section N 7.1 Engine Refitting the gear interlock plunger and pawl assembly Fit the pawl (4), washer (2) and spring (1) on the retaining screw (3). Fit the assembled unit on the clutch-side crankcase half, locating the end of the spring (1) behind the crankcase rib. Tighten the screw (3) to the specified torque (Sect.
Page 499 section N 7.1 Engine Apply grease and then fit the ball (8), spring (7), and seal (6) into interlock plunger (5) and screw the interlock plunger assembly into the crankcase. Tighten the gear interlock plunger to the specified torque (Sect. C 3, Engine torque settings). Monster 696/696+ - M.Y.
Page 500: Reassembly Of The Gearchange Mechanism
section N 7.1 Engine Reassembly of the gearchange mechanism 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 501 section N 7.1 Engine 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 locknut (13) and turn eccentric pin (15). Position the spring (10) between the shaft (16) and the fork (14).
Page 502 section N 7.1 Engine Monster 696/696+ - M.Y. 2009 - edition 00...
Page 503: Refitting The Gearchange Mechanism
section N 7.1 Engine Refitting the gearchange mechanism Position the gearchange mechanism (25) in the chain-side crankcase. Locate the gearbox drum selector claw in the centre of the drum rollers. Temporarily fit the gearbox lever (or a service lever) and engage third gear. Fit the plate 88713.1091 in the claw shaft pins (see figure).
Page 504 section N 7.1 Engine With the gearbox in neutral, check that the lever travel is the same when shifting up and down. The same should apply when a gear is engaged. Operate the gearchange lever and turn the front sprocket at the same time to check that all the gears engage when shifting up and down.
Page 505: Gearbox Assembly: Gearbox Shafts
section N 7.2 Engine 7.2 - Gearbox assembly: gearbox shafts Gearbox input shaft Gearbox output shaft 1 Shim, thickness 1 17 Needle roller bearing 2 Gearbox input shaft 18 1 speed driven gear 3 Shim, thickness 0.5 19 Shim, thickness 1 4 Needle roller bearing 20 5 speed driven gear...
Page 506: Removal Of The Gearbox Assembly
section N 7.2 Engine Removal of the gearbox assembly Operation Section reference Separation of the crankcase halves N 9.2, Separation of the crankcase halves Withdraw the selector fork shafts (30). Move the forks (28) and (29) to disengage them from the slots in the selector drum (13). Withdraw the selector drum (13) taking care not to lose shims (31) and (27) mounted on the shaft.
Page 507 section N 7.2 Engine Remove gear selector forks (29) and (28). Remove the gearbox input (2) and output (25) shafts complete with gears, taking care to recover the spacers on the ends of the shafts. If the bearing inner races (A) are left on the shafts, slide them off the ends of the gearbox input (2) and output (25) shafts (Sect.
Page 508: Disassembly Of The Gearbox Shafts
section N 7.2 Engine Disassembly of the gearbox shafts Place the shaft in a vice in such a way as to facilitate the disassembly operations. Important Take care not to invert the positions of the shims on reassembly: this would potentially lead to jamming when using the gear selector control, making it necessary to reopen the engine crankcase. Disassembly of the gearbox output shaft Remove the chain-side shim (15) and clutch-side shim (26) from the output shaft.
Page 509 section N 7.2 Engine Remove the fifth speed driven gear (20). Use two flat blade screwdrivers to remove the circlip (7) taking care not to damage the shaft surface. Remove the circlip (7) and the splined washer (6). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 510 section N 7.2 Engine Withdraw the fourth speed driven gear (21) with the roller cage (4) and splined washer (12). Remove the third speed driven gear (22) with the roller cage (4) and the splined washer (6). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 511 section N 7.2 Engine Remove the circlip (7) and remove the sixth speed driven gear (23). Remove the circlip (7) and withdraw the splined washer (6) and the second speed driven gear (24). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 512 section N 7.2 Engine Withdraw the roller cage (4) and the shim (3). All the components have thus been removed from gearbox output shaft (25). Disassembly of the gearbox input shaft Remove the chain-side shim (11) and the clutch-side shim (1) from the input shaft. Monster 696/696+ - M.Y.
Page 513 section N 7.2 Engine Remove the second speed driving gear (10). Use two screwdrivers to prise out the circlip (7) and the splined washer (6). Important Take care to avoid damaging the surface of the shaft while removing circlip (7). Monster 696/696+ - M.Y.
Page 514 section N 7.2 Engine Remove the sixth speed driving gear (9) with its roller cage (4). Remove the splined washer (6) and the circlip (7). Withdraw the third and fourth speed driving gear (8). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 515 section N 7.2 Engine Remove the circlip (7) and the splined washer (6). Remove the fifth speed driving gear (5) with the roller cage (4). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 516: Overhaul Of The Gearbox
section N 7.2 Engine Slide the shim (3) off the input 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 517: Inspection Of The Gear Selector Forks
section N 7.2 Engine Inspection of the gear selector forks Visually inspect the gear selector forks. Bent forks must be renewed as they may lead to difficulties in gear changing or may suddenly disengage when under load. Use a feeler gauge to check the clearance of each fork in its gear groove. If the service limit has been exceeded, check whether or not it is necessary to renew the gear or the fork by referring to the limits specified for each part (Sect.
Page 518: Inspection Of The Gear Selector Drum
section N 7.2 Engine 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 renewed by comparing these dimensions with those of new components (Sect.
Page 519: Reassembly Of The Gearbox Shafts
section N 7.2 Engine Reassembly of the gearbox shafts Figure 1 shows all the parts to be reassembled on the gearbox input shaft (2), with the calculated end shims (1) and (11) (Sect. N 9.2, Shimming the shafts). Fig. 1 Figure 2 shows all the parts to be reassembled on the gearbox output shaft (25), with calculated end shims (15) and (26) (Sect.
Page 520 section N 7.2 Engine Reassemble the gears on the gearbox shafts by reversing the disassembly procedure. Take particular care when installing the idler gears. The assembly of the 3 and 4 speed gears and the relative fixing components on the output shaft is given as an example. Fit the circlip (7), checking that it is fully inserted into its groove on the shaft.
