Page 1 Reproduction and disclosure of all or part of the contents of this manual are strictly forbidden without prior written authorization of Ducati Motor Holding S.p.A. All rights on this manual are reserved for Ducati Motor Holding S.p.A. Applications for authorization must be submitted in writing and must specify the reasons for reproduction or disclosure.
Page 2 Caution The manual structure has been designed to be applied to all the different models manufactured by DUCATI MOTOR HOLDING. To make reading easier, the sub-sections table of contents is kept unchanged for all models. file:///C|/Documents%20and%20Settings/F4i/My%...0manual/wsm/usa/Mon695_MY07_A_1_3_00.3.1.html (2 of 2) [10/7/2008 8:41:32 PM]...
Page 3: Symbols - Abbreviations - References
Symbols - abbreviations - references 2 - Symbols - abbreviations - references For easy and rational reading, this manual uses graphic symbols for highlighting situations in which maximum care is required, practical advice or simple information. Please pay maximum attention to these symbols as they are meant to avoid repeating technical concepts or safety rules throughout the text.
Page 4 Symbols - abbreviations - references Anti-freeze (nitride, amine and phosphate SHELL free) 30-40% water solution. Advance coolant or Glycoshell GREASE A Multipurpose, medium fiber, lithium SHELL Alvania R3 grease. GREASE B Molybdenum disulphide grease, high SHELL mechanical stress and high temperature Retinax HDX2 resistant.
Page 5 LOCK 11 Instantaneous jelly sealant featuring Loctite 454 gel tensile / cut strength. DUCATI liquid gasket 942470014 Exhaust pipe paste. Self-curing sealant, Fire gum holts hardens when heated. For temperatures over 1,000°C. Spray used in treating electrical systems SHELL to eliminate moisture and condensation.
Page 6: Dangerous Products – Warnings
Dangerous products – warnings 3 - Dangerous products – warnings General safety rules Carbon oxide When a maintenance operation must be performed with the engine running, position the motorcycle out of doors or in a well-ventilated area. Never operate the engine in an enclosed place. Warning Exhaust emissions contain carbon oxide, which is a poisonous gas and may lead to loss of conscience or even death.
Page 7: General Maintenance Indications
Do not smoke near the battery. Make sure the area is well ventilated when charging a battery. General maintenance indications A word of advice Ducati would like to suggest that you follow the instructions below so to ensure an efficient, fault-free motorcycle operation. When diagnosing breakdowns, primary consideration should always be given to what the customer reports.
Page 8 Description 0Description 1 - How to use the manual Manual layout 4 2 - Symbols - abbreviations - references Product specifications 6 3 - Dangerous products – warnings General safety rules 8 General maintenance indications 9 file:///C|/Documents%20and%20Settings/F4i/My%20D...i%20manual/wsm/usa/Mon695_MY07_A_IND_00.2.1.html [10/7/2008 8:41:43 PM]...
Page 9: Identification Data
1 - Identification data Identification data for Monster 695 i.e. Each Ducati motorcycle has two identification numbers - frame number and engine number, and an EC nameplate (A) (not used in the USA version). file:///C|/Documents%20and%20Settings/F4i/My%...0manual/wsm/usa/Mon695_MY07_B_1_1_00.7.1.html (1 of 4) [10/7/2008 8:41:45 PM]...
Page 10 The frame and engine numbers identify the motorcycle model; please state these numbers when ordering spare parts. Data punched on frame European version 1 Manufacturer’s name: Ducati Motor Holding 2 Type – same on all Monsters 3 Variant 4 Version...
Page 11 3 Variant – Code number or Check digit (X) 4 Model year (7=2007) 5 Plant of manufacture 6 Progressive serial No. Data punched on engine European version 1 Manufacturer’s name: Ducati Motor Holding 2 Engine type 3 Progressive production No. file:///C|/Documents%20and%20Settings/F4i/My%...0manual/wsm/usa/Mon695_MY07_B_1_1_00.7.1.html (3 of 4) [10/7/2008 8:41:45 PM]...
Page 12 Identification data Data punched on engine USA version 1 Engine type 2 Model year 3 Progressive production No. file:///C|/Documents%20and%20Settings/F4i/My%...0manual/wsm/usa/Mon695_MY07_B_1_1_00.7.1.html (4 of 4) [10/7/2008 8:41:45 PM]...
Page 13 Model-specific information 0Model-specific information 1 - Identification data Identification data for Monster 695 i.e. 3 file:///C|/Documents%20and%20Settings/F4i/My%20D...i%20manual/wsm/usa/Mon695_MY07_B_IND_00.6.1.html [10/7/2008 8:41:46 PM]...
Page 14: Technical Specifications
Technical specifications 1.1 - Technical specifications Description Reference Technical specifications Vehicle dimensions Total length 2100 mm Total width 794 mm Total height 1058 mm Wheelbase 1440 mm Handlebar height - from grip to the 980 mm. ground Seat height 770 mm Front footpeg height 360 mm Rear footpeg height...
Page 15 One filtering element in the airbox Crankshaft type Enbloc Cylinders "L" at 90° Colors Description Code Ducati anniversary red, red frame F_473.101 (PPG) and black wheel rims Shining black, black frame and 248.514 (PPG) wheel rims Matte black, black frame and 291.501 (PPG)
Page 16 Technical specifications Exhaust 10.30 mm Opening rocker arm - intake 0.10-0.15 mm 0.05-0.15 mm Opening rocker arm - 0.10-0.15 mm 0.05-0.15 mm exhaust Closing rocker arm - intake 0-0.05 mm 0-0.20 mm Closing rocker arm - 0-0.05 mm 0-0.20 mm exhaust Adjusting timing 145 Hz (horizontal)
Page 17 Technical specifications Front wheel Reference Standard value Service limit Tread min. thickness In the most worn position 2 mm Tyre pressure Cold 2.1 bar - 2.3 bar Wheel shaft eccentricity On 100 mm 0.2 mm Wheel rim eccentricity Radial 0.8 mm 2 mm Axial 0.5 mm...
Page 18 Technical specifications Thickness 4 ± 0.1 mm 3.6 mm (min.) Flange material Steel Braking ring material Steel Diameter 300 mm Braking surface 44 cm per disc Brake caliper Make Brembo Type PF 2x28 - 2 pistons Caliper cylinder diameter 30 mm - 34 mm Pads friction material FERIT I/D 450-FF Brake master cylinder...
Page 19 Technical specifications Firing points per injector Injection system Make Type Control unit Marelli CPU 5AM2 Lights / instrument panel Reference Technical specifications Bulbs Front headlamp (low beam / high 12V - 55/60W beam) Number plate light 12V - 5W Parking / stop light 12V - 5/21W Turn indicator light 12V - 10W...
Page 20 Dimensions 1.2 - Dimensions file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_1B4_00.10.1.html (1 of 2) [10/7/2008 8:41:59 PM]...
Page 21 Dimensions file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_1B4_00.10.1.html (2 of 2) [10/7/2008 8:41:59 PM]...
Page 22 Fuels and lubricants 2 - Fuels and lubricants Fuels Type cu. dm (liters) Fuel tank, including a 3 cu. dm (litres) Lead-free fuel with at least 95 - 98 RON reserve at origin Engine sump and oil filter SHELL Advance Ultra 4 Clutch and front/rear brake circuits SHELL Advance Brake Dot 4 Protection for electrical contacts...
Page 23: Lock
Torque settings 3 - Torque settings Frame torque settings Part Thread (mm) Nm tolerance ±10% Note Chain, front sprocket Front sprocket retaining screw M 5x0.8 LOCK 1 Front sprocket guard screw M 6x1 Light units Headlight retaining screw M 8x1.25 Tail light nuts M 6x1 Screw securing headlight holder to...
Page 24 Torque settings Screw retaining voltage regulator to oil M 6x1 breather tank and frame Screw retaining regulator to oil breather M 6x1 tank Screw retaining battery mount to M 6x1 silentblocks Nut retaining battery mount to cylinder M 8x1.25 head Control unit retaining screw M 6x1 Screw retaining ground cable to engine...
Page 25 Torque settings Counterweight retaining screw M 6x1 Rear shock absorber Rear shock absorber upper screw M 10x1.25 42 * GREASE B Rear shock absorber lower screw M 10x1.25 42 * GREASE B Suspension linkage upper screw M 10x1.25 42 * GREASE B Suspension rocker arm to frame fixing M 12x1.5...
Page 26 Torque settings Seat Seat lock ring nut M 22x1.5 LOCK 3 Seat lock holder retaining screw M 5x0.8 Seat cover holder retaining screw M 5x0.8 Seat pulley screw Self-tapping LOCK 2 Screw retaining seat cover and tool box M 6x1 compartment cover to seat Seat lock retaining screw M 5x0.8...
Page 27 Torque settings Oil drain plug M 22x1.5 Oil mesh filter M 22x1.5 Oil filler plug M 22x1.5 Steel/alum. crankshaft blanking plug M 20x1 13.5 16.5 THREE BOND 1375B Gearbox drum locating screw M 16x1.5 Oil filter nipple M 16x1.5 LOCK 2 or THREE BOND 1324 Oil cartridge filter M 16x1.5...
Page 28 Torque settings Intake and exhaust flange stud bolts M 8x1.25 LOCK 2 or THREE BOND 1324 Intake manifold nuts M 8x1.25 Oil pump screws M 8x1.25 Casing jointing screws: M 8x1.25 1 st snug torque final torque Casing drilled screw M 8x1.25 Fixed tensioner M 8x1...
Page 29 Torque settings Screws M 6x1 Screws M 5x1 Note For product specifications and symbols, refer to "Product specifications" (A 2). file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_3_4_00.12.1.html (7 of 7) [10/7/2008 8:42:18 PM]...
Page 30: Service Tools
Service Tools 4 - Service Tools Spare parts catalogue Workshop special tools Engine special tools Part No. Description 88700.5644 Tool to set belt roller ring nut for camshaft 88713.2107 Reaction tool to tighten timing belt rollers 88713.2676 Head nuts tightening tool 88713.2103 Support for head assembly file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_4_4_00.13.1.html (1 of 9) [10/7/2008 8:42:23 PM]...
Page 31 Service Tools 98112.0002 Timing degree wheel 88713.0123 Timing check tool DDS (Ducati Diagnosis System) + kit for measuring cylinder 97900.0215 vacuum 88713.0137 Crankshaft sprocket stop tool 88765.1058 Valve lift gauge file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_4_4_00.13.1.html (2 of 9) [10/7/2008 8:42:23 PM]...
Page 32 Service Tools 88765.1000 0.1 mm fork feeler gauge 88765.1005 0.2 mm fork feeler gauge 88765.1006 0.3 mm fork feeler gauge 88713.2362 Tool to fit spring and closing rocker arm 88713.2009 Tool to lock belt rollers 88713.0262 Pin to fit the rocker arms 88713.0844 Drift to fit split rings file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_4_4_00.13.1.html (3 of 9) [10/7/2008 8:42:23 PM]...
Page 33 Service Tools 88713.2011 Crankshaft locking tool 88700.5749 Cap for closing the crankcases 88713.1091 Plate for gear selector fork positioning 88713.1749 Puller for drive belt roller and cover 88765.1297 TDC check gauge file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_4_4_00.13.1.html (4 of 9) [10/7/2008 8:42:23 PM]...
Page 34 Service Tools 88713.1994 Rocker arm shaft puller 88713.2556 ATPC system clutch housing locking tool 88713.2591 Clutch screw 88713.1010 Exhaust gas pick-up point 88713.1215 Timing belt tensioner file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_4_4_00.13.1.html (5 of 9) [10/7/2008 8:42:23 PM]...
Page 35 Service Tools 88713.2036 Generator locking tool for nut tightening 88713.2092 Primary gears puller 88713.0879 Valve guide extraction tool 88713.0874 Exhaust valve guide drift 88713.0875 Intake valve guide drift file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_4_4_00.13.1.html (6 of 9) [10/7/2008 8:42:23 PM]...
Page 36 Service Tools 88713.1078 Drift to install exhaust valve seat 88713.1079 Drift to install intake valve seat 88713.2422 Wrench for tightening the primary sprocket ring nut Spare parts catalogue Workshop special tools Frame special tools Part No. Description 677.4.003.1A Chain joint 88713.1072 Bottom yoke bearing drift file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_4_4_00.13.1.html (7 of 9) [10/7/2008 8:42:23 PM]...
Page 37 Service Tools 88713.1344 Chain assembly tool 8000.70139 Front wheel shaft tool 88713.1096 Fork overhaul tool - for fitting the seal 88713.1515 Frame/engine support 88713.1058 Tool to fit steering tube top bolt file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_4_4_00.13.1.html (8 of 9) [10/7/2008 8:42:23 PM]...
Page 38 Service Tools 88713.1062 Tool to fit steering tube bearings file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_C_4_4_00.13.1.html (9 of 9) [10/7/2008 8:42:23 PM]...
Page 39 Specifications 0Specifications 1.1 - Technical specifications Description 3 Colors 4 Transmission assembly 4 Timing/valves 4 Cylinder / piston 5 Gearbox 5 Cooling system 5 Front wheel 5 Front suspension 6 Rear wheel 6 Rear suspension 6 Hydraulic brakes 7 Charging system / generator 7 Ignition system 7 Fuel system 8 Injection system 8...
Page 40: Preliminary Checks
During the whole running-in period, the maintenance and service rules recommended in the warranty card should be observed carefully. Failure to comply with these rules will release Ducati Motor Holding S.p.A. from any liability whatsoever for resulting engine damage or shorter engine life.
Page 41 Preliminary checks Warning Failure to carry out these checks before riding, may lead to motorcycle damage and injury to rider. Before riding, perform a thorough check-up on your bike as follows: Fuel level in the tank Check fuel level in the tank. Fill tank if needed (Sect. C 2, Fuels and lubricants).
Page 42 Starting – engine warm-up 2 - Starting – engine warm-up Starting the engine Cold ambient temperature (10 °C / 50 °F - 35 °C / 95 °F) Turn the ignition switch to ON. Check that the green and red lights on the instrument panel are on (Sect.
Page 43 Starting – engine warm-up Caution If the engine fails to start, check that the stop switch (2) is positioned to (RUN), and then press the starter button (3) within 15 seconds from KEY ON. Note This model is equipped with a servoignition system, and the engine is started by pressing the button (3) and releasing it immediately.
Page 44 Starting – engine warm-up file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_D_2_5_00.16.1.html (3 of 3) [10/7/2008 8:42:28 PM]...
Page 45 Routine maintenance table 3 - Routine maintenance table Scheduled maintenance chart: operations to be performed by the dealer Km. x1000 List of operations and type of intervention [set mileage (km/mi) or time interval *] mi. x1000 22.5 37.5 Months Changing engine oil •...
Page 46 Routine maintenance table * service on the set interval, whichever comes first (mileage or months) (1) Operation to be performed only if set mileage is reached Scheduled maintenance chart: operations to be performed by the customer Km. x1000 List of operations and type of intervention [set mileage (km/mi) or time interval *] mi.
Page 47: Maintenance Operations
Maintenance operations 4 - Maintenance operations Checking the engine oil level Check the engine oil level in the sight glass (1) on the RH side of the oil sump. After switching off, allow several minutes for the oil to settle before checking the level. Check the level with the motorcycle perfectly vertical and with the engine hot (but stopped).
Page 48 Maintenance operations Caution Dispose of used cartridge. Do not reuse cartridges. Grease the seal with engine oil and then fit the new cartridge (4). Note If you wish to skip this last check, fill the filter cartridge (2) with oil before installation and you will not need to top up level later.
Page 49 Maintenance operations Remove the filler plug (2) and fill with the recommended oil (Sect. C 2, Fuels and lubricants). Fill until the oil reaches the MAX mark on the sight glass. Refit the filler plug (2). Run the engine at idling speed for several minutes. Check for oil leaks.
Page 50 Maintenance operations With the valve in the rest position, slide a feeler gauge between closing rocker arm and shim to measure clearance. Clearance must be within the specified limits: Closing rocker arm Intake: Nominal 0-0.05 mm In operation 0-0.20 mm Exhaust: Nominal 0-0.05 mm...
Page 51 Maintenance operations Adjusting valve clearances Proceed as described under Section N 4.1, Checking and adjusting valve clearance. Changing and cleaning the air filters The air filter must be changed at the intervals indicated in the "Routine maintenance table" (Sect. D 3). Raise the fuel tank (Sect.
Page 52 Maintenance operations Caution A clogged air filter will reduce air intake and engine power leading to increased fuel consumption, and cause a build up of deposits on the spark plugs. Do not run the engine without the air filter. Running the engine without a filter will draw impurities into the engine and may damage the engine.
Page 53 Maintenance operations Suck the oil up from the reservoir (A). Fill reservoir (A) with fresh oil up to MAX level. Pump up two or three times with the lever to pressurize the circuit. Keep the lever pulled toward the handgrip. Loosen the bleed valve (2) so that oil flows off.
Page 54 Maintenance operations Filling the rear brake circuit Remove the cap (3) from the rear brake cylinder reservoir (B). Connect a clear hose to the bleed valve (4); put one end of the hose into a container on the floor. Suck the oil up from the reservoir (B). Fill reservoir (B) with fresh oil up to MAX level.
Page 55 Maintenance operations Warning When filling up, keep oil level above MIN mark to avoid air bubbles into the circuit. Let oil flow off from the bleed valve (4) until of different color. Tighten the bleed valve (4) to the specified torque (Sect. C 3, Frame torque settings) and top up oil to correct level.
Page 56 Maintenance operations Connect a common brake bleeder, easily available on the market, to the caliper bleed valve (2- front) or (4 -rear). Note If you are using a commercial bleeder, follow the manufacturer's instructions. Unscrew the bleed valve and pump the bleeder until all the fluid has fully drained off the circuit. If you do not have a brake bleeder available, attach a length of transparent plastic tubing to the caliper bleed valve (2 -front) or (4 -rear) and put the other end of the hose into a container holding spent brake fluid you will have placed on the floor.
Page 57 Maintenance operations Warning Brake fluid will damage painted surfaces if spilled on them. In addition, it will cause severe injury if spilled on the skin or into your eyes. In the event of accidental contact with skin or eyes, wash the affected area with abundant running water.
Page 58 Maintenance operations If you do not have a brake bleeder available, connect a length of transparent plastic tubing to the bleed valve as outlined in the draining procedure. Open the bleed valve by one fourth of a turn and operate the brake lever (or pedal) several times until the fluid starts coming out of the bleed valve.
Page 59 Maintenance operations Top up and fit the covers. Tighten the screws (1) onto the reservoir (A) and the cap (3) onto the reservoir (B). Changing the clutch fluid Warning Clutch fluid will damage painted surfaces if spilled on them. In addition, it will cause severe injury if spilled on the skin or into your eyes.
Page 60 Maintenance operations Connect a clear hose to the bleed valve (3); put one end of the hose into a container on the floor. Suck the oil up from the reservoir (A). Fill reservoir (A) with fresh oil up to MAX level. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_D_4_5_00.18.1.html (14 of 29) [10/7/2008 8:42:49 PM]...
Page 61 Maintenance operations Pump up two or three times with the lever to pressurize the circuit. Keep the lever pulled toward the handgrip. Loosen the bleed valve (3) so that oil flows off. Warning When filling up, keep oil level above MIN mark to avoid air bubbles into the circuit. Let oil flow off from the bleed valve (3) until of different color.
Page 62 Maintenance operations or into your eyes. In the event of accidental contact with skin or eyes, wash the affected area with abundant running water. Slip off the protective cap to expose the bleed valve (3). Connect a bleeder to the bleed valve (3) on the transmission unit. Note If you are using a commercial bleeder, follow the manufacturer's instructions.
Page 63 Maintenance operations To help drain the circuit fully, unscrew the three retaining screws (4) of the transmission unit and remove. Withdraw the clutch transmission unit (5). Be careful of the O-ring (6) placed inside. Push in the piston to expel all fluid inside the unit. Refit transmission unit and tighten the retaining screws (4) to the specified torque (Sect.
Page 64 Maintenance operations Caution During the next operation, the fluid level must remain topped up at all times. The end of the transparent plastic tubing must remain immersed in the discharged brake fluid at all times. Operate the clutch lever several times to let the fluid reach all points of the circuit and expel any air. Connect the bleeder to the bleed valve (3).
Page 65 Maintenance operations Open the bleed valve (3) by one fourth of a turn and operate the clutch lever several times until the fluid starts coming out of the bleed valve (3). Pull the lever fully in and slacken the bleed valve by at least one fourth of a turn. Allow several seconds and then release the lever gradually and close the bleed valve (3).