Page 521 section N 7.2 Engine Fit the three-pointed washer (12), which can be distinguished from its counterpart (6) by its bigger outside diameter. Fit another needle roller cage (4) using the method already described. Fit the 4 speed gear (21). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 522 section N 7.2 Engine Fit another 3-pointed washer (6) and another circlip (7) onto the shaft Seat the circlip using the drift used previously. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 523: Reassembly Of The Gearbox
section N 7.2 Engine Reassembly of the gearbox To reassemble the gearbox components follow the procedure under Sect. N 9.2 relating to “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 524: Flywheel - Alternator
section Engine 8 - Flywheel - alternator 19 18 31 30 1 Clip 20 Electric starter driven gear 2 Pick-up sensor inspection screw 21 Starter clutch 3 Seal 22 Flywheel-starter clutch assembly 23 Alternator rotor 4 O-ring 5 Cover 24 Screw 6 Screw 25 Screw 7 Washer...
Page 525: Removal Of The Alternator-Side Crankcase Cover
section Engine Removal of the alternator-side crankcase cover Operation Section reference Drain the engine oil D 4, Changing the engine oil and filter cartridge Remove the gearchange mechanism F 5, Removal of the gearchange mechanism Remoe the clutch slave cylinder F 2, Removal of the clutch slave cylinder Remove the front sprocket cover G 8, Removal of the front sprocket...
Page 526 section Engine Fix service tool no. 88713.1749 to the holes left vacant by the two screws (6) you have just removed. Turn the tool shaft slowly to separate the cover (28) from the LH crankcase half. 88713.1749 Monster 696/696+ - M.Y. 2009 - edition 00...
Page 527: Disassembly Of The Alternator-Side Crankcase Cover
section Engine Disassembly of the alternator-side crankcase cover Undo the three stator retaining screws (24) and the two screws (31) securing the cable guide bracket (30) from inside the alternator-side crankcase cover. Remove the stator (32) and the cable guide (30). The alternator-side crankcase cover is fitted with a bearing (26), held in place by circlip (27), which locates on the end of the crankshaft.
Page 528: Removal Of The Flywheel/Alternator Assembly
section Engine Removal of the flywheel/alternator assembly Use service tool no. 88713.2036 fixed to the M10 sidestand fixing holes (D). Secure the tool to the flywheel with the screw (E). 88713.2036 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 529 section Engine Remove the inner race (18), the needle roller bearing (19) and the washer (17). Important Examine the inner race (18), needle roller bearing (19) and internal washer (17) for wear. Notes The hole in the inner race (18) allows the passage of oil for lubrication of needle roller bearing (19). Monster 696/696+ - M.Y.
Page 530: Checking The Flywheel/Alternator Assembly
section Engine Checking the flywheel/alternator assembly Examine the inner part of alternator rotor (23) for signs of damage. Check that the starter clutch is working properly and that the needle races do not show signs of wear or damage of any kind. If there is any malfunction, remove the whole assembly.
Page 531 section Engine Reassembly of the flywheel-alternator assembly Install the starter clutch (21) in the flange (13), making sure it is properly seated. Important Orient the flange so that the side with the bevelled edge (A) faces the starter clutch. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 532 section Engine Seat the flange (13) with the starter clutch in the flywheel (16), aligning the flange locating hole (B) with the flywheel locating hole (C). When refitting the flange to flywheel, insert a pin or a wrench inside the hole (C) for the rotor flywheel locating dowel (14) in order to line up the flywheel holes with flange threads.
Page 533 section Engine Install the rotor (23) on the flywheel (16), aligning the flywheel locating dowel (14) with the rotor locating hole (D). Apply threadlocker to the rotor/flywheel fixing screws (25) and start them in their threads. LOCK LOCK Monster 696/696+ - M.Y. 2009 - edition 00...
Page 534 section Engine Tighten the screws (25) to the specified torque (Sect. C 3, Engine torque settings). Install the driven gear (20) on the starter clutch, ensuring it is properly seated. Check that the driven gear can rotate freely in the direction of the green arrow but not in the direction of the red arrow. If either of these two conditions is not met, this means that the starter clutch has not been installed correctly.
Page 535: Refitting The Flywheel-Alternator Assembly
section Engine Refitting the flywheel-alternator assembly Fit the washer (17) (suitably lubricated), needle roller bearing (19), and inner race (18) to the crankshaft. Make sure the inner race is centred relative to the washer. Install the flywheel-rotor-driven gear assembly on the crankshaft, taking care not to alter the position of the inner race (18) relative to the washer (17).
Page 536 section Engine Apply the recommended threadlocker to the threads of the crankshaft and the flywheel nut (34). LOCK Restrain the rotation of the flywheel with the holding tool 88713.2036. 88713.2036 Important Tighten the nut (34) to the specified torque (Sect. C 3, Engine torque settings). Remove all traces of Loctite from the threads of the nut (34) and the crankshaft (A).
Page 537: Reassembly Of The Alternator-Side Crankcase Cover
Remove any scale and grease from the mating surfaces of the left-hand crankcase half and the crankcase cover. Fit the two locating bushes (29). Spread a continuous uniform bead of DUCATI liquid gasket on the mating surface of the cover (28), ensuring continuity around the holes for the retaining screws and locating bushes.
Page 538 section Engine Insert the fixing screws in their holes following the indications given in the table. Description M6x20 mm screws M6x25 mm screws M6x30 mm screws M6x30 mm screws Install under the screw (12), in correspondence with the starter motor, the spacer (8), the guide (9), the washer (35) and install the cover (36) under screw (11) in correspondence with the alternator lead: for instructions on the positioning of the wiring under the cover (36) see below.
Page 539 section Engine Check that the fuel tank drain hose (T) and the airbox drain hose (U) are positioned in the lower slot of the cover (36) as shown. Offer the cover (36) up to the alternator-side crankcase cover and position the fuel tank breather hose (T) and the airbox drain hose (U), the sidestand cable (R), alternator cable (S) and the starter motor cable (Q) as shown.
Page 540 section Engine Position the fuel tank drain hose (T), inserting it in the guide (9). Dampen the oil seal (3) with alcohol and install it in the alternator-side crankcase cover, in correspondence with the gearchange shaft (Sect. F 5, Refitting the gearchange mechanism), using the specific installation tool 88713.1411. 88713.1411 Monster 696/696+ - M.Y.
Page 541 section Engine Make sure that the O-ring (4) is installed in the cover (5). Apply threadlocker to the screws (6). Tighten the two retaining screws (6) of the inspection cover (5) over the end of the crankshaft to the specified torque (Sect C 3, Engine torque settings).
Page 542 section Engine Positioning of cables/hoses under the breather hose cover mounted on the alternator-side crankcase cover Monster 696/696+ - M.Y. 2009 - edition 00...
Page 543 section Engine Monster 696/696+ - M.Y. 2009 - edition 00...
Page 544: Crankcase Assembly: External Components
section N 9.1 Engine 9.1 - Crankcase assembly: external components 2 3 4 16 15 1 Key 21 Gear shaft 2 Timing gear pair 22 Washer 3 Lock washer 23 Starter motor gear 4 Hex nut 24 Washer 5 Key 25 Circlip 6 Aluminium gasket 26 Screw...
Page 545: Removal Of External Components
section N 9.1 Engine Removal of external components Operation Section reference Remove the engine from the frame N 1, Removal of the engine Remove the lubrication system N 2.1, Removal of the oil pump Remove the cylinder head assemblies and N 4.2, Cylinder head assemblies: timing the timing parts belt covers/timing system...
Page 546 section N 9.1 Engine Undo and remove the earth cable screw (7) with its seal (6). Remove the gauze pickup filter (18) with its seal from the clutch-side crankcase half as described in Sect. D 4, Changing the engine oil and filter cartridge. Unscrew the plug (27), taking care to recover the relative seal (28).
Page 547 section N 9.1 Engine Remove the neutral switch (19) with seal (20). Remove the cylinder head studs (12) with the aid of the appropriate tool. Remove the gear interlock pawl and plunger as described in Sect. N 7.1, Disassembly of the gear interlock plunger and pawl assembly.
Page 548 section N 9.1 Engine Remove the bush (40) and recover the seal (37), the spring (39) and the ball (38). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 549: Refitting The External Components
section N 9.1 Engine 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. Tighten the screw (30) to the specified torque (Sect. C 3, Engine torque settings). Tighten the two plugs (14) with the seals (8) to the specified torque (Sect.
Page 550 section N 9.1 Engine Apply the recommended threadlocker to the nipple (17). Tighten the oil filter support nipple (17) to the specified torque (Sect. C 3, Engine torque settings). LOCK Screw in the drain plug (9) with its seal (29) and tighten to the specified torque (Sect. C 3, Engine torque settings), after applying the recommended threadlocker.
Page 551 section N 9.1 Engine Refit the gear interlock pawl and plunger (Sect. N 7.1, Refitting the gear interlock plunger and pawl assembly). Now fit the studs (12) in the crankcase halves, applying threadlocker and tightening to the specified torque value (Sect.
Page 552 section N 9.1 Engine Use a feeler gauge to check the clearance between the engine pickup (34) and the timing gear (2). The value must be between 0.6 and 0.8 mm. Fit the earth lead retaining screw (7) with the seal (6) in the crankcase and tighten to the specified torque (Sect. C 3, Engine torque settings).
Page 553 section N 9.1 Engine If removed, fit the seal (16) to the service plug (15): the seal must be oriented so that the square edge faces the clutch-side crankcase. Apply the recommended threadlocker to the thread of the plug (15) and tighten it to the specified torque (Sect. C 3, Engine torque settings).
Page 554: Removal Of The Timing Gears
section N 9.1 Engine Removal of the timing gears Operation Section reference Remove the alternator-side crankcase N 8, Flywheel - alternator cover and the alternator assembly Slide out driving gear (A) of timing gear pair (2) and remove the Woodruff key (5). Relieve the staking on the lock washer (3) of the nut (4).
Page 555 section N 9.1 Engine Remove the nut (4), washer (3), driven timing gear (B) and Woodruff key (1) from the timing belt driveshaft shaft. Monster 696/696+ - M.Y. 2009 - edition 00...
Page 556: Refitting The Timing Gears
section N 9.1 Engine 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. Refitting is the reverse of removal. Important On completion of the refitting operations, check that tab washer (3) is staked against nut (4) in such a way as to prevent the nut from working loose.
Page 557: Removal Of The Starter Motor Idler Gear
section N 9.1 Engine Removal of the starter motor idler gear Operation Section reference Remove the flywheel/alternator assembly N 8, Flywheel - alternator Remove the circlip (25) and the washer (24). Remove the starter motor idler gear (23) and shim (22). Undo the screw (26) securing the idler gear shaft (21) and remove the shaft.
Page 558: Refitting The Starter Motor Idler Gear
section N 9.1 Engine Refitting the starter motor idler gear Refitting is the reverse of removal. Notes Apply the prescribed threadlocker to the screw (26) and tighten to the prescribed torque (Sect. C 3, Engine torque settings). LOCK Operation Section reference Refit the flywheel/alternator assembly N 8, Flywheel - alternator Monster 696/696+ - M.Y.
Page 559: Crankcase Assembly: Crankcase Halves
section N 9.2 Engine 9.2 - Crankcase assembly: crankcase halves 28 29 28 24 9 10 11 17 18 12 13 1 Circlip 16 Clutch-side crankcase half 2 Timing belt driveshaft 17 Spacer 3 Alternator-side crankcase half 18 Screw 4 Bearing 19 Bush 5 O-ring 20 Seal...
Page 560: Separation Of The Crankcase Halves
section N 9.2 Engine Separation of the crankcase halves Operation Section reference Remove the engine from the frame N 1, Removal of the engine Remove the lubrication system N 2.1, Removal of the oil pump Remove the cylinder head assemblies and N 4.2, Removal of the timing belt covers the timing parts Remove the cylinder barrel/piston...
Page 561 section N 9.2 Engine Unscrew the two screws (25) on the clutch side crankcase half (16) near the vertical cylinder. Re-use the alternator-side crankcase cover or a service cover with puller 88713.1749. Secure it to the crankcase half using several of the original screws and begin to separate the crankcase halves by turning the central pin of the tool.