Page 66 Maintenance operations Excessive handlebar play or shaking forks in the steering head indicate that the play in the steering head bearings requires adjustment. Proceed as follows: Loosen the four bolts (1), remove both clamps (2) and remove the handlebar. Loosen the screws (3) on the steering head at the fork leg clamps. Loosen the clamp screw (4) securing the steering tube to the steering head.
Page 67 Maintenance operations Tighten all the previously loosened screws to the specified torque (Sect. C 3, Frame torque settings). Reposition the handlebar, fit the two U-bolts (2) and tighten the four U-bolt screws (1) to the specified torque (Sect. C Frame torque settings).
Page 68 Maintenance operations Caution A slack chain will lead to early wear of the transmission components. Check that the reference marks on both sides of the swingarm are lined up. This indicates perfect wheel alignment. Tighten the nuts (1) onto wheel shaft to the specified torque (Sect. C 3, Frame torque settings).
Page 69 Maintenance operations Caution If one of the pads is worn, change both pads. Change the brake pads as follows. Remove the split pins (2) from the pad retaining pin. Force the brake pads apart to force the caliper pistons into their housings. Withdraw the brake pad retaining pin (3) from the outside.
Page 70 Maintenance operations Top up to max level using the specified brake fluid. Reassemble. Checking rear brake pad wear Check through the slot between the two caliper halves that there is at least 1 mm of friction material on the pads. Caution If one of the pads is worn, change both pads.
Page 71 Maintenance operations Note Change pads which are shiny or vitrified. Insert the new pads and the clip (3). Insert the retaining pin (2) and push it fully home. Fit the split pin (1) with the end (A) pointing to the wheel. Operate the brake pedal repeatedly so that the pads bed in under the action of the brake fluid.
Page 72 Maintenance operations Fine adjustment can be made by turning the adjuster (1) on the twistgrip. For larger adjustments of the throttle cable, use the adjuster (2) located on the RH side of the throttle body. Remove the cap, loosen the lock nut (3) and turn the adjuster (2) to obtain the required play. Tighten the lock nut and refit the cap.
Page 73 Maintenance operations Grease the cable end (10) and the pulley. Refit the cover with extreme care. Insert the cable (10) in the slider (A) of the cover (8). Tighten the two screws (9) to secure the cover. Adjusting the position of the gear change and rear brake pedals The position of the gear change and rear brake pedals in relation to the footpegs can be adjusted to suit rider preferred riding position.
Page 74 Maintenance operations Tighten the two lock nuts onto the rod. To adjust the position of the rear brake pedal, proceed as follows: Loosen the lock nut (4). Turn the pedal travel adjuster screw (5) until the pedal is in the desired position. Tighten the lock nut (4).
Page 75 Maintenance operations Standard setting: from the fully closed position (clockwise) turn out the adjuster (1) by 18 clicks. To change spring preload, slacken the upper ring nut (2) with a pin wrench. Tighten or slacken the lower ring nut (3) to increase or decrease preload.
Page 76 Testers 5 - Testers 1 97900.0211 DDS (Ducati Diagnosis System) base unit 2 97900.0227 Power cord and diagnosis cable D607 3 97900.0222 Power cord and diagnosis cable 1060838 (Measurement Module) 4 97900.0218 Vacuum sensor 5 552.1.039.1A Pressure sensor 6 97900.0220 Pressure/vacuum tube 7 97900.0221 Fitting...
Page 77 Testers 19 514.1.033.1A Lighter socket adapter Spare parts catalogue Diagnosis tester DDS Workshop special tools Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Tester description The “DDS”...
Page 78 Self-diagnosis module (B) establishes communication of the DDS (1) with the vehicle control unit. The user interface software resides in the display memory card (C) located in the palmtop display (A). The software for communicating with the DUCATI control units resides in the BBAD memory card (D) located in the BBAD module (B).
Page 79 Testers A printer can be connected to the DDS (1) via the serial port (COM1) (G) positioned on top of the instrument (1) in order to print test reports. Specifications Power supply: - from the mains - 220 V; - from the vehicle battery - 12 V. Components supplied with the DDS The DDS (1) is supplied in a DDS kit, together with: - DDS rechargeable battery...
Page 80 Testers Connection to the bike Supply voltage must be between 9 and 16 Volt DC. Make sure voltage never drops below this limit during operation: this could happen when starting the engine or when the engine is idling if the bike battery is in less than perfect operating conditions. If the tester detects a power supply voltage below 9 Volts, it will abort any procedures underway at that time.
Page 81 Testers connecting the power and diagnosis cable (2) to instrument diagnosis connector (P); connecting battery adapter (8) to power and diagnosis cable connector (R) and then connecting the adapter to the vehicle battery. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_D_5_5_00.19.1.html (6 of 41) [10/7/2008 8:43:05 PM]...
Page 82 Testers Note For device connection and diagnosis procedures, refer to the user’s manual supplied with the tester DDS diagnosis instrument In short, the "DDS" has the following functions: - Error reading (failures) for ignition-injection system errors stored in engine control unit memory and error deletion. Parameter reading, such as engine rpm, coolant and air temperature, atmospheric pressure, throttle opening value, battery voltage, injection times, ignition advance values and so on.
Page 83 Testers Switch on the DDS (1), refer to "Instrument power supply". Connect the power and diagnosis cable (Measurement Module) (3) to measurement module connector (F) of the DDS (1). Connect the belt tension sensor (15) to power and diagnosis cable (Measurement Module) (3) connector (V). Secure the belt tension sensor bracket (15) using belt cover screw (21).
Page 84 Testers Press on "Measurement module" icon on DDS (1) to select the "Measurement module" function; then press on "Belt tension" icon and then "Start" to enter the "Belt mechanical tension" page. The page shows you which socket of the cable (Measurement Module) (3) is to be used with a capital A, B or C. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_D_5_5_00.19.1.html (9 of 41) [10/7/2008 8:43:05 PM]...
Page 85 Testers Lightly flick the belt with a finger and then read frequency value (Hz) on the DDS. Note Do not flick several times, as the DDS needs at least 1 second to read the value. Warning Check tension reading on the belt sections (22) and (23) indicated in the figure. Belt tension values are indicated in Sect.
Page 86 Testers Warning Timing belt tension could decrease in time as a result of normal wear and tear. When checking belt tension, restore specified nominal values (Sect. C 1.1, Timing/valves) or in any case set tension to at least 80% of nominal values when reading is below 70 Hz.
Page 87 Testers Set the crankshaft at the TDC of the vertical cylinder, in the combustion stroke (valve closed), and repeat the same procedure used for the horizontal cylinder, reading tension on section (22) of the vertical belt. Disconnect the belt tension sensor and the DDS from the vehicle. Operations Reference See Section Remove side covers...
Page 88 Testers Enter the general functions menu, pressing "Menu Key 1" icon (C). Press the "Vehicle selection" icon and press "Vehicle selection" icon in the following page; choose the model and confirm, then select the version and confirm. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_D_5_5_00.19.1.html (13 of 41) [10/7/2008 8:43:05 PM]...
Page 89 Testers Press "System selection" icon displayed to show the vehicle systems that can be diagnosed. Select "Engine electronic system" and press "Confirm" (D) to confirm. Then press "Self-diagnosis" icon to enter self- diagnosis function. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_D_5_5_00.19.1.html (14 of 41) [10/7/2008 8:43:05 PM]...
Page 90 Testers The DDS queries the control unit and the elements under analysis are displayed together with their relevant values. Note Perform the necessary connections with the ignition key set to OFF. Press "Settings" icon to display the special parameters. Select "TPS reset" and press "Execute". file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_D_5_5_00.19.1.html (15 of 41) [10/7/2008 8:43:05 PM]...
Page 91 Testers If the operation is performed, the message "Was the operation successful?" is displayed; press "Confirm" (D). If there are problems in performing the operation, the relevant error messages are displayed: you need to confirm or reject each message by pressing "Confirm" (D) or "Exit" (E), respectively. The zero setting procedure establishes a connection between electronic control unit and throttle body.
Page 92 Testers Ensure that throttles are against the stop screw (throttle twistgrip fully closed). Ensure choke is off and that throttle cable free play is correct. Reset the TPS as indicated in "Zero setting the throttle position sensor (TPS)", in this section.
Page 93 Testers cylinders and check again CO level once idling rpm is correct. If adjustment results were negative, repeat the procedure, starting from throttle position sensor (TPS) reset. Note The vacuum gauge is not used since "cylinder synchronisation procedure" is not necessary. Adjusting the choke Work the choke control adjuster (22) to adjust choke lever (23) so that the lever (24) can travel smoothly all its stroke.
Page 94 Testers Insert fitting (9) in the hose (12) fitting, and place two copper washers (20) in-between. Screw the connector (9) of the hose (12) into the threaded hole (M10x1mm) in the RH cover. Screw the connector all the way in. Refit the pressure switch (21) complete with seal to the connector (9) and reconnect it to the electric system connector (A).
Page 95 Testers Switch on the DDS (1), refer to "Instrument power supply". Connect the power and diagnosis cable (Measurement Module) (3) to measurement module connector (B) of the DDS (1). Connect the pressure sensor (5) to port (A) or (C) of cable (3). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_D_5_5_00.19.1.html (20 of 41) [10/7/2008 8:43:05 PM]...
Page 96 Testers Press "Measurement module" icon on DDS (1) to select the "Measurement module" function; then press on "Pressure Measurement" icon (D) and then "Start" (E). The page shows you which socket of the cable (Measurement Module) (3) is to be used with a capital A, B or C. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_D_5_5_00.19.1.html (21 of 41) [10/7/2008 8:43:05 PM]...
Page 97 Testers Start the engine. Values can be displayed in three ways: as numbers (one mode) or as graphs (two modes); press "Display mode" (F) to select the display mode. Measured value is indicated next to letter (A) or (C) depending on the cable used: if socket (A) of cable (3) is used, measured value will correspond to letter (A) on the screen.
Page 98 Testers Oil pressure test values: Warm engine (Oil temperature at least = 80°C) 1100 - 1300 rpm over 0.8 bar 3500 - 4000 rpm over 4 bar Caution Maximum pressure must not exceed 6.0 bar. A pressure which is too high indicates that the pressure-relief valve is jammed. A pressure which is too low indicates that the pressure-relief valve is jammed in the open position, that the spring is too weak, or that the oil pump is faulty.
Page 99 Testers Disconnect the DDS. Checking cylinder compression Note A table at the end of this section explains the icons used in this procedure. The performance and efficiency of an engine are directly linked to the compression inside the combustion chambers of the two cylinders.
Page 100 Testers To prevent sparks, earth the spark plug cable. Screw the cylinder compression cable (11) into the spark plug hole. Connect the pressure sensor (5) to cable (11). Switch on the DDS (1), refer to "Connection to the bike". Connect the power and diagnosis cable (Measurement Module) (3) to measurement module connector (B) of the DDS (1).
Page 101 Testers The page shows you which socket of the cable (Measurement Module) (3) is to be used with a capital A, B or C. Crank the engine using the starter motor until the pressure reading stops rising. Check the compression of both cylinders. - standard value: 11-12 bar;...
Page 102 Testers Checking fuel pressure Note A table at the end of this section explains the icons used in this procedure. Lift the fuel tank (Sect. L 2, Removing the fuel tank). Remove the fuel delivery hose (20). Using fuel pressure tube (17), connect one end (D) to union of delivery hose to tank and the other end (E) to delivery hose (20): in this way you create a pressure pick-up point (F).
Page 103 Testers Switch on the DDS (1), refer to "Instrument power supply". Connect the power and diagnosis cable (Measurement Module) (3) to measurement module connector (E) of the DDS (1). Connect the pressure sensor (5) to port (A) or (C) of cable (3). Press "Measurement module"...
Page 104 Testers The page shows you which socket of the cable (Measurement Module) (3) is to be used with a capital A, B or C. Values can be displayed in three ways: as numbers (one mode) or as graphs (two modes); press "Display mode" (H) to select the display mode.
Page 105 Testers Procedure to override the immobilizer system Note A table at the end of this section explains the icons used in this procedure. If the immobilizer is faulty, follow the emergency procedure to start the engine described in section P 8, Immobilizer and Transponder that consists in entering the emergency code, also using the DDS.
Page 106 Testers Press the "Vehicle selection" icon and press "Vehicle selection" icon in the following page; choose the model and confirm, then select the version and confirm. Press "System selection" icon displayed to show the vehicle systems that can be diagnosed. Select "Engine electronic system"...
Page 107 Testers The DDS queries the control unit and the elements under analysis are displayed together with their relevant values. Note Perform the necessary connections with the ignition key set to OFF. Press "Actuators" (C) to display actuators and components connected to ECU. Select "Immobilizer override"...
Page 108 Testers A box is displayed with a field for the five figures of the emergency code. Use the red arrows (E) and (F) to enter each digit: confirm each digit entered pressing "Confirm" (B). Once the code is complete, press "Confirm" (B). If the operation is performed, the message "Was the operation successful?"...
Page 109 Testers Remove the Diagnosis instrument. Guided diagnosis Note A table at the end of this section explains the icons used in this procedure. The DDS guides the operator step by step through the various diagnosis stages and provides the descriptions and the documents on the different vehicle components such as wiring diagrams for the electronic systems and details on the system layout and parts location.
Page 110 Testers Press the "Vehicle selection" icon and press "Vehicle selection" icon in the following page; choose the model and confirm, then select the version and confirm. Press "System selection" icon displayed to show the vehicle systems that can be diagnosed. Select "Engine electronic system"...
Page 111 Testers Press "Step-by-step diagnosis" icon (C) to enter the "Step-by-step diagnosis" function. A few pages will give indications on the procedure for a correct diagnosis. It is possible to enter the Self-diagnosis function, pressing "Self-diagnosis" icon, to see if the system is faulty. If errors are present, the symbol (D) is displayed.
Page 112 Testers The DDS queries the control unit and the elements under analysis are displayed together with their relevant values. Checking the charging system Note A table at the end of this section explains the icons used in this procedure. You can determine the engine rpm required for generator to produce just enough current to charge battery, feed the injection-ignition system and all electric items fitted to motorcycle.
Page 113 Testers Connect the ammeter clamp to socket (E) of the power and diagnosis cable (Measurement Module) (3). Warning The ammeter clamp shall not be connected to live cables. Then, apply the amperemeter clamp to the battery positive terminal lead with the arrow on the clamp pointing towards the battery positive (+) terminal.
Page 114 Testers The page shows you which socket of the cable (Measurement Module) (3) is to be used with a capital A, B or C. If the measured current is a positive quantity, it means that generator is feeding all electric items and charging battery at the same time.
Page 115 Testers Caution If polarity is reversed when clamping amperemeter onto cable, readings polarity will also be reversed. This will lead to wrong diagnosis. Icons table Symbol Description Confirm Exit Measurement module Belt tension Start/stop Menu key 1 Vehicle selection Vehicle selection Self diagnosis file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_D_5_5_00.19.1.html (40 of 41) [10/7/2008 8:43:05 PM]...
Page 116 Testers Settings Execute Cylinder synchronisation Display mode Reset Pressure measurement Cylinder compression Actuators Guided diagnosis System selection Errors Clamp-type amperemeter file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_D_5_5_00.19.1.html (41 of 41) [10/7/2008 8:43:05 PM]...
Page 117 Use and maintenance operations 0Use and maintenance operations 1 - Preliminary checks Running-in precautions 3 Pre-ride checks 4 2 - Starting – engine warm-up Starting the engine 5 3 - Routine maintenance table Scheduled maintenance chart: operations to be performed by the dealer 7 Scheduled maintenance chart: operations to be performed by the customer 8 4 - Maintenance operations Checking the engine oil level 9...
Page 118 Use and maintenance operations Adjusting idling condition 54 Checking engine oil pressure 56 Checking cylinder compression 61 Checking fuel pressure 64 Procedure to override the immobilizer system 67 Guided diagnosis 71 Checking the charging system 74 Icons table 77 file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_D_IND_00.14.1.html (2 of 2) [10/7/2008 8:43:08 PM]...
Page 119 Rear-view mirrors 1 - Rear-view mirrors 1 Rear-view mirror 2 Screw 3 U-bolt Spare parts catalogue Handlebar and controls Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Disassembling the rear-view mirrors Use a hexagonal wrench to loosen mirror (1) and remove it from the U-bolt (3).
Page 120 Rear-view mirrors Unscrew the screws (2) to remove the U-bolts (3), if necessary. Refitting the rear-view mirrors Position the rear-view mirror (1) to the U-bolt (3). Screw the mirror fully in. Position and tighten the mirror (1) with a hexagonal wrench. Refit the clamps (3), if removed, and fix them with screws (2).
Page 121 Seat 3 - Seat 1 Seat 2 Helmet anti-theft cable 3 Screw 4 Washer 5 Washer 6 Cover 7 Screw 8 Special screw 9 Screw 10 Washer 11 Side body panel 12 Washer 13 Nut 14 Insert 15 Seat lock 16 Splashguard Spare parts catalogue file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_E_3_4_00.22.1.html (1 of 7) [10/7/2008 8:43:13 PM]...
Page 122 Seat Seat Frame Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the seat Release the lock (15) and lift the seat. Remove the complete seat (1).
Page 123 Seat Reassembling the seat Refit the cover (6) and tighten the screw (8). Tighten the screw (8) to the specified torque (Sect. C 3, Frame torque settings). Refitting the seat Insert the seat (1) and press until the lock (15) becomes engaged. file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_E_3_4_00.22.1.html (3 of 7) [10/7/2008 8:43:13 PM]...
Page 124 Seat Removing the splash guard Remove the seat as described under "Removing the seat" in this section. Loosen and remove the screws (3). Collect the washers (4). Undo the nuts (13) and collect the washers (5). The screw (7) remains on oil breather tank (A). Remove the screw (7) from oil breather tank (A).
Page 125 Seat Refitting the splash guard Insert the splashguard (16) from the rear end of the motorcycle. Fit the screw (7) with washer (12) to the oil breather tank front hole (A). Position the washer (5) and tighten the nut (13) on the screw (7). Start the screws (3) with their washers (4) in their holes and tighten the screws (3) to the specified torque (Set.
Page 126 Seat Refitting the side body panels Refit the RH and LH side body panels (11), fit the inserts (14) and the washers (10) and start the screws (9) in their threads. Tighten the screws (9) to the specified torque (Sect. C 3, Frame torque settings).
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Page 128 Front and rear mudguard 4 - Front and rear mudguard 1 Front mudguard 2 Nylon washer 3 Screw 4 Rear mudguard 5 Screw Spare parts catalogue Frame Swingarm and chain Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 129 Front and rear mudguard Removing the front mudguard Unscrew the retaining screws (3). Remove the retaining screws (3) and their nylon washers (2). Remove the front mudguard (1). Note The USA versions fit a cat's eye on front mudguard (1). Refitting the front mudguard Warning Do not ride the motorcycle without the front mudguard, or the brake hoses might touch the wheel under braking.
Page 130 Front and rear mudguard Position the front mudguard (1) and start the retaining screws (3) complete with their washers (2) in their holes. Tighten the screws (3) to the specified torque (Sect. C 3, Frame torque settings). Removing the rear mudguard Unscrew the four screws (5) and detach the mudguard (4) from the swingarm.
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Page 132 Fairing 0Fairing 1 - Rear-view mirrors Disassembling the rear-view mirrors 4 Refitting the rear-view mirrors 4 3 - Seat Removing the seat 6 Refitting the seat 8 Removing the splash guard 9 Refitting the splash guard 10 Removing the side body panels 11 Refitting the side body panels 12 4 - Front and rear mudguard Removing the front mudguard 14...
Page 133 Throttle control – choke 1 - Throttle control – choke 1 Twistgrips 2 Choke cable 3 Screw 4 Screw 5 Throttle control 6 Throttle cable 7 Spring 8 Throttle control adjuster on handlebar 9 Blanking plug 10 Throttle control adjuster on throttle body 11 choke control adjuster on throttle body 12 Choke control adjuster on handlebar 13 Cover...
Page 134 Throttle control – choke Handlebar and controls Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Adjusting the throttle and choke cables Read Sect. D 4, Adjusting the throttle and choke cables, for relevant instructions.
Page 135 Throttle control – choke Remove the throttle cable (6) from the motorcycle. Remove the plug (9) on the handlebar. Loosen the two screws (3) securing the throttle control to the handlebar. Remove the throttle control (5) from the handlebar. Warning Disturbing the throttle cable may affect the throttle body adjustments.