Page 562 section N 9.2 Engine Remove the gearbox shafts (A) and gearbox selector drum (B) from the crankcase (Sect. N 7.2, Gearbox assembly: gearbox shafts). Drive out the crankshaft (C) using a plastic mallet and taking care not to lose the shims (D). Remove the timing belt driveshaft (2).
Page 563: Overhaul Of The Crankcase Halves
section N 9.2 Engine Overhaul of the crankcase halves Carefully examine the engine crankcase halves. Check that the surfaces of the crankcases are perfectly flat using a reference surface. Check that the bearings (4) and (23) are in good condition. Note that main bearings must always be changed in pairs (refer to the procedure below in “Main bearings”). Notes When overhauling an engine it is good practice to renew all the crankcase bearings.
Page 564 section N 9.2 Engine In the event of renewal of needle roller bearings (24) and oil seals (28) on the swingarm pivot shaft, lubricate the seats of the bearings and the lips of the oil seals with the recommended grease. Install the inner oil seal (28) as shown in figure (E) ansd seated against the circlip (29);...
Page 565 section N 9.2 Engine Check the condition of locating bushes (19). In the event of evident signs of distortion or excessive assembly clearance in their bores, remove the locating bushes using appropriate tools. If the removal of the bushes (19) from the casing proves difficult, use a left-handed thread tap to force the bushes out. Important The bushes (19) must always be renewed when they have been removed using the above procedure.
Page 566: Overhaul Of The Main Bearings
section N 9.2 Engine Overhaul of the main bearings The main bearings have are of the angular contact type with offset inner races so that the balls transmit loads from one groove to the other along straight lines at an angle to the axis of the bearing. Angular contact thrust bearings are designed to withstand combined loads (radial and axial loads).
Page 567: Reassembly Of The Crankcase Halves
section N 9.2 Engine Reassembly of the crankcase halves The crankcase halves must be in good condition and perfectly clean. The mating surfaces must be perfectly flat and free from burrs. Refitting the clutch-side crankcase half The following parts must be present on the internal side of the crankcase half: The output shaft end bearing (15): apply grease to the bearing rollers.
Page 568 section N 9.2 Engine The gearbox input shaft end bearing (12) with the inner spacer (B): apply grease to the bearing rollers. Fit the inner race (A) removed previously from the bearing. Apply grease to the inner race. The main bearing (4). LOCK The ball bearing (7) with circlip (6), in correspondence with the timing belt driveshaft, oriented si that the closed side of the plastic roller cage faces the crankcase half.
Page 569: Shimming The Shafts
section N 9.2 Engine Shimming the shafts Before assembling the crankcase halves, calculate the shims required to obtain the correct end float of the crankshaft and gearbox shafts. To determine the correct shim thicknesses proceed as follows. Shimming the crankshaft After fitting the new main bearings, proceed as follows to determine the total shim thickness “SA”: measure the distance “LA”...
Page 570 section N 9.2 Engine Practical method for determining crankshaft shims In addition to the above procedure, the following is a practical shimming method, providing a guide on how to calculate the crankshaft shim thicknesses accurately. Install a shim (R) of minimum thickness (1.90 mm) on each side of the crankshaft to prevent contact between the crankshaft web and the engine block.
Page 571 section N 9.2 Engine Bring the stylus into contact with the end of the crankshaft and set the dial gauge to zero in this position. Insert a lever (L) between the crankcase and the crank web and force the crankshaft towards the dial gauge. Note the dial gauge reading.
Page 572 section N 9.2 Engine Shimming the gearbox shafts To establish the total shim thicknesses to be installed on the input shaft “SP” and the output shaft “SS”, proceed as follows: measure the dimensions “LP” and “LS” on the input and output shafts (for the output shaft add shim thickness “R” of 2.3 mm; measure the depth corresponding to the distance between the contact surface of the crankcase half and the contact surface of the inner race of the bearing for the input shaft (“CP1”...
Page 573 section N 9.2 Engine Shimming the gearbox selector drum To determine the total thickness “ST” of the gearbox selector drum shims, proceed as described below. Given that: LT1 = clutch-side crankcase half depth; LT2 = chain-side crankcase half depth; LT = gearbox selector drum shoulder. Given that the end float should be 0 10 to 0.40 mm and taking the mean optimal value of 0.25 mm.
Page 574: Reassembly Of The Crankcase Halves
section N 9.2 Engine Reassembly of the crankcase halves Install the timing belt driveshaft (2) in the roller bearing (21) in the clutch-side crankcase half. To avoid damaging the oil seal (20) on the timing belt driveshaft, protect the threaded end of the shaft with the special protective cap 88700.5749.
Page 575 section N 9.2 Engine Mesh the gearbox shafts and install them on the clutch-side crankcase half with the calculated shims. Install the forks of the 1 and 2 gears (F) in their respective grooves in the secondary shaft driven gears. Notes The two selector forks are identical.
Page 576 Apply a uniform and continuous bead of DUCATI liquid gasket (A) to the mating surfaces of the crankcase halves, going around all the holes as shown in the figure.
Page 577 section N 9.2 Engine 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 578 section N 9.2 Engine Ensure that the crankshaft can be turned with a degree 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. Proceed to install the oil seal (11) and the spacer with the O-ring in the gearbox output shaft using the specific tool (T).
Page 579: Crankcase Assembly: Crankshaft/Connecting Rods Assembly
section N 9.3 Engine 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 Special screw 9 Shim 10 Key Parts catalogue 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 the...
Page 580: Disassembly Of The Crankshaft/Connecting Rods Assembly
section N 9.3 Engine Removal of the crankshaft/connecting rods assembly Operation Section reference Remove the engine from the frame N 1, Removal of the engine Remove the lubrication system N 2.1, Removal of the oil pump Remove the cylinder head assemblies and N 4.3, Cylinder head assemblies: the timing parts camshafts...
Page 581: Overhaul Of The Connecting Rods
section N 9.3 Engine Overhaul of the connecting rods Make the following dimensional checks on the connecting rods: - assembly clearance with gudgeon pin at time of fitting (Sect. C 1.1, Cylinder/Piston). In case of excessive wear, renew the connecting rod. The small end bushing must be in good condition and firmly driven into its seat.
Page 582 section N 9.3 Engine Renewal of the connecting rod bearings It is good practice to renew the bearings (7) each time the engine is overhauled. Replacement bearings are supplied ready for assembly and they must not be reworked with scrapers or emery cloth. Monster 696/696+ - M.Y.
Page 583 section N 9.3 Engine Renewal of the small end bushing To renew the bushing (6) use the tool shown in figure to simultaneously drive out the old bushing and install the new one (A). Position the new small-end bushing so that the split is at 90° relative to the upper hole in the small-end. Split Drill lubrication holes into the new bushing in correspondence with the existing lubrication holes on the connecting rod small end.
Page 584 section N 9.3 Engine Crankshaft overhaul The main bearing and big-end journals should not be scored or grooved; the threads, keyways, and slots must be in good condition. Check for fretting or burrs in the fillet between journal and shoulder. Fillet radius: 1.5 mm.
Page 585 section N 9.3 Engine Use a hot air gun capable of reaching 150 °C. Clean all the oilways using suitable diameter metal brushes and then blow with compressed air to remove any residues that have accumulated and are restricting the oil flow. Monster 696/696+ - M.Y.
Page 586 N 9.3 Engine Apply DUCATI liquid gasket on the threads of plugs (3), (4) and (2) and then refit the plugs. Tighten all the plugs to the specified torque (Sect. C 3, Engine torque settings). Big-end bearing shell-journal clearance To check the assembly clearance between the bearing shells and crankshaft journals you will lay a strip (A) of GREEN “Plastigage PG-1”...
Page 587: Reassembly Of The Connecting Rods
section N 9.3 Engine 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 588 section N 9.3 Engine Fit the spacer (H) of the tool 88713.2878 between the connecting rods and take up residual axial play 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. 88713.2878 Tighten the screws (8) in three stages to the specified torque (Sect.
Page 589: Refitting The Crankshaft/Connecting Rod Assembly
section N 9.3 Engine Refitting the crankshaft/connecting rod assembly Install the connecting rod/crankshaft assembly in the crankcase and follow the shimming procedure as described in Sect. N 9.2, Crankcase assembly: crankcase halves. Important Make sure that the connecting rods (5) are correctly positioned in the respective cylinder seats. Incorrect positioning of the connecting rods at this stage will inevitably lead to the need to re-open the crankcase.
Page 591 P - Electrical system...
Page 592 section Electrical system 1 - Wiring diagram Key to wiring diagram Wiring colour codes Key to fusebox Routing of wiring on frame Plate A Plate B Plate C Plate D Plate E Plate F Plate G Plate H Plate J Plate K Plate L Plate M...
Page 593 section Electrical system 8 - Immobilizer and transponder 9 - Diagnostic instruments Using a multimeter to check the electrical systems Monster 696/696+ - M.Y. 2009 - edition 00...
Page 594 MODE TURN HORN DIMMER PASSING FUSES BOX G/Bk Br BY O Gr Wire Wire FUNCTION STARTER ENGINE STOP LOCK Br BW KEY/ON BW Bk PARK FREE PUSH PUSH 10/93 LIGHTS PUSH LOADS DASHBOARD INJECTION 30 A Gr/R B/Bk Bn/W 1 2 3 4 5 6 7 8 4 3 2 1 R/Bk P/Bk...
Page 595 section Electrical system Key to wiring diagram 1 Right-hand handlebar switch 2 Key switch 3 Horizontal cylinder spark plug 4 Vertical cylinder spark plug 5 Starter motor 6 Starter contactor 7 Battery 8 Main fuse 9 Regulator 10 Alternator 11 Rear right turn indicator 12 Tail light 13 Number plate light 14 Rear left turn indicator...
Page 596: Key To Fusebox
section Electrical system Key to fusebox Position Item Rating Key ON 10 A Side lights, high/low beam 15 A Consumers 15 A Instrument panel Injection 20 A Spare 20 A Spare Monster 696/696+ - M.Y. 2009 - edition 00...
Page 597: Routing Of Wiring On Frame
section Electrical system 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. The plates on the following pages show the origins (“0”...
Page 598 section Electrical system Plate N Right rear turn indicator connector Plate N Rear brake light connector Plate O Fusebox Plate O Throttle pressure/vacuum sensor Plate P Contactor/battery positive terminal cable Plate P Injection/lights relay Plate P ECU connector Plate P Vertical cylinder coil connector Plate P Starter contactor connector...
Page 599 section Electrical system Plate A “Point 0” Plate B Monster 696/696+ - M.Y. 2009 - edition 00...
Page 600 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 601 section Electrical system Plate C Monster 696/696+ - M.Y. 2009 - edition 00...
Page 602 section Electrical system Plate D Monster 696/696+ - M.Y. 2009 - edition 00...
Page 603 section Electrical system Plate E “V” “O” Monster 696/696+ - M.Y. 2009 - edition 00...
Page 604 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 605 section Electrical system Plate F Monster 696/696+ - M.Y. 2009 - edition 00...
Page 606 section Electrical system Plate G Plate H Monster 696/696+ - M.Y. 2009 - edition 00...
Page 607 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 608 section Electrical system Plate J Plate K 29 “O” Monster 696/696+ - M.Y. 2009 - edition 00...
Page 609 section Electrical system Plate L “O” “O” “V” “V” “V” Monster 696/696+ - M.Y. 2009 - edition 00...
Page 610 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 611: Plate M
section Electrical system Plate M Plate N Monster 696/696+ - M.Y. 2009 - edition 00...
Page 612 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 613: Plate O
section Electrical system Plate O Monster 696/696+ - M.Y. 2009 - edition 00...
Page 614 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 615: Plate P
section Electrical system Plate P “V” Monster 696/696+ - M.Y. 2009 - edition 00...
Page 616 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 617: Plate Q
section Electrical system Plate Q Monster 696/696+ - M.Y. 2009 - edition 00...
Page 618: Plate R
section Electrical system Plate R Monster 696/696+ - M.Y. 2009 - edition 00...
Page 619 section Electrical system Plate S Monster 696/696+ - M.Y. 2009 - edition 00...
Page 620 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 621: Plate T
section Electrical system Plate T Monster 696/696+ - M.Y. 2009 - edition 00...
Page 622: Plate U
section Electrical system Plate U Monster 696/696+ - M.Y. 2009 - edition 00...