Page 136 Throttle control – choke Note Refer to the figures on the next pages for the correct routing of the throttle cable. Removing the choke control Slacken the retaining screw (F) of the choke cable. Slip off the rubber gaiter (C), slacken the check nut and turn out the adjuster (11) until it comes off the bracket. Withdraw the choke control (2) and collect the spring (7).
Page 137 Throttle control – choke Warning Disturbing the choke cable may affect the throttle body adjustments. Before refitting choke control cable read Sect. D Zero setting the throttle position sensor (TPS). Refitting the choke control Note The spare choke cable is supplied together with adjusters and drive cable. Grease the choke cable (2).
Page 138 Throttle control – choke Check that the choke control lever is in the rest position. Insert the new control cable (2) in the frame. Observe the original routing. Tighten the adjuster (11) into the throttle body support. Thread the core cable (2) through the linkage hole, the spring (7) and the throttle body pawl. Pull the end of the core cable to keep the cable taut and tighten the pawl screw (F).
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Page 140 Throttle control – choke file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_F_1_6_00.25.1.html (8 of 8) [10/7/2008 8:43:19 PM]...
Page 141 Clutch hydraulic control 2 - Clutch hydraulic control 1 Clutch master cylinder 2 Spare sight glass 3 Spare lever pin 4 Lever with dowel 5 Spare cap 6 Clutch hose 7 Spare clamp 8 Gasket 9 Special screw 10 Filler 11 Bleed unit 12 Dust seal 13 O-ring...
Page 142 Clutch hydraulic control Spare parts catalogue Clutch Clutch control Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the clutch master cylinder assembly Warning Critical safety components.
Page 143 Clutch hydraulic control Tighten the retaining screws (7) to the specified torque (Sect. C 3, Frame torque settings) working in a 1-2-1 sequence. Position the pipe (6) onto the clutch cylinder assembly (1) with a seal (8) and secure with special screw (9). Do not tighten it yet.
Page 144 Clutch hydraulic control Fill the clutch circuit D 4, Filling the clutch circuit Removing the clutch transmission unit Warning Critical safety components. The clutch transmission unit manufacturer recommends that you do not attempt to service the internal components of the clutch transmission unit (14). Incorrect overhaul of these critical safety components can endanger rider and passenger safety.
Page 145 Clutch hydraulic control Refitting the clutch transmission assembly Lubricate and refit the clutch pushrod (16) with both O-rings (17). Lubricate the seal (13) and fit with the transmission unit (14) onto the casing. Tighten the screws (15) to the specified torque (Sect. C 3, Frame torque settings).
Page 146 Clutch hydraulic control Warning Incorrectly positioned hoses can cause faults and interfere with moving parts. Position both seals (8) and tighten the screw (10) to the specified torque (Sect. C 3, Frame torque settings). Refit the drain (11) and the dust seal (12). Please refer to the table on next page for proper positioning of clamps for hose (6).
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Page 148 Clutch hydraulic control file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_F_2_6_00.26.1.html (8 of 8) [10/7/2008 8:43:23 PM]...
Page 149 Front brake control 3 - Front brake control 1 Front brake master cylinder 2 Lever with dowel 3 Rubber pad 4 Nut 5 Microswitch 6 Spare lever pin 7 Screw 8 Spare cap 9 Spare sight glass 10 Spare clamp Spare parts catalogue Front brake Caution...
Page 150 Front brake control Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the front brake master cylinder Warning Critical safety components. The brake master cylinder manufacturer recommends that you do not attempt to service the internal components of the brake master cylinder.
Page 151 Front brake control diagram. Line up the clamp / master cylinder body (1) split line (A) with the dot (B) on the handlebar. Fit the two screws of the clamp (10) securing front brake master cylinder to the handlebar. Tighten U-bolt (10) screws to the specified torque (Sect.
Page 152 Rear brake control 4 - Rear brake control 1 Special screw 2 Seal, thk.1 3 Rear brake hose 4 Clamp 5 Pin 6 Spring 7 Special screw 8 Rubber block 9 Brake lever 10 Nut 11 Clip 12 Washer 13 Switch 14 Bush 15 Clevis pin 16 Hose...
Page 153 Rear brake control 19 Adjuster rod 20 Screw 21 Blanking plug 22 Complete brake fluid reservoir 23 Spare connector 24 Dust cap 25 Washer Spare parts catalogue Rear brake Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 154 Rear brake control Remove the footpeg plate (Sect. H 4, Removing the footpegs). Withdraw the retaining pin (5) securing the rear brake lever to the footpeg bracket. Remove the spring (6), the complete brake lever (9) and the washer (12). Disassembling the rear brake control The spare brake master cylinder is supplied as a complete assembly.
Page 155 Rear brake control Remove the system component parts as shown in the exploded view at the beginning of this section. Warning After servicing the rear brake control, check the brake pedal position following the instructions given in Sect. D 4, Adjusting the position of the gear change and rear brake pedals.
Page 156 Rear brake control Caution The correct position of the spring (6) is shown in the diagram. Ensure that hose connecting brake master cylinder to caliper is correctly positioned as shown on next page. Operations Reference See Section Fill the braking system D 4, Filling the brake circuit Rear brake hose routing...
Page 157 Rear brake control file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_F_4_6_00.28.1.html (6 of 6) [10/7/2008 8:43:29 PM]...
Page 158 Gear change control 5 - Gear change control 1 Pivot bolt 2 Gear change pedal 3 Screw 4 Rubber block 5 Bush 6 Washer 7 Nut 8 Ball joint 9 Nut 10 Actuating rod 11 Nut 12 Nut 13 Ball joint 14 Gear small lever 15 Screw 16 Screw...
Page 159 Gear change control Spare parts catalogue Gearchange lever - foot rest Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the gear change control Unscrew and remove the retaining pin (1) of the gear change pedal (2), collect the washer (6) and the O-rings (17).
Page 160 Gear change control Warning After servicing the gear change control, check the gear change pedal position. To adjust the gear change pedal, follow the instructions provided in Sect. D 4, Adjusting the position of the gear change and rear brake pedals.
Page 161 Seat lock and releasing mechanisms 6 - Seat lock and releasing mechanisms 1 Screw 2 Latch 3 Rubber block 4 Screw 5 Lever 6 Ring nut 7 Plate 8 Seat lock 9 Spring washer 10 Screw Spare parts catalogue Seat Caution file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_F_6_6_00.30.1.html (1 of 3) [10/7/2008 8:43:33 PM]...
Page 162 Seat lock and releasing mechanisms Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the seat releasing mechanism The seat releasing mechanism is best accessed with the seat removed (Sect. E 3, Removing the seat).
Page 163 Seat lock and releasing mechanisms Refitting the seat releasing mechanism Note The spare latch (2) comes complete with Bowden cable. Latch and Bowden cable should never be separated. Installation is a reversal of the removal procedure. Smear threadlocker on ring nut (6) and screws (4). If you have removed the seat, refit it (Sect.
Page 164 Controls - Devices 0Controls - Devices 1 - Throttle control – choke Adjusting the throttle and choke cables 4 Disassembling the throttle control 4 Reassembling the throttle control 6 Removing the choke control 7 Refitting the choke control 8 2 - Clutch hydraulic control Removing the clutch master cylinder assembly 11 Refitting the clutch master cylinder assembly 12 Removing the clutch transmission unit 13...
Page 165 Front wheel 1 - Front wheel 1 Nut 2 Screw 3 Spacer 4 Seal 5 Bearing 6 Inner spacer 7 Valve 8 Front wheel shaft 9 Front wheel rim Spare parts catalogue Front fork Front and rear wheels Caution file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_G_1_8_00.32.1.html (1 of 7) [10/7/2008 8:43:38 PM]...
Page 166 Front wheel Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the front wheel Support the bike adequately so that the wheel to be removed is raised from the ground. Loosen the two screws (A) securing the caliper to the fork leg and remove the front brake caliper (B).
Page 167 Front wheel Working from the left side, use a plastic hammer to knock the wheel shaft (8) out to the other side. Slide the wheel out. Collect the spacer (3) on the LH side. Overhauling the front wheel Overhauling the front wheel bearings Before checking dimensions, check wear on wheel hub bearings.
Page 168 Front wheel Tap with a hammer until knocking out the bearing. Apply pressure at different positions to keep the bearing square during removal. Caution Do not refit bearings once they have been removed. Before you fit new bearings, check that the seat is clean and free from scoring and damage.
Page 169 Front wheel Overhauling the front and rear wheel rim After you have checked the bearings, check the rims as follows. Visually inspect the rim for cracks, scoring and deformation; change the rim if damaged. Insert the wheel shaft in the wheel and mount the shaft on two fixed reference blocks. Using a dial gauge, measure rim run-out and out-of-round relative to wheel shaft axis (see Sect.
Page 170 Front wheel Warning Position the front wheel; note that the arrow on the wheel rim indicates direction of rotation when running. Insert the wheel shaft (8) from the right side. Place the spacer (3) between wheel and left fork leg. Apply service tool part no.
Page 171 Front wheel Check that the brake discs run smoothly inside the calipers. Before tightening the pinch bolts (2), lower the bike to the ground and press up and down on the handlebars to load the suspension so the fork legs will become properly seated onto the wheel shaft. Grease the pinch bolts (2).
Page 172 Front fork 2 - Front fork 1 Screw 2 Screw 3 Steering head 4 Bottom yoke 5 Left fork leg assembly 6 Right fork leg assembly 7 Blanking plug 8 Washer 9 Spring 10 Hose 11 Outer sleeve 12 Complete damper cartridge 13 Adjusting screw 14 Gasket 15 Bush...
Page 173 Front fork 18 Slider 19 Bush 20 Cap 21 Seal 22 O-ring 23 Lock nut 24 Spring guide 25 Circlip 26 Cartridge Spare parts catalogue Front fork Handlebar and controls Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 174 Front fork Slide the fork legs (5) and (6) out downwards. Overhaul where necessary. Overhauling the front fork Note Loosen the plug (7) on the fork leg when still fitted onto the vehicle. Note The special tools required for front fork overhaul are listed in Section C 4, Frame special tools.
Page 175 Front fork Disassembling the front fork Tighten the lock nut (23) with a hexagonal wrench. Use another hexagonal wrench and loosen plug (7) from cartridge (26), collect gasket (22). Loosen the lock nut (23), until all thread on cartridge (26) is exposed. Hold the spring (9) with a hand, collect washer (8) from one side and slowly release spring (9).
Page 176 Front fork Remove the spring (9). Remove the preload tube (10). Pump the outer sleeve (11) and the cartridge (26) to let oil off the leg. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_G_2_8_00.33.1.html (5 of 14) [10/7/2008 8:43:44 PM]...
Page 177 Front fork Warning When pumping, oil is pressurised. Aim the fork at a container you will have prepared previously to avoid contact with fork oil. Clamp the slider (18) in a vice equipped with protection jaws. Unscrew the compression adjuster (13). Remove the adjuster screw (13) and collect the seal (14).
Page 178 Front fork Remove the dust seal (16) from the outer sleeve (11) with a screwdriver. Remove the snap ring (17). Caution Do not damage the slider (18) and the snap ring (17) housing on the outer sleeve (11). Pull out the outer sleeve (11) from the slider (18). Quickly tap to counteract the pilot bush (19). Remove the bush (15) from the slider by inserting a screwdriver into the bush opening.
Page 179 Front fork Checking the front fork Place the spring on a flat surface and measure free length (L). Service limit: 270 mm Change the spring if not within limit. Check outer surface of both sliders and inner surface of both outer sleeves. They should show no signs of scores, scratches or distortions.
Page 180 Front fork Reassembling the front fork Clamp the slider in a vice. Tape stanchion tube end to protect it. Caution Lubricate sliding surfaces with fork oil or seal grease before fitting the oil seal (21). When fitting the oil seal (21), its marked surface should point the dust seal (16). Fit the following parts into the slider (18): - dust seal (16);...
Page 181 Front fork Note Lubricate bush sliding surfaces with fork oil before assembling. Seat the pilot bush (19) and the ring (20) into the outer sleeve (11) with the special tool (F, part no. 88713.1096). Seat the seal ring (21) into the outer sleeve using the same tool. Fit the snap ring (17) and the dust seal (16).
Page 182 Front fork Tighten to 30-40 Nm. Fill each leg with half the amount of the recommended oil (Sect. C 2, Fuels and lubricants). Pump up and down to fill whole inner volume. Take both damper cartridge and outer sleeve to the end of their stroke. Fill the remaining oil into the leg and measure level.
Page 183 Front fork Warning When refitting the washer (8) compress the spring (9) with a hand. Tighten the lock nut (23) onto cartridge (26) with a hexagonal wrench. Use the same wrench to hold the lock nut and tighten the upper plug (7) with O-ring onto the cartridge (26). Tighten the cap nut (7) to the specified torque (Sect.
Page 184 Front fork Position the fork legs (5) and (6) correctly. Tighten screws (2) and (1) to the specified torque (Sect. C 3, Frame torque settings) in a 1-2-1 sequence to clamp the fork legs securely in the bottom yoke (4) and steering head (3). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_G_2_8_00.33.1.html (13 of 14) [10/7/2008 8:43:44 PM]...
Page 185 Front fork Caution If the pinch bolts (1) and (2) have been removed on disassembly, smear the threads with the specified grease before tightening. Warning Do not ride without the front mudguard, or the brake hoses might contact the wheel under braking. Refit any components you have removed from the frame: Operations Reference See Section...
Page 186 Front brake 3 - Front brake 1 Spare pins and split pin 2 Screw 3 Right brake caliper 4 Seal, thk.1 5 Spare caliper bleed valve 6 Special screw 7 Dust seal 8 Cylinder-to-calipers hose 9 Set of brake pads 10 Left brake caliper 11 Springs 12 Cable guide...
Page 187 Front brake Front head-light Front and rear wheels Front brake Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Braking system maintenance Warning Corrosion and irritant hazard.
Page 188 Front brake Remove the brake cylinder (Sect. F 3, Removing the front brake master cylinder). Unscrew the two screws (2) securing the front brake left caliper (10) to the fork leg. Repeat the process for the right caliper (3). Unscrew the special screws (6) on each front brake caliper and detach the calipers from the hose (8). Removing the brake discs The front brake discs are made up of an inner rotor, which is fixed to the wheel rim, and an outer friction rotor.
Page 189 Front brake Overhauling the front brake components Caution Critical safety components. The brake caliper manufacturer recommends that you do not attempt to service the internal components of the brake calipers. Incorrect overhaul of these critical safety components can endanger rider safety.
Page 190 Front brake Warning Incorrectly positioned hoses can cause brake faults and interfere with moving parts. Correct position is shown in the diagram. Fit the special seals (4) to the connector when securing the brake hose to the brake caliper or the brake cylinder. Arrange the connector at the correct angle and then tighten the screw (6) to the specified torque (Sect.
Page 191 Front brake Position the brake cylinder-and-lever assembly (Sect. F 3, Refitting the front brake master cylinder). Slide the hose (8) into the headlight bracket (15). Thread the hose through the hose guide (12). The particular bent shape of the hose guide is designed to restrict hose (8) movement under braking and avoid damage.
Page 192 Front brake Operations Reference See Section Fill the braking system D 4, Draining the braking circuit file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_G_3_8_00.34.1.html (7 of 7) [10/7/2008 8:43:49 PM]...
Page 193: Rear Wheel
Rear wheel 4 - Rear wheel 1 Nut 2 Pin 3 Plate 4 Screw 5 Bearing 6 Inner spacer 7 Valve 8 Wheel rim 9 Vibration damping pad 10 Bearing 11 Brake disc 12 Screw 13 Screw 14 Washer 15 Cover 16 Slider Spare parts catalogue file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_G_4_8_00.35.1.html (1 of 5) [10/7/2008 8:43:53 PM]...
Page 194 Rear wheel Front and rear wheels Swingarm and chain Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the rear wheel Place the motorcycle on a paddock stand so as to lift the rear wheel off the ground. Undo the nut (1) on the right side of the swingarm.
Page 195 Rear wheel Overhauling the rear wheel Remove the rear sprocket flange from the wheel (Sect. G 8, Removing the rear sprocket). For bearing (5), bearing (10) and wheel shaft (2) inspection and for wheel rim (8) overhaul, please refer to "Overhauling the front wheel"...
Page 196 Rear wheel Refitting the rear wheel Fit the rear sprocket flange onto the wheel (Sect. G 8, Refitting the rear sprocket). If the slider (16) has been removed, fit it into the swingarm together with the cover (15) and start the screws (4) in their holes.
Page 197 Rear wheel Tighten the nut finger-tight. Tension the chain and align the wheel (Sect. D 4, Adjusting chain tension). Make sure the brake hose does not become trapped or is exceedingly bent. Tighten the nut (1) onto wheel shaft (2) to the specified torque (Sect. C 3, Frame torque settings).
Page 198: Rear Swingarm
Rear swingarm 5 - Rear swingarm 1 Screw 2 Upper chain sliding shoe 3 Plate 4 Blanking plug 5 Circlip 6 Swingarm shaft 7 Screw 8 Rear swingarm 9 Shim 10 Upper chain sliding shoe 11 Shim Spare parts catalogue Half crankcases Swingarm and chain file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_G_5_8_00.36.1.html (1 of 6) [10/7/2008 8:43:57 PM]...
Page 199 Rear swingarm Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the swingarm Operations Reference See Section Remove the rear wheel G 4, Removing the rear wheel Remove the rear mudguard E 4,...
Page 200 Rear swingarm Use a suitable punch (C) and push shaft (6) outwards until the swingarm is not fixed to the engine any more. Remove the swingarm (8) from the frame. Swingarm shaft inspection Measure swingarm shaft distortion (3) using a dial gauge. Place the shaft (3) on two reference blocks of the same size.
Page 201 Rear swingarm Hold the left arm of the swingarm (8) against the engine and measure play on the other side of engine using a feeler gauge or calibrated shims. Maximum side play allowed is up to 0.1 mm. When a 0.10 mm feeler gauge or shim is hard to fit, there is no need to shim the shaft. Otherwise, shims are available in two sizes (0.20 mm and 0.10 mm) to adjust play.
Page 202 Rear swingarm Working on the swingarm left side, fit the greased shaft (6) and the circlip (5) and insert it for half its length. Push the swingarm left section against the crankcase, and fit the shim (9) chosen during end float inspection in-between swingarm right section and engine.
Page 203 Rear swingarm Refit the final drive assembly G 8, Final drive Refit the rear mudguard E 4, Refitting the rear mudguard Refit the rear wheel G 4, Refitting the rear wheel file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_G_5_8_00.36.1.html (6 of 6) [10/7/2008 8:43:57 PM]...
Page 204 Rear brake 6 - Rear brake 1 Special screw 2 Seal, thk.1 3 Rear brake caliper 4 Caliper mounting plate 5 Screw 6 Spring washer 7 Washer 8 Spare pin and clip 9 Dust seal 10 Spare bleed valve 11 Set of brake pads 12 Hose retainer 13 Speed sensor 14 Screw...
Page 205 Rear brake Rear brake Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the rear brake system Operations Reference See Section Draining the braking system D 4, Draining the braking circuit Remove the screw retaining the hose...
Page 206 Rear brake Remove the rear wheel to remove the caliper plate (Sect. G 4, Removing the rear wheel). Slide caliper plate out of swingarm shaft (P). Refit the caliper mounting plate on the swingarm shaft. Refit the rear wheel (Sect. G 4, Refitting the rear wheel).
Page 207 Rear brake Tighten the special screws (1) to the specified torque (Sect. C 3, Frame torque settings). Position the brake hose (A) to the swingarm and secure the retainer (12) with the screw (16). Fit the rear brake caliper (3) to the brake disc matching the holes in the caliper plate. Grease the thread and underhead of the screws (5).
Page 208 Rear suspensions 7 - Rear suspensions 1 Rocker arm assembly 2 Seal 3 Roller bearing 4 Bush 5 Screw 6 Shock absorber 7 Screw 8 Spacer 9 Washer 10 Screw 11 Screw 12 Bush 13 Ball joint 14 Spacer 15 Linkage 16 Nut Spare parts catalogue file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_G_7_8_00.38.1.html (1 of 8) [10/7/2008 8:44:04 PM]...
Page 209 Rear suspensions Rear suspension Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Rear suspension The rear suspension consists in a fully adjustable hydraulic shock absorber (6) with progressive actuation. This system consists of an upper rocker arm (1) and a non adjustable linkage (15) secured to the single-sided swingarm.