Page 623 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 624 section Electrical system Plate V Monster 696/696+ - M.Y. 2009 - edition 00...
Page 625 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 626: Battery Charging System
section Electrical 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 ammeter. Follow the instructions given in the paragraph “Testing the battery charging system” (Sect. D 5). A negative value means that charging system is not powering the loads and a significant amount of current must be supplied by the battery, which is discharging at the time of the measurement.
Page 627: Recharging The Battery
section Electrical system Recharging the battery Examine the label on the battery showing the check intervals in order to determine when to test the voltage. Charge the battery if the open circuit voltage is lower than 12.8 V. Leaving the battery discharged for more than one month could damage it.
Page 628: Topping Up The Electrolyte
section Electrical system Topping up the electrolyte Remove the battery from the motorcycle. Warning Read carefully the relevant safety rules before working on the battery (Sect. A 3, General safety rules). The electrolyte in the battery is toxic and can cause burns if it comes into contact with the skin because it contains sulphuric acid. Wear protective clothing, a face-mask and goggles when adding electrolyte.
Page 629 section Electrical system Important Keep the cap strip (3) to hand because it will be used later as caps 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 630 section Electrical system For 3-12 Ah batteries, leave to stand for at least 30 mins. For batteries of over 12 Ah, leave to stand for at least 1 hour. Notes If using an automatic charge reducing battery charger, make certain that the charger current (amps) is greater than or equal to the standard (STD) recharging system indicated on the battery.
Page 631: Battery
section Electrical system Battery Safety rules Warning Read carefully the relevant safety rules before working on the battery (Sect. A 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 632 section Electrical system Refitting the battery Install the battery in the battery support and secure it with the elastic retaining strap (2). Warning Connect the positive lead (19) to the positive terminal and the negative lead (16) to the negative terminal, as shown in the photo. Insert the screws in the terminals (16) and (19) always starting with the positive terminal (red lead).
Page 633: Battery Support
section Electrical system Battery support Remove the battery as described in this section in the paragraph “Battery”. Remove the vertical cylinder coil as described in Sect. M 3, Coil. Unscrew the screws (7) and screw (5) and remove the battery support from the airbox. Refit the components reversing the order in which they were removed;...
Page 634: Alternator
section Electrical system Alternator The motorcycle is equipped with a 12 V, 520 W alternator, consisting of a stator (A) located in the left-hand side crankcase cover and a rotor (B) fixed to the crankshaft. Warning To check the charging system for faults, use the DDS tester and follow the instructions given under the heading “Testing the battery charging system”...
Page 635: Rectifier-Regulator
section Electrical system Rectifier-regulator The regulator (1) is fixed to the RH air scoop (2). 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 636 section Electrical system Unscrew the screw (3) amd remove the LH air scoop (2) from the RH air scoop (4). Undo the screws (5) and remove the RH air scoop (4) from the frame. Disconnect the alternator/regulator connector (B) from the main wiring harness (Sect. P 1, Routing of wiring on frame). Remove the regulator (7) from the RH air scoop (4) by unscrewing the two screws (6).
Page 637 section Electrical system Refitting the regulator Check that the two threaded clips (8) are installed on the RH air scoop (4) and positioning as shown in the figure. Fix the regulator (7) to the RH air scoop (4) with the two screws (6). Tighten the screws (6) to the specified torque (Sect.
Page 638 section Electrical system Refit the LH air scoop (2) to the RH air scoop (4) with the screws (3). Refit the LH air scoop (2) to the frame and tighten the screws (1) to the specified torque (Sect. C 3, Frame torque settings). Notes To position the regulator wiring correctly, designated (14), follow the indications in plate E in the chapter “Routing of wiring on frame”, Sect.
Page 639 section Electrical system Regulator fuse The 30 A fuse located on the airbox protects the electronic regulator. To gain access to the fuse, remove the fuel tank (Sect. L 2, Removal of the fuel tank) and disconnect the regulator (A). A blown fuse can be identified by breakage of the inner filament (B).
Page 640 section Electrical system 3 - Electric starting system Notes The references of the elements shown below are to be found in the “Wiring diagram”, in Sect. P 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 641 section Electrical system Starter motor Power: 700 W with 12 V power. Direction of rotation: counterclockwise viewed from power take-off side. The starter motor is highly compact and reliable and therefore rarely gives any type of problem. In case of malfunction, ensure that the starter motor wiring terminal is properly tightened under the nut and shows no sign of corrosion.
Page 642 section Electrical system Notes 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. Locate the gasket (2) and the starter motor on the crankcase and tighten the bolts (1) to the specified torque (Sect. C 3, Frame torque settings.
Page 643: Starter Contactor
section Electrical system LOCK If the starting gears assembly has been renewed, refit the starter motor idler gear and the timing gears (Sect. N 9.1, Refitting the starter motor idler gear). Refit the alternator-side crankcase cover (Sect. N 8, Reassembly of the alternator-side crankcase cover). Starter contactor The starter motor contactor (1) is elastically mounted to the airbox.
Page 644 section Electrical system Remove the protective caps (A). Unscrew the nuts (4), taking care to recover the spring washers (3). Remove the starter motor-contactor cable (2). Remove the contactor-battery cable (5). Disconnect the wiring connector (2) of the starter contactor from the wiring harness. Checking operation of the starter contactor Apply 12 V (battery voltage) across the positive terminal (A) and negative terminal (B) of the connector.
Page 645 section Electrical system Fit the contactor by inserting it on the tabs (E), orienting it as shown in the figure. Refit the wiring connector (2) to the wiring and refit the protective caps (A). Monster 696/696+ - M.Y. 2009 - edition 00...
Page 646: Lights And Indicating Devices
section Electrical system 4 - Lights and indicating devices Renewal of the headlight Undo the screws (2) and remove the instrument panel shroud (1). Disconnect the instrument panel connector (A) from the main wiring harness (see plates in the chapter “Routing of wiring on frame”, Sect.
Page 647 section Electrical system Remove the front light assembly, withdrawing the pins (C) from the support bracket. Release the headlight from the front light assembly by unscrewing the screws (3). Remove the front turn indicators (4) by removing the circlip (5) and unscrewing the screw (6). Notes On the USA version a spacer is installed between the turn indicator and the front light asssembly support.