Page 210 Rear suspensions Overhauling the rear shock absorber Measure the length of the preloaded spring (L) before disassembling. The measured length must be restored on refitting. Disassembling the rear shock absorber Loosen the ring nut (A) and the adjusting ring nut (B) of the spring with a pin wrench or special tools. Remove the retainer (C) and the spring.
Page 211 Rear suspensions Visually inspect the shock absorber and locate any oil leaks or other faults. Replace the shock absorber if needed. Reassembling the rear shock absorber Insert the spring into the shock absorber casing with the taper end pointing at the bottom end connection. Install the retainer (C).
Page 212 Rear suspensions Remove the shock absorber top from the rocker as described in "Removing the monoshock absorber" under this section. Unscrew the screw (7) and disconnect linkage (15) from rocker arm (1). Keep the bushes (4) at the sides of the ball joint (13).
Page 213 Rear suspensions Reassembling the rear suspension rocker arm Fit two new roller bearings (3) onto the drift part no. 88713.1071 Support the rocker arm and drive the needle roller bearings fully home into the rocker arm. Caution Fit the bearings squarely in the hole: use a press in case of jams. Fit a new seal (2) on the drift as shown in the cross-section view.
Page 214 Rear suspensions Refitting the rear suspension Grease shank and thread of the screw (10) and the contact faces of the washer (9) with specified grease. Grease shank and thread of pivot bolt and the underside of nut (16) with specified grease. Insert the complete rocker arm between the frame supports, as shown in the figure.
Page 215 Rear suspensions Grease the thread and underhead of the upper retaining screws (7) and (5) of shock absorber and linkage and start them in the holes in the rocker arm. Insert the upper ball joint of the shock absorber into the rear hole of the rocker arm. Tighten the screw (7) to the specified torque (Sect.
Page 216 Final drive 8 - Final drive 1 Pin 2 Rear chain sprocket flange 3 Bush 4 Bearing 5 Rear sprocket Z=48 6 Nut 7 Circlip 8 Spacer 9 Chain 10 Screw 11 Front sprocket retaining plate 12 Front chain sprocket 13 Front sprocket cover 14 Screw Spare parts catalogue...
Page 217 Final drive Gear-box Alternator cover Front and rear wheels Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Final drive inspection Check the wear of the final drive. Visually inspect the front (12) and rear (5) sprockets. If the tooth profile is as shown by the broken line in the figure, change the sprockets.
Page 218 Final drive Caution The rear sprocket (5), the front sprocket (12) and the chain (9) must all be changed together. Removing the chain sprocket Unscrew the screws (14) and take off the sprocket cover (13). Slacken the chain (Sect. D 4, Adjusting chain tension).
Page 219 Final drive Insert the retaining plate (11) on the gearbox secondary shaft (B) and rotate it inside the recess (A) so that the plate holes (11) match the threaded holes in the sprocket (12); position the retaining plate with the rounded corner facing the sprocket.
Page 220 Final drive Slacken the chain D 4, Adjusting chain tension Remove the rear wheel G 4, Removing the rear wheel Slide the complete rear sprocket flange (2) off the rear wheel. Hold the pins (1) at the rubber cush pads steady and undo the nuts (6) retaining the sprocket to the flange. Caution The pins (1) have left-hand threads.
Page 221 Final drive Operations Reference See Section Refit the rear wheel G 4, Refitting the rear wheel Adjust chain tension D 4, Adjusting chain tension file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_G_8_8_00.39.1.html (6 of 6) [10/7/2008 8:44:07 PM]...
Page 222 Wheels - Suspensions - Brakes 0Wheels - Suspensions - Brakes 1 - Front wheel Removing the front wheel 4 Overhauling the front wheel 6 Refitting the front wheel 8 2 - Front fork Removing the front fork 11 Overhauling the front fork 12 Refitting the front fork 20 3 - Front brake Braking system maintenance 23...
Page 223 Wheels - Suspensions - Brakes Removing the rear suspension rocker arm 49 Overhauling the rear suspension rocker arm 50 Refitting the rear suspension 52 8 - Final drive Final drive inspection 54 Removing the chain sprocket 55 Refitting the chain sprocket 56 Removing the rear sprocket 57 Refitting the rear sprocket 58 file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_G_IND_00.31.1.html (2 of 2) [10/7/2008 8:44:09 PM]...
Page 224 Handlebar 1 - Handlebar 1 U-bolt 2 Blanking plug 3 Screw 4 Handlebar 5 Twistgrips Spare parts catalogue Handlebar and controls Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 225 Handlebar Operations Reference See Section Remove the throttle control F 1, Disassembling the throttle control Remove the right and left switches P 5, Checking the indicators and lighting system components Remove the front brake control F 3, Removing the front brake master cylinder Remove the clutch hydraulic control F 2,...
Page 226 Handlebar Please refer to the exploded view at the beginning of this section for handgrips (5) removal procedure. Refitting the handlebar Position the handlebar (4) to its seat in the steering head. Position the clamps (1) to the handlebar. Caution The arrow (B) on the back of the clamps must be facing the tank.
Page 227 Handlebar Apply specified grease on the thread of the screws (3). Tighten the screws (3) to secure the clamps (1). Tighten the screws (3) to the specified torque (Sect. C 3, Frame torque settings). Operations Reference See Section Install the front brake control F 3, Refitting the front brake master cylinder...
Page 228 Steering 2 - Steering 1 Screw 2 Steering head 3 Ring nut 4 Seal 5 Bearing 6 Bearing 7 Seal 8 Washer 9 Bottom yoke 10 Screw 11 Grub screw 12 Nut 13 Splashguard Spare parts catalogue Handlebar and controls file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_H_2_7_00.42.1.html (1 of 8) [10/7/2008 8:44:15 PM]...
Page 229 Steering Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Adjusting steering bearing play Note See Section D 4, Adjusting steering bearings play, for steering bearing play adjustment. If the problem persists, inspect the steering bearings (5) and (6) for wear and replace as required.
Page 230 Steering Insert a 6-6.5 mm calibrated feeler gauge (A) on the fork sleeve, or use a gauge. Turn the front fork assembly to the right until the shim (A) contacts the frame upper tube. Bring the adjusting grub screw (11) on the left side in contact with the end stop on steering head. Apply threadlocker to the nut thread (12).
Page 231 Steering Note All components installed to steering head and bottom yoke, including electrical cables and Bowden cables, may be left in place, as long as they do not impair the disassembly procedure. Loosen the screw (1) securing the steering head (2) to the ring nut (3). Lift the steering head (2).
Page 232 Steering Caution Do not refit oil seals (4) and (7) and bearings (5) and (6) once they have been removed. Always fit new components. Using a drift, remove the outer bearing rings (C) from the steering tube. Proceed with care. Do not damage the ring seats.
Page 233 Steering Fit the washer (8), the seal ring (7) with trim side up and the inner ring (A) of the lower bearing (6) into the steering shaft. Heat it up at 125 °C for ten minutes first. Fit the drift no. 88713.1072 into the steering shaft. Keep the inner ring (A) pressed onto seal (7) manually for at least 10-15 seconds.
Page 234 Steering Fit steering shaft into steering tube and push until it becomes fully seated axially. Install the bottom yoke assembly to the frame. Grease the ball ring (B) and fit it to the top outer ring (C) of the frame. Fit the inner ring (A) of the upper bearing (5) onto the steering shaft;...
Page 235 Steering Install the steering head (2) to the ring nut (3) so that the fork leg clamp holes match those in the bottom yoke. Refit the fork legs as described in Sect. G 2, Refitting the front fork. Grease the screw (1). Tighten the screw (1) on the steering head to the specified torque (Sect.
Page 236 Footpeg supports 4 - Footpeg supports 1 Vibration damping pad 2 Washer 3 Screw 4 Pin 5 Circlip 6 Spring 7 Complete RH footpeg 8 RH footpeg plate 9 Ball 10 Plate 11 Washer 12 Spring 13 Screw 14 LH guard 15 Screw 16 Washer 17 RH guard...
Page 237 Footpeg supports 19 Screw 20 Complete LH footpeg 21 Spacer Spare parts catalogue Gearchange lever - foot rest Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the footpegs The removal procedure described below applies to both RH and LH footpegs.
Page 238 Footpeg supports Remove the complete right footpeg plate (8) and collect the washers (11). To remove the rear footpeg from the plate, extract the snap ring (5) and withdraw the pin (4) to release footpeg (7), plates (10), balls (9) and springs (12). To remove the front footpeg from the plate, extract the snap ring (5) and withdraw the pin (4) to release footpeg (7) and spring (6).
Page 239 Footpeg supports Ensure that the straight end of the spring locates into the plate hole. Grease the pin (4) and fit it from the top end. Fit the snap ring (5) at the other end to hold the pin in place. Position spring (12), plates (10), balls (9) and rear footpeg (7) between the end stops of the right footpeg plate (8).
Page 240 Footpeg supports Hold nuts and tighten the screw (E) to the specified torque (Sect. C 3, Frame torque settings). Repeat procedure for the left footpeg. Fit the rear brake control (A) to the right footpeg, tighten the screws (B) to the specified torque (Sect. C 3, Frame torque settings).
Page 241 Stands 5 - Stands 1 Side stand 2 Screw 3 Stand plate 4 Screw 5 Switch 6 Spring 7 Plate 8 Pivot 9 Nut 10 Plate pin Spare parts catalogue Stands Caution file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_H_5_7_00.44.1.html (1 of 3) [10/7/2008 8:44:21 PM]...
Page 242 Stands Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the side stand Disconnect the connector (A) of the side stand switch (5) from the main wiring harness. Undo the two screws (2) that secure stand plate (3) to engine.
Page 243 Stands See Sect. P 6, Checking protection and safety devices components, for switch (5) testing. Reassembling the side stand Grease the stand (1) and fit it to the plate (3). Secure it with pivot (8) and nut (9). Tighten the pivot (8) to the specified torque (Sect.
Page 244: Frame Inspection
Frame inspection 6 - Frame inspection 1 Frame Spare parts catalogue Frame Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the frame and related components Before performing the frame dimensional checks, you will need to remove a number of components to give all-round access to the frame.
Page 245 Frame inspection file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_H_6_7_00.45.1.html (2 of 4) [10/7/2008 8:44:22 PM]...
Page 246 Frame inspection Frame overall dimensions (mm) Legend A 315 mm A1 32 mm A2 205.3 - 205.8 mm A3 100 mm B 692.5 mm B1 239.5 mm C 34 ± 0.5 mm C1 149.2 ± 0.5 mm C2 100 - 100.3 mm C3 26 ±...
Page 247 Frame inspection Checking the frame Check the dimensions of the frame against those indicated here to determine whether frame needs changing. Caution Badly damaged frames must be changed, not repaired. Any changes to the frame might cause danger. Changes can also break E.E.C.
Page 248 Tail light and number plate holder 7 - Tail light and number plate holder 1 Number plate holder 2 Clamp 3 Tail light 4 Tail guard 5 Tail light 6 Screw 7 Vibration-damping pad 8 Spacer 9 Nut 10 Turn indicator 11 Wiring 12 Nut 13 Plate...
Page 249 Tail light and number plate holder 19 Cat's eye 20 Plate 21 Nut 22 Rubber block 23 Spacer Spare parts catalogue Plate holder - rear light Frame Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 250 Tail light and number plate holder file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_H_7_7_00.46.1.html (3 of 3) [10/7/2008 8:44:25 PM]...
Page 251 Frame 0Frame 1 - Handlebar Removing the handlebar 4 Refitting the handlebar 5 2 - Steering Adjusting steering bearing play 8 Adjusting the steering angle 9 Disassembling the steering tube components 10 Refitting the steering tube components 12 4 - Footpeg supports Removing the footpegs 16 Refitting the footpegs 18 5 - Stands...
Page 252 Description 0Description 0Model-specific information 0Specifications 0Use and maintenance operations 0Fairing 0Controls - Devices 0Wheels - Suspensions - Brakes 0Frame 0Fuel system / Exhaust system 0Injection - ignition system 0Engine 0Electric system 0GENERAL SUMMARY Section A 0Description 1 - How to use the manual Manual layout 4 2 - Symbols - abbreviations - references Product specifications 6...
Page 253 Description Identification data for Monster 695 i.e. 3 Section C 0Specifications 1.1 - Technical specifications Description 3 Colors 4 Transmission assembly 4 Timing/valves 4 Cylinder / piston 5 Gearbox 5 Cooling system 5 Front wheel 5 Front suspension 6 Rear wheel 6...
Page 254 Description Section D 0Use and maintenance operations 1 - Preliminary checks Running-in precautions 3 Pre-ride checks 4 2 - Starting – engine warm-up Starting the engine 5 3 - Routine maintenance table Scheduled maintenance chart: operations to be performed by the dealer 7 Scheduled maintenance chart: operations to be performed by the customer 8 4 - Maintenance operations Checking the engine oil level 9...
Page 255 Description Zero setting the throttle position sensor (TPS) 50 Adjusting idling condition 54 Checking engine oil pressure 56 Checking cylinder compression 61 Checking fuel pressure 64 Procedure to override the immobilizer system 67 Guided diagnosis 71 Checking the charging system 74 Icons table 77 Section E 0Fairing...
Page 256 Description Adjusting the throttle and choke cables 4 Disassembling the throttle control 4 Reassembling the throttle control 6 Removing the choke control 7 Refitting the choke control 8 2 - Clutch hydraulic control Removing the clutch master cylinder assembly 11 Refitting the clutch master cylinder assembly 12 Removing the clutch transmission unit 13 Refitting the clutch transmission assembly 14...
Page 257 Description 2 - Front fork Removing the front fork 11 Overhauling the front fork 12 Refitting the front fork 20 3 - Front brake Braking system maintenance 23 Removing the front brake system 23 Removing the brake discs 25 Overhauling the front brake components 25 Refitting the front brake system 26 4 - Rear wheel Removing the rear wheel 30...
Page 258 Description Refitting the chain sprocket 56 Removing the rear sprocket 57 Refitting the rear sprocket 58 Section H 0Frame 1 - Handlebar Removing the handlebar 4 Refitting the handlebar 5 2 - Steering Adjusting steering bearing play 8 Adjusting the steering angle 9 Disassembling the steering tube components 10 Refitting the steering tube components 12 4 - Footpeg supports...
Page 259 Description 0Fuel system / Exhaust system 1 - Fuel system description 2 - Plastic fuel tank Removing the fuel tank 6 Removing the filler plug unit - plastic tank 7 Refitting the filler plug unit - plastic tank 7 Replacing fuel tank flange 8 Refitting the plastic fuel tank 9 6 - Throttle body for plastic tank Removing the throttle body 13...
Page 260 Description Operating stages 9 2 - Injection - ignition system 3 - Fuel injection-ignition system components Electronic control unit 11 Electric injector 15 Lambda sensor 16 Air temperature / pressure sensor 18 Spark plugs 19 Coil 20 Throttle position sensor 22 Rpm/timing sensor 23 Main and injection relays 24 Section N...
Page 261 Description 4.2 - Cylinder heads: side covers / timing system Removing the timing side covers 28 Disassembling the timing system 29 Reassembling the timing system 33 Refitting the timing side covers 40 4.3 - Head unit: camshafts Removing the engine oil temperature sensor 42 Refitting the engine oil temperature sensor 43 Disassembling the intake manifold 44 Refitting the intake manifolds 45...
Page 262 Description Removing the clutch cover 105 Disassembling the clutch cover 106 Reassembling the clutch cover 108 Refitting the clutch cover 109 6.3 - Clutch unit: primary gears Disassembling the primary drive gears 112 Refitting the primary drive gears and checking meshing play 116 7.1 - Gearbox assembly: gear selector levers Removing the gear selector levers 120 Disassembling the gear selector levers 121...
Page 263: Table Of Contents
Description Reassembling the timing lay gear 167 Removing the starter motor driven gear 168 Refitting the starter motor driven gear 169 9.2 - Casing unit: crankcases Opening the casings 171 Overhauling the casings 174 Overhauling the main bearings 176 Reassembling the casings 177 Shimming the shafts 179 Closing the casings 189 9.3 - Casing unit: connecting rods...
Page 264 Description Diagram L 18 Diagram M 19 Diagram N 20 Diagram P 21 Diagram Q 22 2 - Charging system – battery Checking the charging system 23 Recharging the battery 24 Adding electrolyte 25 Battery 28 Battery mount 29 Generator 30 Rectifier - regulator 31 3 - Electric starting Electric starting system 33...
Page 265 Description How to use the multimeter to check electric systems 66 file:///C|/Documents%20and%20Settings/F4i/My...ti%20manual/wsm/usa/Mon695_MY07_IND.1.1.html (14 of 14) [10/7/2008 8:44:33 PM]...
Page 266 Fuel system / Exhaust system 0Fuel system / Exhaust system 1 - Fuel system description 2 - Plastic fuel tank Removing the fuel tank 6 Removing the filler plug unit - plastic tank 7 Refitting the filler plug unit - plastic tank 7 Replacing fuel tank flange 8 Refitting the plastic fuel tank 9 6 - Throttle body for plastic tank...
Page 267 Fuel system description 1 - Fuel system description Spare parts catalogue Fuel system The main fuel system components are mounted to a flange that is accommodated under the fuel tank. Under the fuel tank are the fuel delivery and return hoses from the injectors and the drain/bleed hose. The flange consists of a pump (1) and a filter (2) that can be replaced Inside the flange is a thermistor (5) outputting fuel level and a pressure regulator.
Page 268 Fuel system description The fuel system takes the fuel to the electric injectors and controls its pressure. Electric injectors are suitably controlled by the control unit and spray the fuel that thus mixes with air taken in by the engine. Fuel capacity varies depending on the engine operating conditions.
Page 269 Canister Filter 10 - Canister Filter 1 Screw 2 Rubber block 3 Vibration-damping pad 4 Cable guide 5 Hose 6 Plate 7 Spacer 8 Nut 9 CANISTER Filter 10 Hose guide 11 Hose guide 12 Filter-to-tank outlet hose 13 Hose guide 14 Hose 15 Hose guide 16 Hose...
Page 270 Canister Filter 19 Coupling 20 Aluminium gasket 21 Hose 22 Spring 23 Fitting 24 Hose guide 25 Breather hose Spare parts catalogue Fuel tank Fuel Infeed Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 271 Canister Filter Removing the Canister filter Operations Reference See Section Lift the fuel tank L 2, Removing the fuel tank Lift the seat E 3, Removing the seat Loosen the clamp (13) securing the Canister filter (9) connection hose to the tank and disconnect the hose (12). Loosen clamps (18) securing the Canister Filter (9) connection hoses to horizontal and vertical cylinder manifolds.
Page 272 Canister Filter Lift the Canister Filter (9) and release it from the plate (6). Refitting the Canister Filter Refitting is a reversal of the removal procedure, tighten the screws (A) to the specified torque (Sect. C3, Frame torque settings). Operations Reference See Section Refit the fuel tank L 2,...
Page 273 Canister Filter file:///C|/Documents%20and%20Settings/F4i/My%...anual/wsm/usa/Mon695_MY07_L10_10_00.53.1.html (5 of 11) [10/7/2008 8:44:39 PM]...
Page 274 Canister Filter Routing of hoses, clamps and Canister filter position file:///C|/Documents%20and%20Settings/F4i/My%...anual/wsm/usa/Mon695_MY07_L10_10_00.53.1.html (6 of 11) [10/7/2008 8:44:39 PM]...
Page 275 Canister Filter file:///C|/Documents%20and%20Settings/F4i/My%...anual/wsm/usa/Mon695_MY07_L10_10_00.53.1.html (7 of 11) [10/7/2008 8:44:40 PM]...
Page 276 Canister Filter Routing of hoses, clamps and Canister filter position file:///C|/Documents%20and%20Settings/F4i/My%...anual/wsm/usa/Mon695_MY07_L10_10_00.53.1.html (8 of 11) [10/7/2008 8:44:40 PM]...
Page 277 Canister Filter file:///C|/Documents%20and%20Settings/F4i/My%...anual/wsm/usa/Mon695_MY07_L10_10_00.53.1.html (9 of 11) [10/7/2008 8:44:40 PM]...
Page 278 Canister Filter Routing of hoses, clamps and Canister filter position file:///C|/Documents%20and%20Settings/F4i/My...nual/wsm/usa/Mon695_MY07_L10_10_00.53.1.html (10 of 11) [10/7/2008 8:44:40 PM]...
Page 279 Canister Filter file:///C|/Documents%20and%20Settings/F4i/My...nual/wsm/usa/Mon695_MY07_L10_10_00.53.1.html (11 of 11) [10/7/2008 8:44:40 PM]...
Page 280 Plastic fuel tank 2 - Plastic fuel tank 1 Tank 2 Pad 3 Screw 4 Hook 5 Bush 6 Shim 7 Pin 8 Split pin 9 Screw 10 Cable guide 11 Screw 12 Screw 13 Screw 14 Filler plug 15 Washer 16 Panel (BLACK) 17 Sticker 18 Gasket...
Page 281 Plastic fuel tank 19 Coupling 20 Hose 21 Hose 22 Hose guide 23 Coupling 24 Breather hose 25 Self-tapping screw 26 Complete flange 27 Screw 28 Thermistor 29 O-ring 30 O-ring 31 Collar 32 Hose 33 Collar 34 Filter 35 Quick-release fitting 36 Hose guide Spare parts catalogue Inlet dict...
Page 282 Plastic fuel tank Detach the connector (A) of fuel sensor and fuel pump from the main wiring harness. Disconnect the quick-release fittings (35) of delivery hose (C) and return hose (D) from the flange and leave the hoses connected to the throttle body. Remove the split pin (8), slide out pin (7), keep bushings (5) and washers (6), then remove the tank from the frame.
Page 283 Plastic fuel tank The filler plug is fitted with a breather cap (E). When fitting a new breather cap, apply an even film of speed bonder all round the cap (E) groove. Install the cap. Make sure it becomes properly seated in the seat in the recess. Refitting the filler plug unit - plastic tank Refit the complete plug (14) in the tank housing and tighten the screws (13) and (12) to the specified torque (Sect.
Page 284 Plastic fuel tank Release the clamps (31) and (33) at the fuel filter (34) with the suitable tool available on the market. Detach the filter from the connection hoses and replace filter. On refitting, clean off any build-up or scale accumulation from all components. Caution Position the new filter (34) with the arrow stamped on the outer casing pointing towards the flange.
Page 285 Plastic fuel tank Refitting the plastic fuel tank Place the fuel tank in the frame and connect the following components: - connector (A) of fuel pump and fuel sensor wiring; - Delivery hose (C) quick-release fitting (35); - Return hose (D) quick-release fitting (35) ; - breather hose (20) and drain hose (21).
Page 286 Plastic fuel tank Plastic tank drain breather hoses routing file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_L2_10_00.49.1.html (7 of 10) [10/7/2008 8:44:44 PM]...
Page 287 Plastic fuel tank Fuel hoses routing - from plastic fuel tank to throttle body file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_L2_10_00.49.1.html (8 of 10) [10/7/2008 8:44:44 PM]...
Page 288 Plastic fuel tank file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_L2_10_00.49.1.html (9 of 10) [10/7/2008 8:44:44 PM]...
Page 289 Plastic fuel tank file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_L2_10_00.49.1.html (10 of 10) [10/7/2008 8:44:44 PM]...
Page 290 Throttle body for plastic tank 6 - Throttle body for plastic tank 1 Complete fuel system assembly 2 Throttle position sensor 3 Clamp 4 Hose coupling 5 Clip “R” 6 Hose 7 Clamp 8 Injector 9 Hose 10 Clip “M” 11 Complete throttle body 12 Screw 13 Hose...
Page 291 Throttle body for plastic tank Inlet dict Fuel system Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the throttle body Operations Reference See Section Remove the fuel tank L 2,...
Page 292 Throttle body for plastic tank Unscrew the two screws (12) to release the throttle position sensor (2) from the throttle body. Removing the injectors Loosen the clips (7) that hold delivery hose (9), return hose (13) and injector connection hose (6) to the injectors. Unscrew the screws (14) to release the injectors from the throttle body.
Page 293 Throttle body for plastic tank Refitting the throttle body If you have removed the hose couplings (4), refit them to the throttle body and lock them with clips (3). Correct position of hose couplings and clips is shown in the figure. Note Fit the hoses with the smaller diameter end facing the throttle body.
Page 294 Throttle body for plastic tank torque settings). Connect connectors (C) connecting main wiring harness to the injectors (8). Connect the main wiring harness connector (B) to the throttle position sensor (2). Caution Should the throttle body or throttle position sensor be replaced, reset the throttle body as specified under "Zero setting the throttle position sensor (TPS)"...
Page 295 Throttle body for plastic tank Refit the fuel tank L 2, Refitting the plastic fuel tank Injector connection hose routing file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_L6_10_00.50.1.html (6 of 6) [10/7/2008 8:44:47 PM]...
Page 296 Airbox 7 - Airbox 1 Filter-to-tank outlet hose 2 Filter element 3 Airbox cover 4 Stud bolt 5 Filter housing 6 Hose 7 Peg 8 Rubber block 9 Hook 10 Pin 11 Clamp 12 Spacer 13 Screw Spare parts catalogue Inlet dict file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_L7_10_00.51.1.html (1 of 7) [10/7/2008 8:44:50 PM]...
Page 297 Airbox Electric system Air inductio and oil vent Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the airbox Operations Reference See Section Remove the fuel tank L 2, Removing the fuel tank...
Page 298 Airbox Loosen the hose clips (11) and withdraw the hoses from the housing. Loosen the screw (13), collect the spacer (12). file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_L7_10_00.51.1.html (3 of 7) [10/7/2008 8:44:50 PM]...
Page 299 Airbox Lift the complete filter housing. Be sure to collect the rubber blocks (8) of the stud bolts securing the housing to the frame. Remove the drain hose (6) from the filter housing (5). Unscrew the pegs (7). Unscrew the stud bolts (4). See Sect.
Page 300 Airbox Screw in the screw (13) with relevant spacer (12) onto filter housing (5) and insert it in the relevant rubber block (8) on the frame. Tighten the hose clips (11) to the specified torque (Sect. C 3, Frame torque settings) to secure the hoses to the filter housing (5).
Page 301 Airbox Place the filter element (2) into the housing. Fit the cover (3) and lock with the clips (9). Connect the coil connector to the wiring harness. Refit the fuel tank (Sect. L 2, Refitting the plastic fuel tank). Oil breather tank to air box hose routing file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_L7_10_00.51.1.html (6 of 7) [10/7/2008 8:44:50 PM]...
Page 302 Airbox file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_L7_10_00.51.1.html (7 of 7) [10/7/2008 8:44:50 PM]...
Page 303: Exhaust System
Exhaust system 8 - Exhaust system 1 Exhaust seal 2 Mount 3 Vibration-damping pad 4 Nut 5 Horizontal head exhaust pipe 6 Vertical head exhaust pipe 7 Blanking plug 8 Clamp 9 Rubber block 10 Spacer 11 Screw 12 RH silencer 13 RH bracket 14 Washer 15 Nut...
Page 304 Exhaust system 19 LH bracket 20 Bush 21 Seal, thk.1 22 Spacer 23 Screw 24 Screw 25 Screw 26 Washer 27 Lambda sensor Spare parts catalogue Exhaust system Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 305 Exhaust system Detach the two silencers from the horizontal head exhaust pipe (5). Loosen the clamp (8) of horizontal head exhaust pipe (5) and vertical head exhaust pipe (6). file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_L8_10_00.52.1.html (3 of 9) [10/7/2008 8:44:54 PM]...
Page 306 Exhaust system Undo and remove the nuts (4) that retain the exhaust pipe flanges to the heads. Remove the flanges from the heads. Unscrew the two retaining screws (24) of the exhaust pipes. file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_L8_10_00.52.1.html (4 of 9) [10/7/2008 8:44:54 PM]...
Page 307 Exhaust system Collect the spacer (22). Remove the horizontal exhaust pipe (5) from horizontal head and vertical head exhaust pipe (6); collect the seal (1). Disconnect the lambda sensor (27) from main wiring harness (Sect. P1, Arrangement of wiring on frame).
Page 308 Exhaust system Refitting the exhaust system Change the seals (1). Refit the horizontal exhaust pipe (5) and the vertical exhaust pipe (6) to the heads. Tighten the nuts (4) securing the flanges to the heads to the specified torque (Sect. C 3, Frame torque settings).
Page 309 Exhaust system Install the four vibration damping pads (9) – if they have been removed, on both sides of the footpeg plate (A). Fit the bushes (20) into the silencer brackets (19) and (13). Rest the silencer brackets against footpeg plates (A) and insert the bushes (10) fully home. Insert the screws (11).
Page 310 Exhaust system Position the clamps (8) retaining the silencers to the exhaust pipe so that the screws are parallel to the axis of the exhaust pipe slots (B). The clamps (8) should be flush with the exhaust pipes and the slots (B) should be partially covered. Tighten the clamps (8) to the specified torque (Sect.
Page 311 Exhaust system file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_L8_10_00.52.1.html (9 of 9) [10/7/2008 8:44:55 PM]...
Page 312 Description of the fuel injection-ignition system 1 - Description of the fuel injection-ignition system General information on the fuel injection-ignition system Integrated electronically controlled ignition and injection piloted by just one control unit ensure optimal i.c. engine performance and output, thus reducing consumption and harmful substances into the exhaust gas.
Page 313 Description of the fuel injection-ignition system file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_M_1_3_00.55.1.html (2 of 8) [10/7/2008 8:44:59 PM]...
Page 314 Description of the fuel injection-ignition system Marelli injection-ignition system (I.A.W.) The Marelli injection-ignition system is the Alfa/N type, in which the engine speed and throttle position are used as main parameters for measuring the quantity of intake air. If the quantity of air is known, the quantity of fuel is dosed in accordance with the required mixture.
Page 315 Description of the fuel injection-ignition system For testing the components and relative wiring of the injection-ignition system, use the "DDS", following the indications under "Guided diagnosis" (Sect. D 5). Legend to sensor position diagram 1 Coil (horizontal cylinder) 2 Electronic control unit 3 Coil (vertical cylinder) 4 Spark plug 5 Throttle position sensor...
Page 316 Description of the fuel injection-ignition system Fuel circuit A pump located on a flange at the bottom of fuel tank pumps fuel into delivery tube (OUT) and toward injectors. The flange also fits the pressure regulator controlling fuel feed and keeping it constant at a value higher than engine-generated vacuum.
Page 317 Description of the fuel injection-ignition system Intake air circuit The air circuit consists of two intake manifolds (1), a throttle body (2) and an airbox (3) installed over the throttle body. file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_M_1_3_00.55.1.html (6 of 8) [10/7/2008 8:44:59 PM]...
Page 318 Description of the fuel injection-ignition system The engine control system (ignition and injection) relies on several sensors which correct mixture strength according to air pressure and temperature and engine load. An absolute air pressure and temperature sensor (4) -onto headlight support RH side- takes atmospheric pressure values and sends them to the ECU for necessary correction of injected fuel if riding on variable sea-level roads.
Page 319 Description of the fuel injection-ignition system A throttle position sensor (6) is fitted onto the rear cylinder throttle shaft. It sends to ECU an indirect signal of air amount taken in by the engine (indirect value for engine load). Operating stages Normal operation When the engine is fully warm, the unit calculates injection time and advance, by comparing the stored map values, in accordance with the RPM and throttle position.
Page 320 Injection - ignition system 2 - Injection - ignition system Following is a list of injection-ignition system electrical components: indicated reference number refers to diagram in Sect. P 1, Wiring diagram key: Fuel injection-ignition system diagram key 13 Fuse box 14 Starter contactor 15 Battery 16 Tank...
Page 321 Fuel injection-ignition system components 3 - Fuel injection-ignition system components Electronic control unit Engine ECU (1) is an electronic digital microprocessor-based unit. It controls both injectors and coils, thus controlling injection and ignition depending on engine operating conditions as detected by the following sensors. - Absolute pressure sensor for atmospheric pressure - Air temperature sensor for temperature of intake air - Engine temperature sensor for engine oil temperature...
Page 322 Fuel injection-ignition system components Unscrew the other screw (3) and remove the control unit. Refitting the electronic control unit Position the control unit to the battery mount (5) (on the right side of the motorcycle) and start the two screws (3) in their holes. Place the ground cable (4) under the rear screw as shown in the figure.
Page 323 Fuel injection-ignition system components Warning The control unit is in the correct position when the lugs (A) are pointing to the right (viewing the motorcycle from rider position). Tighten the screws to the specified torque (Sect. C 3, Engine torque settings).
Page 324 Fuel injection-ignition system components Caution If the control unit is replaced, it is necessary to use the DDS and carry out the procedure for Zero setting the throttle position sensor (TPS) (Sect. D 5). Make sure the clip (B) for connector (1) is “released” (as shown in the diagram). Push the connector axially fully home into the control unit.
Page 325 Fuel injection-ignition system components Electric injector Injectors (1) deliver the right amount of fuel for trouble-free engine operation. The ECU controls power supply to a winding, which creates a magnetic field attracting an armature and causing fuel injection. Assuming that fuel properties such as viscosity and density as well as injector delivery and pressure head -which is controlled by fuel pressure regulator- do not change over time, the amount of injected fuel depends on injector opening time.
Page 326 Fuel injection-ignition system components The injector is made up of a body (2) and a needle (3) which is connected to the armature (4). The needle is pressed against the seat by a helical spring (5), whose loading is determined by an adjustable pushrod (6).
Page 327 Fuel injection-ignition system components The outer surface of the zirconium dioxide element is exposed to the exhaust gas, whereas the inside is vented to the atmosphere. Both the inner and outer surfaces are coated with a thin layer of platinum. Oxygen ions flowing through the ceramic electrically charge the platinum layer, which acts as an electrode and produces a measurable voltage;...
Page 328 Fuel injection-ignition system components To refit, tighten the sensor to the specified torque (Sect. C 3, Frame torque settings). Air temperature / pressure sensor This sensor is powered by the electronic unit. It supplies information about the absolute air pressure in a neutral area of the motorbike and measures temperature.
Page 329 Fuel injection-ignition system components Spark plugs Blow spark plug recesses with compressed air to remove any dirt. Take out spark plug caps (1) on both heads and remove spark plugs. Take care not to let any foreign body enter the combustion chambers. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_M_3_3_00.57.1.html (9 of 15) [10/7/2008 8:45:06 PM]...
Page 330: Thread
Fuel injection-ignition system components Caution Check gap between centre and side electrodes. If gap is outside the specified limits or in case of carbon deposits on spark plug surface, change spark plug. Screw the spark plug in by hand until the full thread is into the head. Tighten it to the specified torque (Sect.
Page 331 Fuel injection-ignition system components that calculates the ignition advance. The power module (built into the electronic control unit) also guarantees constant coil charge, operating on the dwell angle. Horizontal head coil (1) is placed under the airbox. Remove the airbox (Sect L 7, Removing the airbox) to gain access to the coil.
Page 332 Fuel injection-ignition system components Note To check operation of these items, use the DDS, please refer to "Guided diagnosis" (Sect. D 5). Throttle position sensor This sensor is powered by the electronic unit to which it sends a signal that identifies the position of the throttle.
Page 333 Fuel injection-ignition system components Rpm/timing sensor This is an inductive sensor. This sensor is facing the timing gear and can read the 46 teeth and the gap equal in size to 2 teeth. The signal from the pick-up sensor -facing the timing layshaft gear- is used by the control unit for calculating engine rotation speed and timing reference values.
Page 334 Fuel injection-ignition system components Main and injection relays Relay (1) is located next to the battery and is fixed to battery support. To remove the relay, first lift the fuel tank (Sect. L 2, Removing the fuel tank). Disconnect the relay from the electric system and power contacts (86) and (85) (small contacts) with 12 V (battery).
Page 335 Fuel injection-ignition system components close to zero and, if available, a continuity beep should be heard. If not, replace checked part. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_M_3_3_00.57.1.html (15 of 15) [10/7/2008 8:45:07 PM]...
Page 336 Injection - ignition system 0Injection - ignition system 1 - Description of the fuel injection-ignition system General information on the fuel injection-ignition system 3 Fuel circuit 6 Intake air circuit 7 Operating stages 9 2 - Injection - ignition system 3 - Fuel injection-ignition system components Electronic control unit 11 Electric injector 15...
Page 337 Removing - reassembling the complete engine 1 - Removing - reassembling the complete engine 1 Blanking plug 2 Front mounting bolt 3 Nut 4 Rear mounting bolt 5 Engine Spare parts catalogue Half crankcases Frame Swingarm and chain Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 338 Removing - reassembling the complete engine Removing the engine To remove the engine, you first have to remove other components from the bike. Most disassembly procedures for these components are described in the relevant sections. The following diagram is a logical disassembly sequence of the parts to be removed and makes reference to the relevant sections describing the specific disassembly procedures.
Page 339 Removing - reassembling the complete engine Put a stand under the engine to support it during removal. Undo and remove the nuts (3) on the left side at the engine front mounting bolt (2) and rear bolt (4). Remove the front mounting screw (2) from engine right side. Loosen swingarm clamp screws (A).
Page 340 Removing - reassembling the complete engine Slide out the rear screw (4) up to half its length and insert the suitable support part no. 88713.1515 on the left side. Tighten screw (A) onto swingarm left clamp, in this way you also tighten the support part no. 88713.1515. Completely remove swingarm shaft (A) and the upper screw (4).
Page 341 Removing - reassembling the complete engine Tighten the nuts (3) to the specified torque (Sect. C 3, Engine torque settings). file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_1_9_00.59.1.html (5 of 5) [10/7/2008 8:45:10 PM]...
Page 342 Lubrication system: oil pump 2.1 - Lubrication system: oil pump 1 Complete oil pump 2 O-ring 3 Circlip 4 O-ring 5 Pump body 6 Circlip 7 Reduction bush 8 Spring washer 9 Screw 10 Screw 11 Spring washer 12 Pump control gear 13 Bush 14 By-pass valve cap 15 Centring bush...
Page 343 Lubrication system: oil pump Spare parts catalogue Filters and oil pump Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Lubrication system file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_2A9_00.60.1.html (2 of 7) [10/7/2008 8:45:14 PM]...
Page 344 Lubrication system: oil pump Description of the lubrication system Forced lubrication by gear pump. Built-in pressure relief by-pass valve. Mesh intake filter. Disposable filter cartridge on intake with safety valve preventing cartridge clogging. Low oil pressure indicator on instrument panel. Lubrication system components: A Mesh filter B By-pass spring...
Page 345 Lubrication system: oil pump The breather circuit for vapours built into the engine block includes a reed breather valve at right casing top, a collection tank and a connection line. Removing the oil pump Operations Reference See Section Remove the clutch cover N 6.2, Removing the clutch cover Undo and remove the screws (9) and (10) fixing the complete pump.
Page 346 Lubrication system: oil pump Warning Make sure that vice jaws are duly protected. Remove plug (14) and slide out spring (16) and by-pass valve (17). Check for proper operating conditions. Remove the circlip (6), withdraw the bush (13) and remove the snap ring (3). Remove the pump control gear (12).
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Lubrication system: oil pump Reassembling the oil pump gear Insert pump driving gear (12), snap ring (3) and bushing (13) onto oil pump. Fit the circlip (6) into its seat to lock the components in place. Insert by-pass valve (17) and spring (16) into pump then tighten plug (14) to the specified torque (Sect. C 3, Engine torque settings) applying a medium-strength threadlocker.
Page 348 Lubrication system: oil pump Place the oil pump on the casing and tighten the screws (9) and (10) to the specified torque (Sect. C 3, Engine torque settings). Secure dial gauge part no. 88765.1058 provided with a special pointer on the casing to check the meshing clearance with the crankshaft sprocket.
Page 349 Lubrication system: oil breather reservoir 2.3 - Lubrication system: oil breather reservoir 1 Screw 2 Washer 3 Oil breather tank 4 Hose 5 Clamp 6 Oil breather valve 7 Clamp 8 O-ring 9 Clamp Spare parts catalogue Air inductio and oil vent Caution Bold reference numbers in this section identify parts shown in this exploded view diagram.
Page 350 Lubrication system: oil breather reservoir in the figures near the text. Removing the oil breather tank Operations Reference See Section Remove the seat E 3, Removing the seat Remove the fuel tank L 2, Removing the fuel tank Loosen the clip (7) of the connection hose to the airbox and disconnect hose. Loose the clip (9) of the connection hose (4) to the oil breather valve (6) and disconnect hose from the oil filter valve.
Page 351 Lubrication system: oil breather reservoir Refitting the oil breather tank In particular, in case hose (4) is changed, we recommend you to secure it to oil breather reservoir (3) by tightening clamp (7) to the specified torque (Sect. C 3, Frame torque settings), and then to secure it to breather valve (6) tightening clamp (5) to the specified torque (Sect.
Page 352 Lubrication system: oil breather reservoir Note During removal and installation, keep the hose clips orientated as originally fitted. Operations Reference See Section Refit the fuel tank L 2, Refitting the plastic fuel tank Refit the seat E 3, Refitting the seat file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_2C9_00.61.1.html (4 of 4) [10/7/2008 8:45:17 PM]...