Page 648 section Electrical system Refitting is the reverse of removal: - check that the rubber mountings (7) are installed on the headlight; - apply the recommended grease to the washers (8); - reconnect the wiring connectors of the headlight (B) and the front turn indicators; LOCK - tighten the screws (3), (6) and nuts (2) to the specified torque (Sect.
Page 649 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 650 section Electrical system 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. C 1.1, Lights/instrument panel). Warning The halogen light bulbs in the headlight become hot when switched on and remain hot for some time after they are switched off.
Page 651 section Electrical system High beam (HI) Disconnect the wiring connector (3) from the headlight bulb (4). Release the retaining clip (5). The bulb (4) is of the bayonet-type: press and twist anti-clockwise to remove. Fit the new bulb (4), insert the tabs on the bulb base into the corresponding slots to ensure the bulb is correctly positioned, push the bulb in and turn clockwise until it clicks into place.
Page 652 section Electrical system Side lights (A) To replace the side light bulb, withdraw the bulb holder (7) from the rear of the headlight. Extract the bulb and renew it. Changing the number plate light bulb To access the bulb in the number plate light (8), open the number plate lens, pull the bulb out of the holder and renew it. Monster 696/696+ - M.Y.
Page 653 section Electrical system Changing the direction indicator light bulbs Loosen the screw (1) and detach the lens (2) from the direction indicator support. The bulb has a bayonet-type end fitting: to remove it, push it in and turn it counter-clockwise. Push in the new bulb and turn it clockwise until it clicks into place.
Page 654: High Beam Headlights Relay
section Electrical system High beam headlights relay Located alongside the battery and fixed to the battery support. To gain access to the relay, first remove the fuel tank (Sect. L 2, Removal of the fuel tank). The high beam relay (1) has been added to the electrical circuit to enable the lights power down strategy. This strategy is as follows: 1 if the lights are on during normal riding, they switch off 60 seconds after pressing the engine Stop button (2) and key ON;...
Page 655: Headlight Aim
section Electrical system Headlight aim The motorcycle must be perfectly upright with the tires inflated to the correct pressure and with a rider seated, perfectly perpendicular to the longitudinal axis. Position the motorcycle 10 metres from a wall or a screen. On the wall or surface, draw a horizontal line at the same height from the ground as the centre of the headlight and a vertical line aligned with the longitudinal axis of the motorcycle.
Page 656: Checking The Indicating Devices
section Electrical system 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, disconnect the switch connector from the main wiring harness (Sect. P 1, Routing of wiring on frame). Test the device using either an analogue or digital multimeter (Sect.
Page 657 section Electrical system Flasher (PASSING) Check for continuity across the (Red/Blue and Brown) wires. Refit the left-hand handlebar switch and tighten the screws (1) to the specified torque (Sect. C 3, Frame torque settings). PASSI G Br B O Gr Br BW PUSH PUSH...
Page 658 section Electrical system Starter switch Proceed as described for the engine stop button and check for continuity between the (Blue/White and Black) wires when the STARTER switch is pressed (see Sect. P 9, Diagnostic instruments concerning operation of the multimeter). If there is no continuity, the STARTER switch is defective and must be renewed.
Page 659 section Electrical system 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) brake light switches use a multimeter to check that when the front or rear brake is pressed, there is electrical continuity (Pos.
Page 660 section Electrical system 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. If the light switches on, the neutral light switch should be changed.
Page 661: Changing Light Bulbs
section Electrical system 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. To remove the support (3), for the front turn signals refer to Sect.
Page 662: Protection And Safety Devices
section Electrical system 6 - Protection and safety devices Checking protection and safety device components Checking the key switch Disconnect the key switch (A) from the electrical system by opening its connection (see “Routing of wiring on frame”, Sect. P 1) and use a multimeter to check 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 663 section Electrical system Checking the sidestand switch Remove the switch from the sidestand (Sect. H 5, Removal of the sidestand) and disconnect the main wiring harness connector from the switch (see “Routing of wiring on frame”, Sect. P 1). Use an analogue or digital multimeter (Sect. P 9, Using a multimeter to check the electrical systems) to check operation of the switch (see table).
Page 664: Checking The Fuses
section Electrical system Checking the fuses The main fuse box (1) is located on the right-hand side of the frame. The fuses are accessed by removing the cover, which shows the ampere ratings and mounting locations. For ampere ratings, refer to the “Routing of wiring on frame”, Sect. P 1. Important Before replacing a damaged fuse with a new one of the same rating, identify the cause of the problem.
Page 665: Instruments
section Electrical system 7 - Instruments Instrument panel Undo the screws (2) and remove the instrument panel shroud (1). Disconnect the wiring from the instrument panel (3). Undo the screws (4) and remove the instrumnt panel (3) from the front lights assembly support. When refitting, tighten the screws (2) and (4) to the specified torque (Sect.
Page 666 section Electrical system Monster 696/696+ - M.Y. 2009 - edition 00...
Page 667 section Electrical system Indicator lights The following indicator lights are mounted on the instrument panel. 3) Neutral light (green): illuminates when the gearbox is in neutral. 4) Low fuel light (yellow): illuminates when there are approximately 3.5 litres of fuel left in the tank. 5) Turn signal lights (green): illuminate and flash when the corresponding turn signal is in operation.
Page 668: Display Settings And Functions
section Electrical system Display settings and functions On switching on the power (key turned from OFF to ON), the instrument panel activates all the digits of the LCD for 1 second and switches on all the warning lights in sequence. It then reverts to “normal”...
Page 669 section Electrical system If, however, you press switch (1) in position A “▲” the system enters MENU mode and displays the following functions in sequence: Error (only if active) BATT LIGHT SET LAP (OFF or ON) LAP MEM DDA (OFF or ON) Erase DDA TIME Set CODE (only if active)
Page 670 section Electrical system “Speed” indicator This function enables display of the motorcycle speed. The instrument panel receives actual speed value (expressed in km/h) from the ECU and displays the value increased by 8%. The maximum speed that can be displayed is 299 km/h (186 mph). Over 299 km/h (186 mph) the display will show a series of dashes “- - -“...