Page 353 Head unit: checks and adjustments 4.1 - Head unit: checks and adjustments 1 Closing shim 2 Camshaft 3 Opening shim 4 Valve Spare parts catalogue Head : timing Vertical head Horizontal head Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 354 Head unit: checks and adjustments Checking and adjusting valve clearance Operations Reference See Section Remove valve covers N 4.3, Removing the valve covers Remove timing belt covers N 4.2, Removing the timing side covers Note For reasons of clarity, the figures show an engine block removed from the frame. Take off the inspection cover on generator side and install tool part no.
Page 355 Head unit: checks and adjustments Reset the degree wheel of tool part no. 88713.0123: the horizontal piston is at TDC in the combustion stroke and therefore you can proceed with checking valve clearance on this cylinder head. To measure valve clearance in the vertical cylinder, rotate the crankshaft counterclockwise through 270°. This will bring the vertical piston at TDC during the combustion stroke that is the correct position for checking valve clearance on this cylinder head.
Page 356 Head unit: checks and adjustments Checking closing clearance (Sc) at exhaust/intake When checking closing clearance, use a screwdriver to overcome the preload of closing rocker arm spring, thus taking up any clearance between camshaft and rocker arm. Fit the feeler gauge between closing rocker arm (D) and shim (1): closing clearance (Sc) corresponds to gauge thickness when it allows the shim to freely turn, with no remarkable play.
Page 357 Head unit: checks and adjustments Checking valve lift Fit dial gauge (C) part no. 88765.1058 into the hole of the head cover, as shown. With the camshaft at rest position, take up valve opening clearance fitting a suitably sized feeler gauge between upper rocker arm and opening shim.
Page 358 Head unit: checks and adjustments Note This operation is best done using one dial gauge for the exhaust valve and another one for the intake valve. Make sure the dial gauge fork is centered with valve axis and contacts the closing shim collar. Set dial gauge to zero when the valve is fully closed.
Page 359 Head unit: checks and adjustments Note Engine timing should be checked after replacing such component parts as camshafts, valves or timing belt rollers or when overhauling badly worn engines. Remove the spark plugs and fit tool (E) part no. 88765.1297 in the spark plug hole and determine piston top dead center with gauges (C) part no.
Page 360 Head unit: checks and adjustments Turn degree wheel (G) counter clockwise until dial gauge (C) placed at the exhaust end reads 1 mm lift. Check that angle reading in degrees on the degree wheel (G) is as specified (Sect. C 1.1, Timing/valves). Rotate in the same direction until obtaining 1 mm lift on the intake end.
Page 361 Cylinder heads: side covers / timing system 4.2 - Cylinder heads: side covers / timing system 1 Vertical timing belt cover 2 Horizontal timing belt cover 3 Screw 4 Screw 5 Screw 6 Elastic-stop ring nut 7 Washer 8 Outer timing belt roller 9 Horizontal cylinder toothed belt 10 Middle washer 11 Fixed tensioner assembly...
Page 362 Cylinder heads: side covers / timing system 19 Circlip 20 Bearing 21 Complete tensioner 22 Screw 23 Washer 24 Screw 25 Circlip 26 Key 27 Key 28 Vertical cylinder toothed belt 29 Inner timing belt roller Spare parts catalogue Timing Head : timing Caution Bold reference numbers in this section identify parts shown in this exploded view diagram.
Page 363 Cylinder heads: side covers / timing system Disassembling the timing system Loosen the locating screw (24) of the tensioner (21) of the horizontal cylinder timing belt. Loosen screw (22) securing the horizontal cylinder tensioner, collect washer (23) and move tensioner (21) to its rest position.
Page 364 Cylinder heads: side covers / timing system Repeat the sequence for the timing belt (28) of the vertical cylinder. To remove belt rollers from cylinder head, install tool part no. 88713.2107 to the belt roller to lock rotation, as shown. Fit the bush of tool part no. 88700.5644 to a torque wrench and slacken the belt roller ring nut (13). Remove ring nut (13), washer (14) and belt roller (16).
Page 365 Cylinder heads: side covers / timing system Remove the locating screws (24) and the retaining screws (22) of the timing belt tensioners (21) and washer (23). Remove both tensioners (21). Note The belt tensioners may also be removed leaving the belts in place. Unscrew and remove the fixed tensioners (11).
Page 366 Cylinder heads: side covers / timing system Remove ring nut (6), washer (7) and outer belt roller (8). Remove the first key (27) on the timing layshaft. Remove middle washer (10) and inner belt roller (29). After having removed the inner belt roller (29), remove the second key (26) on the timing layshaft. Remove the circlip (25).
Page 367 Cylinder heads: side covers / timing system Disassembling the mobile tensioner Remove the circlip (19) to release the bearings (20). Check that the tensioner bearings rotate freely without exceeding play. Install bearings (20) into plate (21), take them fully home. Install the snap ring (19) in its seat (A) on pin (21). Disassembling the belt rollers Loosen and remove the three screws (12).
Page 368 Cylinder heads: side covers / timing system Reassembling the timing system Reassembling the timing belt rollers on camshafts Ensure that keyway on camshaft end is in good condition and with no burrs. Install a key (C) into camshaft keyway, if previously removed. Assemble the components fitting belt roller (B) and washer (15) on flange (17) as shown, use reference marks to ensure correct positioning.
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Cylinder heads: side covers / timing system Use tool part no. 88713.2107 to prevent belt roller rotation. Smear a film of recommended grease on ring nut (13) thread and underside, then fit washer (14) and ring nut. Caution At reassembly, always use new ring nuts. Fit the bush of tool part no.
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Cylinder heads: side covers / timing system Reassembling timing belt rollers on layshaft Working from the belt roller side, fit circlip (25) on the timing layshaft. For correct circlip positioning, insert a protection cap part no. 88700.5749 on the end of the timing shaft. Fit the first key (26), the inner belt roller (29) with the projecting hub pointing outwards and the guide washer (10) on the timing layshaft.
Page 371: Thread
Cylinder heads: side covers / timing system Use the spanner of service tool part no. 88700.5644 to lock belt roller rotation. Fit the bush supplied with the tool to a torque wrench and tighten the self-locking ring nut to the specified torque value (Sect. C 3, Engine torque settings).
Page 372 Cylinder heads: side covers / timing system Rotate the crankshaft until bringing the piston of the horizontal cylinder at TDC during the combustion stroke. This is indicated by the mark (A) on the timing layshaft belt roller (8) aligning with the mark (B) on the clutch cover. Unscrew the two screws (D) and remove the small cover (C) from the generator cover.
Page 373 Cylinder heads: side covers / timing system Fit the locking tool part no. 88713.2011 to the crankshaft and tighten by hand pin (E) fully home. Tighten the two tools part no. 88713.2009 as shown in the figure to lock the flanges (17) of the horizontal and vertical belt rollers (16).
Page 374 Cylinder heads: side covers / timing system Check the tensioning and adjust, if necessary, as described in “Checking and adjusting timing belt tension” (Sect. D Warning Check tension reading on the belt sections (H) and (G) indicated in the figure. Set desired tension and ensure that screws (22), (24) and (12) are tightened to the specified torque (Sect.
Page 375 Cylinder heads: side covers / timing system Warning Every time a timing part is replaced, it is good practice to check the timing (Sect. N 4.1, Checking engine timing). Remove the two locking tools (88713.2009) from belt roller flange. Remove the tool part no. 88713.2011 you used to lock the crankshaft. Unscrew the tool bolt (E). Refit the small cover (C) to the generator cover and start the two screws (D) in their holes.
Page 376 Cylinder heads: side covers / timing system Tighten the screws to the specified torque (Sect. C 3, Engine torque settings). Note Before refitting cover (C), check its O-for wear and replace it as necessary. Refitting the timing side covers Position the cover of the horizontal timing belt (2) to the engine. Start the screws (5) and the screws (3) in their holes in the cover and tighten to the specified torque (Sect.
Page 377 Cylinder heads: side covers / timing system Operations Reference See Section Refit the fuel tank L 2, Refitting the plastic fuel tank file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_4B9_00.63.1.html (17 of 17) [10/7/2008 8:45:27 PM]...
Page 378 Head unit: camshafts 4.3 - Head unit: camshafts 1 Screw 2 Vertical rubber cap 3 Seal 4 Roller spacer 5 Bearing 6 Horizontal rubber cap 7 Screw 8 Valve cover 9 Valve cover gasket 10 Vertical head 11 Horizontal head 12 Stud bolt 13 Stud bolt 14 Circlip...
Page 379 Head unit: camshafts 19 Bearing 20 Cap 21 Screw 22 Horizontal head camshaft 23 Copper gasket 24 Screw 25 Intake valve cover 26 Circlip 27 Spacer 28 Aluminium gasket 29 Ring nut 30 O-ring 31 Sensor mount 32 Sensor 33 Nut 34 Intake duct 35 O-ring 36 Rubber cap...
Page 380 Head unit: camshafts Unscrew the ring nut (29) from the cover (25). Remove the circlip (26) from the ring nut and withdraw the sensor mount (31). Refitting the engine oil temperature sensor Check seal (28) and spacer (27). Replace as required. Note Change the O-rings (30) before refitting.
Page 381 Head unit: camshafts Installation is a reversal of the removal procedure. Operations Reference See Section Reconnect oil temperature sensor to P 1, Arrangement of wiring on frame main wiring harness Disassembling the intake manifold Operations Reference See Section Remove the throttle body L 6, Removing the throttle body Note...
Page 382: Thread
Head unit: camshafts Refitting the intake manifolds Smear some recommended threadlocker on stud bolts (12) and (13), install them to heads (10) and (11) and tighten to the specified torque (Sect . C 3, Engine torque settings). Check the O-ring (35) and replace it if worn. Smear O-rings (35) with engine oil, position the intake manifolds (34) and secure them with nuts (33).
Page 383 Head unit: camshafts Tighten the nuts (33) to the specified torque (Sect. C 3) Operations Reference See Section Fit the throttle body L 6, Refitting the throttle body Removing the cam covers Operations Reference See Section Remove the airbox L 7, Removing the airbox Remove the battery mount P 2,...
Page 384 Head unit: camshafts Note Be careful not to displace the keys (15) in the camshafts (16) and (22) when removing the belt rollers. Unscrew the retaining screws (21) of the cover (20) supporting camshaft (16) and (22). Take off the cam cover (20) and its gasket (17). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_4C9_00.64.1.html (7 of 18) [10/7/2008 8:45:35 PM]...
Page 385 Head unit: camshafts Disassembling the cam cover Remove the circlip (18) that holds the bearing in place. Remove the camshaft bearing (19) from the cam cover using a suitable puller. Caution Do not reuse the bearings after removal. Reassembling the cam cover Install the bearing (19) with the shielded side (A) outward.
Page 386 Head unit: camshafts Removing the valve covers To remove the cover on the exhaust side (8) of vertical head (10), loosen screws (7) and collect the gasket (9). To remove the cover on the intake side (8) of vertical head (10), loosen pegs (37) and collect the gasket (9). To remove the cover on the exhaust side (8) of horizontal head (11) and the cover on intake side (25) of horizontal head (11), loosen screws (7) and collect the gaskets (9).
Page 387 Head unit: camshafts Refitting the valve covers Check valve cover gaskets (9) for wear and replace if needed. Position the valve covers (8) and (25) with the gaskets (9) to the heads. Note The cover on intake side (8) of vertical head (10) is secured with pegs (37), while exhaust cover is secured with screws (7).
Page 388 Head unit: camshafts Rotate the camshaft (16) until finding a position at which cams will not contact the rocker arms. This will avoid damage to the components during removal. Extract the vertical head camshaft (16) from its seat. Remove the spacer (4) from the seal (3). Remove the seal (3) from the head.
Page 389 Head unit: camshafts Remove the circlip (14) using suitable tweezers. Use a drift to remove the bearing (5) supporting the camshaft (16). Check bearing (5) and circlip (14) for wear and replace as required. Warning When the bearing is removed, it shall be renewed. Checking the camshafts Check that the contact surfaces of the cams are free from scratches, grooves, steps and waving.
Page 390 Head unit: camshafts Note Actual deviation is half the gauge reading. The camshaft is marked as follows: O: horizontal V: vertical Checking the oil seals Change oil seals at each cylinder head overhaul. Install new seals using suitable tools. Lubricate oil seal lip after installation. This operation requires the utmost care.
Page 391 Head unit: camshafts Checking the bearings Before a dimensional check, inspect bearing for wear. Do this manually with the bearing installed. Turn the inner ring in both directions: it should run smoothly and quiet, without jamming. Push the inner ring outwards at different positions to check for play. Remove any bearings which run hard or are noisy or have play.
Page 392 Head unit: camshafts Install seal (3) as shown. Insert the spacer (4) into the seal (3) and push it until it contacts the bearing (5). Note Ensure that spacer (4) faces the seal so as not to damage it. Caution If you have left the rocker arms in place in the head (Sect.
Page 393 Head unit: camshafts Please refer to "Checking the camshafts". Insert the camshaft (16) from the left side of the head (10). Push camshaft through spacer (4) until it becomes seated into the bearing (5). Check key (15) and keyway for wear and then fit it. Refitting the cam covers Note Check gasket (17) and replace if worn.
Page 394 Head unit: camshafts Secure the cam cover (20) using the screws (21). Tighten the screws (21) to the specified torque (Sect. C 3, Engine torque settings). Note Pay attention to the key (15) in the camshaft (16). Position the horizontal head cover (2) to the left side of head and insert the retaining screws (1). Tighten the screws (1) to the specified torque (Sect.
Page 395 Head unit: camshafts Repeat procedure for the other head. Operations Reference See Section Refit the timing belt rollers to the N 4.2, Reassembling the timing heads system Refit the timing belts and timing belt N 4.2, Refitting the timing side covers covers Refit the battery mount P 2,...
Page 396 Head unit: valves - rocker arms 4.4 - Head unit: valves - rocker arms 1 Clip 2 Shim 3 Opening rocker arm 4 Rocker arm shaft 5 Shim 6 Valve opening shim 7 Split rings 8 Valve closing shim 9 Spring 10 Exhaust valve seal 11 Exhaust valve guide 12 Intake valve seal...
Page 397 Head unit: valves - rocker arms 19 Nut 20 Washer Spare parts catalogue Half crankcases Vertical head Horizontal head Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Disassembling the engine heads Operations Reference See Section...
Page 398 Head unit: valves - rocker arms Slide the complete head off the stud bolts and remove it from the engine block. Removing the valves Operations Reference See Section Remove valve covers N 4.3, Removing the valve covers Slip off the clip (1) of the opening rocker arm (3). Fit tool part no.
Page 399 Head unit: valves - rocker arms Move the rocker arm (3) aside to release the valve opening shim (6). Using two screwdrivers, lock the closing rocker arm (18) with valve open: for position (A) set screwdriver under closing rocker arm, while for position (B) push onto closing rocker arm along valve axis. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_4D9_00.65.1.html (4 of 23) [10/7/2008 8:45:44 PM]...
Page 400 Head unit: valves - rocker arms Slide the valve closing shim (8) along intake valve stem (17) to expose the two split rings (7) that retain the valve. Remove the split rings (7) from valve stem using tweezers. Remove the valve closing shim (8) from the valve (17). Withdraw the valve (17) from the bottom end of head.
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Head unit: valves - rocker arms Removing the valve rocker arms Operations Reference See Section Remove the camshaft covers N 4.3, Removing the cam covers Remove the clip (1) from the rocker arm shaft (4). Screw the tool part no. 88713.1994, featuring M5 pin, on the thread of the opening rocker arm shaft (4). Withdraw the rocker arm shaft (4).
Page 402 Head unit: valves - rocker arms Hook the end of the spring (9) of the closing rocker arm (18) to tool part no. 88713.2362. Remove the closing rocker arm shaft (4) using tool part no. 88713.1994. Collect the two shims (5). Remove rocker arm (18), spring (9) and tool part no.
Page 403 Head unit: valves - rocker arms Overhauling the head parts Overhauling the heads Remove the carbon deposits from the combustion chamber and relevant ducts. Check that there are no cracks and that there are no grooves, steps or damage of any kind on the sealing surfaces. Mating surface to cylinder must be perfectly flat.
Page 404 Head unit: valves - rocker arms Checking the valve Check that the stem and the surface that contacts the valve seat are in good condition. There must be no pitting, cracks, deformations or signs of wear. Check the following: measure the diameter of the stem (B) at various positions along the portion that runs in the valve guide.
Page 405 Head unit: valves - rocker arms Checking the valve seat Visually inspect valve seats: they must not show any signs of pitting or cracks. If the seat is slightly damaged, mill the seat, using suitable 45° cutters, then grind the valves and check valve sealing.
Page 406 Head unit: valves - rocker arms Note Valve guide and valve must always be replaced as a set. Intake valves use cast-iron guides. Exhaust valves use bronze guides. Checking valve - valve seat clearance Use Prussian blue or a mixture of minium and oil to measure the contact surface (W) between valve and seat. Correct size is 1.0-1.5 mm.
Page 407 Head unit: valves - rocker arms Changing valve seats Mill the worn seats to remove them. Ensure that you do not damage the valve seat location on the head. Check the diameter of the housings in the head and choose an adequately oversized valve seat to obtain an interference fit to head of 0.11-0.16 mm.
Page 408 Head unit: valves - rocker arms Overhauling the rocker arms Check that contact surfaces are in perfect condition. Check for signs of wear, grooves or pitting. Check condition of rocker arm bore and shaft. Nominal rocker arm bore diameter: 10.040-10.062 mm Nominal rocker arm shaft diameter: 10.001-10.010 mm Check that the contact surfaces of opening and closing shims are flat and show no signs of wear.
Page 409 Head unit: valves - rocker arms Rocker arm shaft-to-rocker clearance Assembly clearance should be 0.03-0.06 mm. Service limit: 0.08 mm. Rocker arm shaft should be a tight fit in the head. If it is loose, install the 0.02 mm oversized shaft available from the Spare Parts Department. Checking the rocker arm springs Check condition of closing rocker arm return springs.
Page 410 Head unit: valves - rocker arms Reassembling the head Reverse the disassembly sequence. Pay particular attention to the operations described below. It is very important to carefully clean all components. Fit the oil seal (12) and (10) to the valve guide. Oil seals are colour-coded as follows: - green seal for the exhaust valve - black seal for the intake valve.
Page 411 Head unit: valves - rocker arms Refitting the rocker arms Fit the closing rocker arm (18) and its spring (9) to the tool part no. 88713.2362. Insert the assembled tool-rocker arm-and-spring into the head and install the pin part no. 88713.0262 to hold assembly in place.
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Head unit: valves - rocker arms Minimum operating clearance between valve stem and rocker arm: 0.15 mm. Operating axial play of closing rocker arm: 0.05 – 0.20 mm. Remove tool part no. 88713.0262 and insert the rocker arm shaft (4). Caution Install the rocker arm shafts (4) with the threaded hole end (B) pointing outwards.
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Head unit: valves - rocker arms Place the shims (2) at both sides of the clip (1). Axial play of opening rocker arm: 0.05 – 0.20 mm After shimming, remove tool part no. 88713.0262 and position the shaft (4) with the threaded hole end (B) pointing outwards.
Page 414 Head unit: valves - rocker arms Operations Reference See Section Refit the camshaft covers N 4.3, Refitting the cam covers Refitting the valves Fit the valves (16) and (17) into the head. Using two screwdrivers, lock the closing rocker arm (18) with valve open: for position (A) set screwdriver under closing rocker arm, while for position (B) push onto closing rocker arm along valve axis.
Page 415 Head unit: valves - rocker arms Fit the split rings (7) to the valve stem. Remove the two screwdrivers and place the closing rocker arm (18) in the rest position. With the valve in the rest position, push on the rocker arm to counteract return spring action and check clearance between rocker arm sliding shoe and closing shim (Sect.
Page 416 Head unit: valves - rocker arms Position the opening rocker arm (3) and secure it with the clip (1). With the valve in the rest position, check clearance between rocker arm (3) and shim (6) (Sect. N 4.1, Checking opening clearance (Sa) at intake/exhaust).
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Head unit: valves - rocker arms Slide the complete head on the stud bolts and push it down onto the cylinder. Insert the special washers (20) on the stud bolts with the sharp edge facing the head and the flat side pointing inwards.
Page 418 Head unit: valves - rocker arms Fit tool part no. 88713.2676 to a torque wrench and tighten the nuts to the specified torque in a cross sequence (Sect. C 3, Engine torque settings). Caution Follow the above procedure closely. Improper tightening may cause the stud bolts to stretch abnormally leading to severe engine damage.
Page 419 Cylinder / piston assy 5 - Cylinder / piston assy 1 O-ring 2 O-ring 3 Gudgeon pin 4 Vertical cylinder 5 Piston rings 6 Cylinder base gasket 7 Pin 8 Horizontal cylinder 9 Piston 10 Circlip 11 Locating dowel Spare parts catalogue Cylinders - pistons Alternator cover file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_5_9_00.66.1.html (1 of 13) [10/7/2008 8:45:50 PM]...
Page 420 Cylinder / piston assy Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing cylinder / piston assy Operations Reference See Section Remove the heads N 4.4, Disassembling the engine heads...
Page 421 Cylinder / piston assy Working from the opposite side, withdraw gudgeon pin (3) just enough to release the connecting rod. Lift the piston-cylinder assembly clear of the stud bolts. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_5_9_00.66.1.html (3 of 13) [10/7/2008 8:45:50 PM]...
Page 422 Cylinder / piston assy If you need to service the piston, lift gently until clear of the cylinder. Remove the gaskets (6) placed between cylinder and casing. Caution Mark the pistons with their positions so as to refit each piston to the matching cylinder on reassembly: V= Vertical - O= Horizontal Bring the vertical cylinder piston (9) to top dead centre using tool part no.
Page 423 Cylinder / piston assy Change the cylinder if damaged or excessively worn. The special silicon carbide coating applied to the inner bore provides excellent friction and wear resistance, but prevents grinding. The cylinders are marked with their class (a letter punched on the side of the cylinder). Always match cylinder and piston from the same class.
Page 424 Cylinder / piston assy Clean the crown of the piston and the piston ring grooves from carbon deposits. Inspect the dimensions of the piston carefully: there must be no signs of shrinkage, scoring, cracks or damage. Measure piston diameter (P) 10 mm above skirt base, at right angles to the axis of the gudgeon pin. Pistons must always be changed in pairs.
Page 425 Cylinder / piston assy Overhauling the gudgeon pins They must be perfectly smooth, without signs of scoring, steps or blueish stains due to overheating. The well- lubricated gudgeon pin must slide smoothly inside the piston. Assembly clearance must be: 0.002-0.008 mm Max allowed wear limit: 0.035 mm If you change the gudgeon pin, you must also change the connecting rod small end bush.
Page 426 Cylinder / piston assy Piston ring-piston groove clearance Top (1st) ring max. wear limit: 0.15 mm Other rings (2nd ring and scraper ring) wear limit: 0.10 mm Note The mark punched on piston rings must always be facing up. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_5_9_00.66.1.html (8 of 13) [10/7/2008 8:45:50 PM]...
Page 427 Cylinder / piston assy Checking the gudgeon pin-piston clearance Measure the diameter of the piston hole that accommodates the gudgeon pin. Measure gudgeon pin diameter. Wear limit: 0,025 mm Note If you change the gudgeon pin, you must also change the connecting rod small end bush. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_5_9_00.66.1.html (9 of 13) [10/7/2008 8:45:50 PM]...
Page 428 Cylinder / piston assy Piston rings-cylinder clearance It is important that piston ring (A) be perfectly square to cylinder during measurement. To this end, fit the piston (9) without the piston rings into the cylinder and place the piston ring to be measured on top of the piston. Measure the piston ring end gap: Top ring and second ring (nominal): 0.20 - 0.40 mm Wear limit: 0.80 mm.
Page 429 Cylinder / piston assy Lubricate cylinder inner bore with engine oil. Use an all-purpose tool to slide piston gently into cylinder with the smaller valve pocket placed at exhaust end. Clean off any carbon deposits and degrease the mating surfaces of engine casings and cylinders. Ensure that the engine block includes the cylinder centring pins (11).
Page 430 Cylinder / piston assy Push connecting rod small end into the piston so as to line up gudgeon pin (3) hole. Lubricate and fit gudgeon pin. Gudgeon pin must slide smoothly inside the con-rod small end bushing and piston (9). Block off casing opening with a cloth, then fit circlip (10).
Page 431 Cylinder / piston assy Caution Place the locating pins (7) with the smaller hole pointing away from cylinder. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_5_9_00.66.1.html (13 of 13) [10/7/2008 8:45:50 PM]...
Page 432 Clutch unit: APTC wet clutch 6.1 - Clutch unit: APTC wet clutch 1 Screw 2 Cap 3 Clutch control pin 4 Clutch spring 5 Pressure plate 6 Bearing 7 Clutch plates 8 Nut 9 Safety washer 10 Clutch drum 11 Shim 12 Spring 13 Hub Spare parts catalogue...
Page 433 Clutch unit: APTC wet clutch Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. APTC clutch unit description The APTC system is a clutch system with follow-up torque and slipper clutch design to eliminate rear wheel hop under braking.
Page 434 Clutch unit: APTC wet clutch A clutch which slips may be caused by: - insufficient play of the control lever; - worn clutch plates; - weakened springs; - faulty clutch mechanism; - excessive wear of the hub or clutch housing. A noisy clutch may be caused by: - excessive play between the primary drive gears;...
Page 435 Clutch unit: APTC wet clutch Lock the clutch housing with tool part no. 88713.2556 and loosen the nut (8). Remove the safety washer (9). Slide the hub-plates-drum assembly out of the housing (A), use tools part no. 88713.2591. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_6A9_00.67.1.html (4 of 12) [10/7/2008 8:45:55 PM]...
Page 436 Clutch unit: APTC wet clutch Remove the spacer (11) from the housing. Disassembling the hub-plates-drum assembly Remove the three tools part no. 88713.2591. Remove the hub (13) and the plates (7) from the drum (10). Collect the three springs (12). Remove the plates (7) from the hub (13).
Page 437 Clutch unit: APTC wet clutch Caution Keep the plates in the same order as originally fitted. You may find it convenient to tie the plates together while putting them on the bench. Checking and overhauling the APTC unit Clearance between clutch housing and drive plate Insert the drive plate (A) in the clutch housing (B) and measure clearance (S) with a feeler gauge.
Page 438 Clutch unit: APTC wet clutch Caution Overall thickness of the set of clutch plates should not be less than 50,2 mm. Place the plate on a flat surface and check the amount of deformation with a feeler gauge. Max flatness error: 0.2 mm. Overhauling the pressure plate Check bearing (6) condition.
Page 439 Clutch unit: APTC wet clutch Minimum length: 41 mm. Change any springs which are shorter than that. Reassembling the hub-plates-drum assembly Fit the three springs (12) on pin (A) onto drum (10). Fit the clutch plates (7) on hub (13), start with one of the 11 driving plates (B) alternated with the 10 driven plates (C).
Page 440 Clutch unit: APTC wet clutch Insert the three tools part no. 88713.2591 and secure the hub (13) to the drum (10). Screw in the three tools part no. 88713.2591 by hand, press with a hand on the clutch plate pack and hub (13) to overcome the springs (12) load.
Page 441 Clutch unit: APTC wet clutch Note Fit the last clutch plate (A) so that is it "offset" with respect to the others. Fit the safety washer (9) to the primary shaft. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_6A9_00.67.1.html (10 of 12) [10/7/2008 8:45:55 PM]...
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Clutch unit: APTC wet clutch Smear recommended grease onto nut (8) thread and primary shaft thread, then fit the nut finger tight onto primary shaft. Lock clutch housing with tool part no. 88713.2556, so to hold it while tightening nut (8). Tighten the nut (8) to the specified torque (Sect.
Page 443 Clutch unit: APTC wet clutch Insert one spring (4) and one washer (2) in each recess. Tighten the screws (1) to the specified torque (Sect. C 3) in a cross sequence. Remove tool part no. 88713.2556. Operations Reference See Section Refit the clutch cover N 6.1, Refitting the clutch cover...
Page 444 Clutch unit: clutch cover 6.2 - Clutch unit: clutch cover 1 Cover, clutch side 2 Screw 3 Screw 4 Oil sight glass 5 Screw 6 Panel (BLACK) 7 Screw 8 Bush 9 Seal 10 Shim 11 Circlip 12 O-ring 13 Centring bush 14 O-ring 15 Blanking plug 16 Washer...
Page 445 Clutch unit: clutch cover 19 Screw 20 Seal, thk. 2 21 Pressure switch 22 Mount Spare parts catalogue Clutch cover Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 446 Clutch unit: clutch cover Take off clutch cover (1) and collect the locating bush (13). Check locating bush (13). Replace if distorted. Disassembling the clutch cover Unscrew the six retaining screws (19) of the inner cover (17). Remove inner cover (17) and sound-deadening panel (6). file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_6B9_00.68.1.html (3 of 8) [10/7/2008 8:45:59 PM]...
Page 447 Clutch unit: clutch cover Remove the circlip (11) and withdraw the shim (10) and the seal (9). The drilled bush (8) is an interference fit in the cover. Remove with a suitable puller. Visually inspect the seal (9) and replace as required. Remove the plug (15) and its O-ring (14), the engine oil pressure switch (21) and its seal (20) from the cover.
Page 448 Clutch unit: clutch cover Reassembling the clutch cover Fit the plug (15) and the seal (14). Install the pressure switch (21) and the seal (20). When fitting a new bush (8), drive it fully home into the clutch cover seat using a press and a suitable drift. Position the sound-deadening panel (6) inside the clutch cover (1) as shown in the figure.
Page 449 Clean and degrease mating surfaces on cover and casing and ensure that the centring bush (13) and the O-ring (12) at the lubrication drill are fitted in the casing. Apply an even, regular bead of DUCATI liquid gasket (A) on the mating surface of the casing and around all holes. file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_6B9_00.68.1.html (6 of 8) [10/7/2008 8:45:59 PM]...
Page 450 Clutch unit: clutch cover Locate the complete cover (1) to the casing and start the retaining screws in their holes. Tighten the screws (2), (3), (5) and (7) to the specified torque (Sect. C.3, Engine torque settings) in a cross sequence. Note Refit the cable guide (22), bush (18) and washer (16).
Page 451 Clutch unit: clutch cover Fill engine with oil D 4, Changing the engine oil and filter cartridge file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_6B9_00.68.1.html (8 of 8) [10/7/2008 8:45:59 PM]...
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Clutch unit: primary gears 6.3 - Clutch unit: primary gears 1 Clutch housing/Primary drive gears 2 Inner ring 3 Inner bearing 4 Spacer 5 Threaded ring nut 6 Safety washer Spare parts catalogue Clutch Clutch cover Crankshaft Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_6C9_00.69.1.html (1 of 8) [10/7/2008 8:46:02 PM]...
Page 453 Clutch unit: primary gears in the figures near the text. Disassembling the primary drive gears Operations Reference See Section Drain engine oil D 4, Changing the engine oil and filter cartridge Remove the clutch cover N 6.2, Removing the clutch cover Remove the clutch N 6.1, Disassembling the APTC...
Page 454 Clutch unit: primary gears Unbend the safety washer (6) onto ring nut (5) securing the driving gear of primary transmission (B). Hold the primary drive gear (B) using wrench part no. 88713.2423 and release the sprocket ring nut (5) using bush file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_6C9_00.69.1.html (3 of 8) [10/7/2008 8:46:02 PM]...
Page 455 Clutch unit: primary gears part no. 88713.2422. Remove the ring nut (5) and the safety washer (6). Remove the driving gear of primary transmission (B) using the puller part no. 88713.2092; fit an aluminium or brass plate between puller screw and crankshaft. file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_6C9_00.69.1.html (4 of 8) [10/7/2008 8:46:02 PM]...
Page 456 Clutch unit: primary gears Do not damage the key (C) onto the crankshaft and the inner spacer. Refitting the primary drive gears and checking meshing play Degrease the taper end of the crankshaft and the mating surface on the primary drive gear accurately. Check that the key (C) and inner spacer (D) are correctly fitted to the crankshaft.
Page 457 Clutch unit: primary gears Fit the driving gear (B) onto the crankshaft with oil pump control sprocket facing the casing. Temporarily lock with the washer (6) and the ring nut (5). Caution If a new primary driving gear (B) is fitted, check its meshing play. To check the meshing clearance, temporarily fit the clutch housing (1) together with inner spacer (4), driven gear (A), roller bearing (3) and inner ring (2), onto the gearbox primary shaft.
Page 458 Clutch unit: primary gears 88713.2423 and tighten ring nut (5) to the specified torque (Sect. C 3, Engine torque settings). Bend the washer (6) onto the driving gear (B) at milled zone and onto the ring nut (5) at a diametrically opposed position.
Page 459 Clutch unit: primary gears Operations Reference See Section Refit the clutch N 6.1, Reassembling the APTC unit Refit the clutch cover N 6.2, Refitting the clutch cover Fill oil into the engine D 4, Changing the engine oil and filter cartridge file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_6C9_00.69.1.html (8 of 8) [10/7/2008 8:46:02 PM]...
Page 460 Gearbox assembly: gear selector levers 7.1 - Gearbox assembly: gear selector levers 1 Return spring 2 Washer 3 Special screw 4 Ratchet unit 5 Gear stopper bolt 6 Gasket 7 Gear stopper spring 8 Ball 9 Circlip 10 Fork return spring 11 Shim thk.
Page 461 Gearbox assembly: gear selector levers 19 Screw 20 Washer 21 Screw 22 Washer 23 Locating ring 24 Stop plate 25 Shim thk. 0.2 26 Shim thk. 0.5 27 Complete gear selector lever Spare parts catalogue Gearchange Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 462 Gearbox assembly: gear selector levers Disassembling the gear selector levers When one or more components of the lever need replacing, disassemble as shown in the picture. Removing the gear stopper and ratchet Undo the gear stopper bolt (5) and remove seal (6), spring (7) and gear ball (8). file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_7A9_00.70.1.html (3 of 8) [10/7/2008 8:46:06 PM]...
Page 463 Gearbox assembly: gear selector levers Undo clutch-side casing screw (3) and remove ratchet (4), washer (2) and spring (1). Reassembling gear stopper and ratchet Slide ratchet (4), washer (2) and spring (1) on the gear stopper bolt (3). Position gear stopper to clutch-side casing. The end of the spring (1) must locate behind the casing rib. Tighten the bolt (3) to the specified torque (Sect.
Page 464 Gearbox assembly: gear selector levers Reassembling the gear selector lever If the gear selector lever has been taken apart, insert the spring (17) on the shaft (16) as shown in the photograph. Insert plate (23) and shim (24) and fit circlip (9) to secure in place. file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_7A9_00.70.1.html (5 of 8) [10/7/2008 8:46:06 PM]...
Page 465 Gearbox assembly: gear selector levers Position the lever with respect to plate (23). The lever pin should be centred to the shoulders of the plate; loosen check nut (13) and turn eccentric pin (15) to set the position. Tighten the lock nut (13). Place the spring (10) between shaft (16) and fork (14).
Page 466 Gearbox assembly: gear selector levers Reassembling the gear selector lever Position the complete gear selector lever (25) into the chain-side casing. Position the gearbox drum selector fork in the centre of the drum rollers. Temporarily fit gear change lever (or a service lever) and shift to third gear. Fit plate part no.
Page 467 Gearbox assembly: gear selector levers With the gearbox in neutral, check that lever travel is the same when shifting up and down. The same should apply when a gear is engaged. Operate the gear change lever and turn the sprocket at the same time to check that all the gears engage when shifting up and down.
Page 468 Gearbox assembly: gearbox shafts 7.2 - Gearbox assembly: gearbox shafts 1 Shim thk. 1 2 Gearbox primary shaft 3 Shim thk. 0.5 4 Roller cage 5 Driving gear - 5th speed 6 Safety washer thk. 0.5 7 Circlip 8 Driving gear - 3 rd /4 th speed 9 Driving gear - 6 th speed 10 Driving gear - 2 nd speed 11 Shim thk.
Page 469 Gearbox assembly: gearbox shafts 18 Driven gear - 1st speed 19 Shim thk. 1 20 Driven gear - 5 th speed 21 Driven gear - 4 th speed 22 Driven gear - 3 rd speed 23 Driven gear - 6 th speed 24 Driven gear - 2 nd speed 25 Gearbox secondary shaft 26 Shim...
Page 470 Gearbox assembly: gearbox shafts Pull out the fork selector drum (13). Pay attention to the shims (31) and (27) fitted on the shaft, make sure to refit them to their original position. Now you can replace the needle roller stop ring (32) and the special needle rollers (14). Remove the gear selector forks (29) and (28).
Page 471 Gearbox assembly: gearbox shafts To remove them from the shaft ends use puller part no. 88713.1332 and then fit them in their relevant bearings on the casings. Disassembling the gearbox shafts Put the shaft in a vice to make disassembly operations easier. Caution Refit the shims in the original positions on assembly.
Page 472 Gearbox assembly: gearbox shafts Slide out the fifth driven gear (20). Using two flat screwdrivers, remove circlip (7) taking care not to damage the shaft surface. Slide out circlip (7) and safety washer (6). Remove the driven gear for the 4th speed (21), its needle roller cage (4) and the safety washer (12). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_7B9_00.71.1.html (5 of 17) [10/7/2008 8:46:12 PM]...
Page 473 Gearbox assembly: gearbox shafts Remove the driven gear for the 3rd speed (22), its needle roller cage (4) and the safety washer (6). Remove the circlip (7) and remove the driven gear for the 6th speed (23). Remove the circlip (7), the safety washer (6) and the driven gear for the 2nd speed (24). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_7B9_00.71.1.html (6 of 17) [10/7/2008 8:46:12 PM]...
Page 474 Gearbox assembly: gearbox shafts Pull out the roller cage (4) and the shim (3) so that the secondary shaft (25) is fully bare. Disassembling the primary shaft Remove chain-side shim (11) and clutch-side shim (1) from primary shaft. Slide out the 2nd drive gear (10). Using two screwdrivers, remove circlip (7) and safety washer (6). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_7B9_00.71.1.html (7 of 17) [10/7/2008 8:46:12 PM]...
Page 475 Gearbox assembly: gearbox shafts Caution When removing circlip (7), take care not to damage the shaft surface. Slide out sixth drive gear (9) with needle roller bearing (4). Then slide out safety washer (6) and circlip (7). Slide out third and fourth drive gear (8). Slide out circlip (7) and safety washer (6).
Page 476 Gearbox assembly: gearbox shafts Slide out fifth drive gear (5) with needle roller bearing (4). Remove the shim (3) from the primary shaft (2). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_7B9_00.71.1.html (9 of 17) [10/7/2008 8:46:12 PM]...
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Gearbox assembly: gearbox shafts Overhauling the gearbox Check the condition of the gear front coupling dogs. They must not be damaged in any way and must have sharp edges. The idle gears must rotate freely on their shafts. When refitting, make sure the circlips are correctly positioned. Check the needle roller bearings for wear.
Page 478 Gearbox assembly: gearbox shafts Inspecting the fork selector drum To establish the clearance between fork drive pin and selector drum slot, measure their dimensions with a gauge. If the service limit is exceeded, establish which part must be changed, by comparing the values with the values of new components (Sect.
Page 479 Gearbox assembly: gearbox shafts Reassembling the gearbox shafts Fig. 1 shows all parts to be fitted onto the primary shaft (2), after calculating correct thickness for shims (1) and (11) (Sect. N 9.2, Shimming the shafts). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_7B9_00.71.1.html (12 of 17) [10/7/2008 8:46:12 PM]...
Page 480 Gearbox assembly: gearbox shafts Fig. 2 shows all parts to be fitted onto the secondary shaft (25), after calculating correct thickness for shims (15) and (26) (Sect. N 9.2, Shimming the shafts). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_7B9_00.71.1.html (13 of 17) [10/7/2008 8:46:12 PM]...
Page 481 Gearbox assembly: gearbox shafts Fit all gears onto gearbox shafts following the removal procedure in the reverse order. Special care must be taken when fitting idle gears. Installation of 3 rd and 4 th gears and all fasteners onto the secondary shaft is here shown by way of example.
Page 482 Gearbox assembly: gearbox shafts Fit the safety washer (12) onto the gear; it is larger than the other safety washer (6). Fit another needle roller cage (4) as described. Fit the gear for 4 th speed (21). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_7B9_00.71.1.html (15 of 17) [10/7/2008 8:46:12 PM]...
Page 483 Gearbox assembly: gearbox shafts Fit another safety washer (6) and another circlip (7) into the shaft. Seat it using the drift. Reassembling the gearbox Follow the procedure described under Section N 9.2 "Closing the casings" to fit parts of the gearbox assembly. When finished, run a practical test.