Page 671 section Electrical system “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 672 section Electrical system Coolant temperature indicator Displays the engine coolant temperature: Important This display function is only available when the engine is running. Display indications: if the temperature is between -40 °C and +80 °C, the display shows “STATUS 2”; if the temperature is between +81 °C and +110 °C, the display shows “STATUS 3”;...
Page 673 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 authorized Ducati Service Centre.
Page 674 section Electrical system Warning light Error message Error PKUP Pickup sensor SPEED Speed sensor (if present) IMMO Immobilizer (Key missing or antenna disconnected or key not recognised) CAN line (Communication between ECU and instrument panel) LIGHT Lights relay Battery voltage indicator (BATT) To display this function, go into the menu and select the “BATT”...
Page 675 section Electrical system FLASHING FIXED FLASHING FLASHING FLASHING Monster 696/696+ - M.Y. 2009 - edition 00...
Page 676 section Electrical system Adjusting the engine idle speed (rpm) To display the function, access the menu and select the “RPM” page. In addition to the upper rev counter scale, the display also shows engine rpm numerically so that you can adjust the idle speed more precisely.
Page 677 section Electrical system B= ON for 3 secs. B= ON for 3 secs. Press B B= ON for 3 secs. Press B Press B LAP function To activate this function, enter the menu and set the “LAP” function to “On” by keeping switch (1) in position B “▼” for 3 seconds.
Page 678 section Electrical system MENU Press B for 3 secs. Press B for 3 secs. 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 679 section Electrical system “NORMAL” display Press FLASH (Once) Press FLASH (Twice) Press FLASH (from 32 time onwards, unless times are reset) Monster 696/696+ - M.Y. 2009 - edition 00...
Page 680 section Electrical system LAP Memory display Displays the data saved with the LAP function: lap number and time. To display the saved lap times, enter the menu and select the “LAP MEM” page. From this menu page, if you press switch (1) in position B “▼“, the data for “lap 1” will appear. The display will show the lap number, lap time, MAX speed and the MAX rpm reached for the lap in question.
Page 681 If the engine trips the rev limiter during a lap, the “OVER REV.” indicator light will come on during display of the lap time. (9). DDA data acquistion 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.
Page 682 section Electrical system 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 the switch (1) in position B “▼“ for 3 seconds and the DDA is not acquiring data, the message “WAIT…” appears on the display for 10 seconds.
Page 683 section Electrical system Clock setting function To set the clock, enter the menu and select the “SET” page. From this page, if you press the switch (1) in position B “▼” for 3 seconds, you enter clock setting mode. On entering this mode, the message “AM” will flash on the display; pressing the switch (1) in position B “▼” will switch the display to “PM”...
Page 684 section Electrical system Immobilizer override procedure Should the immobilizer become locked, you can perform the “Immobilizer Override” procedure from the instrument panel by entering the respective function as described below. Select the “CODE” page from the menu. Notes This menu should be active only if there is at least one immobilizer error. With this page selected, the initial code is always displayed as “00000”.
Page 685 section Electrical system Press B for 3 secs. flash. Press A Press B 3 times flash. Press A flash. Press A Press B 4 times flash. flash. Press A Press A flash. Press B 2 times flash. Press A Press A flash.
Page 686 section Electrical system 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 687 section Electrical system Service Menu The instrument panel has a service menu, which must be used only by the dealer if necessary. To enter the service menu, hold the switch (1) in position A “▲” while simultaneously turning the key switch from Off to On. Notes Within this “MENU”...
Page 688 section Electrical system Press B for 3 secs. flash. Press A flash. Press B 3 times flash. Press A Press A flash. Press B 4 times flash. Press A Press A Press B 2 times Press A for 3 secs. flash.
Page 689 section Electrical system Loss of both keys After purchasing two new keys, perform the Reprogramming procedure (by entering the code shown on the CODE CARD) with the new keys. Renewal of the instrument panel After purchasing the new instrument panel, perform the normal “Programming” procedure for the immobilizer system. Renewing the instrument panel after renewing one or both of the keys In this case, if you want the immobilizer to be fully functional, before programming the immobilizer, first renew the KEY SET as well (2 black keys + new CODE CARD).
Page 690 section Electrical system Key-Off to exit Press B for 3 secs. Press A Press B for 3 secs. Press B Press A Press B for 3 secs. Press B Press A Press B for 3 secs. Press B Press A Press B for 3 secs.
Page 691 section Electrical system Programming aborted: if you allow the 3 second countdown after Key-On or the 15 second countdown after Key-Off to elapse, or you make a mistake in the programming procedure, the instrument panel will abort the programming operation and display the message “PROG OFF”...
Page 692 section Electrical system 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 693 section Electrical system Immobilizer operating principle At key-on (switching on the instrument panel by turning the key) the decoder (incorporated in the instrument panel) activates the antenna, which emits an electromagnetic field that serves to power the transponder in the key grip. The transponder responds by transmitting the code that is stored on its internal ROM memory, and which is picked up by the antenna and relayed to the decoder.
Page 694 section Electrical system Remove the ties securing the immobilizer antenna wiring. Undo the two nuts (1) securing the immobilizer antenna cover. Remove the cover (2) and slide the antenna (3) out of the ignition switch. Remove the special screws (6). Remove the ignition switch (9) complete with the plate (8) from the frame.
Page 695 section Electrical system 9 - Diagnostic instruments For information on the “DDS” tester, refer to Sect. D 5, DDS tester. Using a multimeter to check the electrical systems Introduction This instrument allows you to measure resistances, voltages, and current values. Multimeters can be divided into two basic types: those with an analogue display and those with a digital display Units of the first type are equipped with a dial and needle.
Page 696 section Electrical system Measurement of resistance values and electrical continuity Resistance measurements must be taken only when the electrical device or section of the circuit is not powered and isolated from the main electrical system (i.e. not connected to the main electrical system). These measurements can be utilised to check the resistance value across several sensors.

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Monster 696+ 2009

Ducati Monster 696 2009 Manual

C Technical Data

Section D Use and Maintenance a

Section E Fairings a

Section F Controls - Devices a

Section G Wheels - Suspension - Brakes a

Section H Frame a

Section L Fuel/Exhaust System a

M Fuel Injection-Ignition System a

Section N Engine a

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