Page 484 Gearbox assembly: gearbox shafts sliding gear (B). Operations Reference See Section Close the casings N 9.2, Closing the casings file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_7B9_00.71.1.html (17 of 17) [10/7/2008 8:46:12 PM]...
Page 485 Flywheel - generator 8 - Flywheel - generator 1 Screw 2 Ignition inspection plug 3 Seal 4 O-ring 5 Cover 6 Screw 7 Engine sensor 8 Thickness 9 O-ring 10 Screw 11 Screw 12 Screw 13 Flange 14 Reference pin 15 Circlip 16 Ignition flywheel 17 Washer...
Page 486 Flywheel - generator 19 Roller cage 20 Starter driven gear 21 Starter clutch 22 Flywheel - starter clutch assembly 23 Generator rotor 24 Screw 25 Screw 26 Bearing 27 Circlip 28 Generator cover 29 Centring bush 30 Cable guide 31 Screw 32 Generator stator 33 Belleville washer 34 Flanged nut...
Page 487 Flywheel - generator Undo the two retaining screws (6) of the small cover (5) placed at crankshaft end. Undo the generator cover retaining screws (10), (11) and (12) (arrowed in the figure). Collect the two washers (35) and hose guide (36). Fix tool part no.
Page 488 Flywheel - generator Disassembling the generator cover Undo the three stator retaining screws (24) and the two cable guide bracket (30) retaining screws (31) from inside the generator cover. Remove stator (32) and cable guide (30). Inside generator cover, at the crankshaft, there is a bearing (26) held in place by a circlip (27). Remove circlip (27) with suitable tweezers.
Page 489 Flywheel - generator Use an “industrial heating gun” to heat the flywheel nut (34) before loosening it; it is recommended not to use bare flame that might damage the starting system components. Warning While unscrewing the nut, keep pressing box end axially onto nut to avoid damage or injury in the event wrench suddenly slips off the nut.
Page 490 Flywheel - generator Caution Check inner ring (18), needle roller bearing (19) and inner washer (17) for wear. Note The inner ring (18) has an oil drilling for needle roller bearing (19) lubrication. Checking the flywheel - generator assembly Check that the generator rotor (23) inner part is not damaged. Check that the starter clutch is working properly and that the needle races do not show signs of wear or damage of any kind.
Page 491 Flywheel - generator Reassembling the flywheel - generator assembly Locate starter clutch (21) to flange (13) with the larger diameter side (+) facing the flange. The flange should have the rounded side facing the starter clutch. When refitting the starter clutch, make sure the arrow etched on outer ring is pointing in the direction of rotation of the engine.
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Flywheel - generator Check that starter clutch is installed correctly as follows. Remember that the flywheel is fitted to the crankshaft spline and will turn with the crankshaft. Turn the crankshaft counterclockwise. The flywheel will turn with the crankshaft, whereas starter motor and idle gear will not move (same as when the engine is running).
Page 493 Flywheel - generator Tighten screws to the specified torque (Sect. C 3, Engine torque settings). Refitting flywheel / generator assembly Fit washer (17), roller bearing (19) and inner ring (18) on crankshaft. Make sure that inner ring becomes seated properly in the centre of the washer. Fit starter driven gear (20) on flywheel starter clutch.
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Flywheel - generator Lock out flywheel rotation using the relevant tool part no. 88713.2036. Remove any Loctite residue from nut (34) and crankshaft (A) thread. In order to ensure correct coupling, sealant should be applied in 3 stripes along the crankshaft thread (A) and one stripe inside the nut (34).
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Clean off any deposits and degrease the mating surfaces of the LH-side casing and the generator cover. Fit the two reference bushes (29). Apply an even bead of DUCATI liquid gasket on the cover surface (28), avoiding the holes for the retaining screws and the centring bushes.
Page 496 Flywheel - generator Qty. Description M6x25 mm screws M6x20 mm screws M6x30 mm screws Tighten the retaining screws to the specified torque (Sect. C 3, Engine torque settings). Fit the washer (35) and the hose guide (36) under the screw (12), close to the starter motor. Tighten the retaining screws to the specified torque (Sect.
Page 497 Flywheel - generator Check air gap between sensor and timing intermediate gear, as described below. Checking the engine sensor air gap Engine sensor can take readings of timing lay gear teeth and, thanks to the gap equal in size to two teeth, it can calculate engine number of revolutions per minute.
Page 498 Flywheel - generator Refit plug (B) with seal (C) and tighten to the specified torque (Sect. C 3, Engine torque settings). Operations Reference See Section Refit the chain sprocket cover G 8, Refitting the chain sprocket Refit the clutch transmission unit F 2, Refitting the clutch transmission assembly...
Page 499 Casing unit: outer components 9.1 - Casing unit: outer components 1 Key 2 Timing gear pair 3 Safety washer 4 Hexagon nut 5 Key 6 Aluminium gasket 7 Screw 8 Aluminium gasket 9 Blanking plug 10 Breather valve 11 O-ring 12 Head stud bolt 13 Locating dowel 14 Blanking plug...
Page 500 Casing unit: outer components 19 Neutral switch 20 Gasket 21 Gear pin 22 Washer 23 Intermediate gear 24 Washer 25 Circlip 26 Screw 27 Blanking plug 28 Gasket Spare parts catalogue Timing Filters and oil pump Half crankcases Electric starter and ignition Caution Bold reference numbers in this section identify parts shown in this exploded view diagram.
Page 501 Casing unit: outer components Undo and remove the oil cartridge filter (Sect. D 4, Changing the engine oil and filter cartridge). Undo and remove oil filter support nipple (17). Undo and remove the screw (7) with gasket (6) to check engine timing sensor air gap. Remove mesh filter (18) and seal from the clutch-side casing as described under Sect.
Page 502 Casing unit: outer components Remove drain plug (9) with seal (28). Remove neutral light switch (19) with seal (20). file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_9A9_00.73.1.html (4 of 10) [10/7/2008 8:46:24 PM]...
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Casing unit: outer components Using the special tool, remove head stud bolts (12). Remove gear selector ratchet and gear stopper as described in Sect. N 7.1, Removing the gear stopper and ratchet. Reassembling the outer components Check O-ring (11) for wear. Change, if necessary. Fit oil breather valve (10) with O-ring (11) inside engine block and tighten to the specified torque (Sect.
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Casing unit: outer components Refit the neutral light switch (19) with seal (20) and tighten to the specified torque (Sect. C 3, Engine torque settings). Apply threadlocker to the plug (27), fit the seal, start it in its thread and tighten it to the specified torque (Sect. C 3, Engine torque settings).
Page 505 Casing unit: outer components Refit the lubrication system N 2.1, Refitting the oil pump Refit the engine to the frame N 1, Reassembling the engine Removing the timing lay gear Operations Reference See Section Remove the generator-side cover N 8, Flywheel - generator and the complete generator Slide out the drive gear (A) of the timing gear pair (2) and the key (5).
Page 506 Casing unit: outer components Slide out nut (4), washer (3), driven gear (B) and the key (1) from the timing layshaft. Reassembling the timing lay gear Before reassembling the removed parts, check timing gears (2) for wear. Change, if necessary. Caution The two timing gears (2) must be always changed in pair.
Page 507 Casing unit: outer components Operations Reference See Section Refit the generator-side cover and N 8, Flywheel - generator the complete generator Removing the starter motor driven gear Operations Reference See Section Remove the generator flywheel unit N 8, Flywheel - generator Remove circlip (25) and washer (24).
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Casing unit: outer components Refitting the starter motor driven gear Installation is a reversal of the removal procedure. Note Apply recommended threadlocker to screw (26), then tighten it to the specified torque (Sect. C 3, Engine torque settings). Operations Reference See Section Refit the generator flywheel unit N 8, Flywheel - generator...
Page 509 Casing unit: crankcases 9.2 - Casing unit: crankcases 1 Circlip 2 Timing lay gear 3 Generator-side casing 4 Bearing 5 O-ring 6 Circlip 7 Bearing 8 Screw 9 Stop plate 10 Bearing 11 Seal 12 Bearing 13 Washer 14 Bearing 15 Bearing 16 Clutch-side casing 17 Spacer...
Page 510 Casing unit: crankcases 19 Bush 20 Seal 21 Bearing 22 Circlip 23 Bearing 24 Roller bearing 25 Screw 26 Screw 27 Screw 28 Special screw 29 Screw 30 Circlip 31 Seal Spare parts catalogue Timing Half crankcases Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Page 511 Casing unit: crankcases Note When removing the circlip, take care not to score the shaft surface. Undo the casing jointing screws working from the generator side (3). Unscrew the two screws (29) on the clutch-side casing (16) near the vertical cylinder housing. Use generator cover or a service cover with puller part no.
Page 512 Casing unit: crankcases Remove gearbox shafts and gearbox selector drum from the casing (Sect. N 7.2, Gearbox assembly: gearbox shafts). Slide out the crankshaft (A) using a plastic hammer. Do not damage or lose the shims. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_9B9_00.74.1.html (4 of 25) [10/7/2008 8:46:34 PM]...
Page 513 Casing unit: crankcases Remove timing layshaft (2). Collect O-Ring (5) in the oil duct between casings. Overhauling the casings Carefully inspect the crankcases. Place the casings on a reference surface and check that the mating surfaces of the casings are perfectly flat. Check bearings (4) and (23) for wear.
Page 514 Casing unit: crankcases When changing the needle roller bearings (24) and the seals (31) on the swingarm shaft, grease the bearing seats and the seal lips with the specified grease. Install the inner oil seal (31) with the flat surface facing the casing and against the circlip (30); outer oil seal is to be fitted in the opposite way.
Page 515 Casing unit: crankcases straight lines at a particular angle to bearing axis. The angle-contact ball bearings are designed for bearing combined loading (radial-axial loads). They may bear axial loading in one direction only. Because of radial loading, the bearing produces an axial force that must be combined with an opposite force and it is thus usually fitted in opposition to another.
Page 516 Casing unit: crankcases Caution After installing new main bearings, shim the crankshaft as described under paragraphs “Shimming the shafts" and "Closing the casings” in this Section. Reassembling the casings Carefully inspect the casings. They should be in perfect conditions and clean. Mating surfaces must be perfectly flat and free from burrs.
Page 517 Casing unit: crankcases Reassembling the generator-side casing Check that the following parts are in place inside casing: The double ball ring bearing (10) for the selector fork shaft with plate (9) and retaining screws (8). The gearbox primary shaft bearing (12) with inner spacer (13). Main bearing (4).
Page 518 Casing unit: crankcases Shimming the crankshaft After fitting the new main bearings, proceed as follows to determine the total shimming “S“. Measure “A” between the crankshaft surfaces that contact the bearings. Measure the depths “P1” and “P2“ corresponding to the distance between the mating surfaces of the two casings and the contact surfaces of the inner races of the bearings;...
Page 519 Casing unit: crankcases Place a dial gauge (T) with magnetic base on a support plate fixed to crankcase. Bring stylus in contact with crankshaft end and set dial gauge to zero with the stylus touching the crankshaft. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_9B9_00.74.1.html (11 of 25) [10/7/2008 8:46:34 PM]...
Page 520 Casing unit: crankcases Place a lever (L) between casing and crank web and lever crankshaft pushing towards dial gauge. Note dial gauge reading. This will be crankshaft end float. Add pre-load (0.30 mm) and total size of shims used (1.90x2=3.8 mm). Divide by two and you have obtained the shimming required for each casing.
Page 521 Casing unit: crankcases SA=PA1+PA2-A-0.15 and SB=PB1+PB2-B-0.15 To establish the size of each shimming, note that: SA=SA1+SA2 and SB=SB1+SB2 Where "SA1" and "SA2" represent the primary shaft shimming on clutch side and chain side and "SB1" and "SB2" represent the corresponding secondary shaft shimming.
Page 522 Casing unit: crankcases Extract the neutral switch (N) before fitting the selector drum into the casing to avoid damage to the switch. Position the selector drum with no shims. Secure the casing by fitting a few screws in the holes near the drum position.
Page 523 Casing unit: crankcases Lever drum and note dial gauge reading. This will be total axial play. Determine the amount of shimming required to obtain a final end float between 0.10 and 0.40 mm. Divide total play by two to determine the amount of shimming required on each side of the selector drum. Note Final end float should be closer to 0.40 rather than 0.10 mm.
Page 524 Casing unit: crankcases Check that the selector drum is in NEUTRAL, looking at the clutch-side end. Now hold the primary shaft in position and check that the clutch dogs of the sliding gear are equally distant from the dogs of the fixed gears. This is done by inserting a feeler gauge (S) between the dogs. Note Press the sliding gear in both directions so as to take up play.
Page 525 Casing unit: crankcases Remove selector drum, forks and pins. Fit the casing and secure it with a few screws (V) near the gearbox shafts. Measure end float of secondary and primary shafts with the dial gauge. Final play must be between 0.05 and 0.20 mm for both shafts. Note Play should be closer to 0.05 rather than 0.20 mm.
Page 526 Casing unit: crankcases Checking gearbox position After shimming the gearbox shafts, separate the casings. Insert the forks of the 1 gears (F) and the fork of the 5 gears (G) into the grooves of the sliding gears. Fit the fork selector drum (P) with calculated shims. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_9B9_00.74.1.html (18 of 25) [10/7/2008 8:46:35 PM]...
Page 527 Casing unit: crankcases Fit the forks to the drum and fit the pins (Q). Close the casings without the crankshaft to check gearbox position. Install and adjust the gear selector lever assembly (M) (see Sect. N 7.1, Reassembling the gear selector lever).
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Casing unit: crankcases Engage a gear and check that the fork is free in the sliding gear groove (Fig. 3). Closing the casings Fit the timing layshaft (2) into the clutch-side casing roller bearing (21). To prevent damage to the oil seal on the timing layshaft, insert a protection cap part no.
Page 529 Casing unit: crankcases Dampen the oil seal (20) with alcohol and fit it on the timing layshaft. Drive it fully home on the roller bearing (21). Fit the circlip (1) into the shaft seat and remove the protection cap. Note When refitting used components, make sure that the inner races (D) of the gearbox shaft end bearings are fitted into the correct bearing and are not on the shaft.
Page 530 Casing unit: crankcases Insert the forks of the 1 st -4 th and 2 nd -3 rd gears (F) into the grooves of the secondary shaft driven gears. Note Both forks are alike. Insert the fork of the 5th-6th gears (G) into the primary shaft driven gear. Fit the fork selector drum (P) in the casings with calculated shims.
Page 531 Make sure that the connecting rods (B) are correctly positioned in the cylinders. Incorrect positioning will inevitably lead to reopening of the casing. Apply a uniform bead of Ducati liquid gasket (A) on the mating surface of the casing, avoiding the holes as shown in the figure.
Page 532 Casing unit: crankcases Match the casings (3) and (16). Tap the area around the shafts with a plastic hammer, if necessary. Start the jointing screws into their holes on the generator-side casing (3). The screws are not all the same length, be sure to position them correctly.
Page 533 Casing unit: crankcases Tighten all screws to the specified torque. Begin with the larger diameter screws. Check that crankshaft rotates with a certain amount of interference in the main bearings. Crankshaft must have a pre- load of 0.15 - 0.20 mm. Check also that all assembled parts can rotate or move correctly. Fit oil seal (11) and spacer with O-ring on gearbox secondary shaft as described under Sect.
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Casing unit: connecting rods 9.3 - Casing unit: connecting rods 1 Crankshaft 2 Special screw 3 Blanking plug 4 Threaded dowel 5 Complete connecting rod 6 Bush 7 Bearing 8 Special screw 9 Shim 10 Key 11 Key Spare parts catalogue Crankshaft Half crankcases file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_9C9_00.75.1.html (1 of 10) [10/7/2008 8:46:40 PM]...
Page 535 Casing unit: connecting rods Caution Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text. Removing the connecting rods Operations Reference See Section Remove the engine from the frame N 1, Removing the engine Remove the lubrication system...
Page 536 Casing unit: connecting rods Big end diameter must be within the specified limits (Sect. C 1.1, Cylinder / piston). Use crankshafts and connecting rods from the same class. Changing the connecting rod big end bearings Change the bearings every time the engine is overhauled. Spare bearings are supplied ready for installation.
Page 537 Casing unit: connecting rods Changing the connecting rod small end bush Replace small end bush (6) using the tool shown in the figure. This tool lets you extract the worn bush and install a new bush (A) at the same time. Locate the new bush to the small end of the connecting rod with the opening at right angles to the upper hole of the con-rod small end.
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Casing unit: connecting rods Overhauling the crankshaft The main bearings and the crank pins must not be grooved or scored. Threads, keyways and slots must be in good condition. Check for fretting or burrs in the fillet between crank pin and shoulder. Fillet radius: 1.5 mm.
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Casing unit: connecting rods Use a dial gauge to measure the alignment of main bearings with the crankshaft placed between two centres (Sect. C 1.1, Cylinder / piston). Undo all crankshaft plugs (4), (3) and (2). If they are hard to remove, heat plug to remove the threadlocker used at assembly.
Page 540: Thread
Clean all lubrication ducts with suitably sized metal brushes and blow with compressed air to remove any deposits preventing proper oil circulation. Apply DUCATI liquid gasket to the threads of the plugs (3), (4) and (2) and then refit them. file:///C|/Documents%20and%20Settings/F4i/My...anual/wsm/usa/Mon695_MY07_N_9C9_00.75.1.html (7 of 10) [10/7/2008 8:46:40 PM]...
Page 541 Casing unit: connecting rods Tighten all plugs to the specified torque (Sect. C 3, Engine torque settings). Big end bearings-crank pin clearance To check clearance between big end bearings and crank pin, use a GREEN “Plastigage PG-1” bar (A) on the crank pin. Fit the connecting rod with the original bearings (7) following the procedure at next page.
Page 542: Thread
Casing unit: connecting rods Wash pins and dry them with compressed air. Clean and lubricate con-rod bearings and crank pin with engine oil. Refit the con-rods in their original mounting position. Fit cap and con-rod with their marks on the same side. Fill the recommended grease into the two ends of the hole to lubricate threads and underside of the new bolts (8) and the thread of the shaft.
Page 543 Casing unit: connecting rods Refitting the connecting rod unit Install the complete connecting rod unit inside casing, proceed to shimming as described in Sect. N 9.2, Casing unit: crankcases. Caution Make sure that the connecting rods (5) are correctly positioned in the cylinders. Incorrect positioning will inevitably lead to reopening of the casing.
Page 544 Engine 0Engine 1 - Removing - reassembling the complete engine Removing the engine 6 Reassembling the engine 9 2.1 - Lubrication system: oil pump Lubrication system 11 Removing the oil pump 13 Disassembling the oil pump gear 14 Reassembling the oil pump gear 15 Refitting the oil pump 16 2.3 - Lubrication system: oil breather reservoir Removing the oil breather tank 18...
Page 545 Engine Checking the bearings 53 Refitting the camshaft 54 Refitting the cam covers 56 4.4 - Head unit: valves - rocker arms Disassembling the engine heads 59 Overhauling the head parts 65 Reassembling the head 72 5 - Cylinder / piston assy Removing cylinder / piston assy 81 Overhauling the cylinder / piston assy 84 Refitting cylinder / piston assy 90...
Page 546 Engine Removing the gearbox 129 Disassembling the gearbox shafts 131 Overhauling the gearbox 136 Inspecting the gear selector forks 137 Inspecting the fork selector drum 138 Reassembling the gearbox shafts 139 Reassembling the gearbox 142 8 - Flywheel - generator Removing the generator cover 144 Disassembling the generator cover 146 Removing the flywheel - generator assembly 147...
Page 547 Engine file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_IND_00.58.1.html (4 of 4) [10/7/2008 8:46:43 PM]...
Page 548: Wiring Diagram
Wiring diagram 1 - Wiring diagram file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_P_1A9_00.77.1.html (1 of 5) [10/7/2008 8:46:49 PM]...
Page 549 Wiring diagram Wiring diagram key 1 RH switch 2 Transponder antenna 3 Key-operated switch 4 Lights relay 5 Fuse box 6 Starter motor 7 Starter contactor 8 Battery 9 Regulator fuse 10 Regulator 11 Generator 12 Rear right turn indicator 13 Tail light 14 Number plate light 15 Rear left turn indicator...
Page 550 Wiring diagram Wire color coding - wiring diagram B Blue Bk Black Bn Brown G Green Gr Grey Lb Light blue O Orange P Pink R Red V Violet W White Y Yellow Legend of fuse box Position Description Rating Instrument panel 2-10 Injection...
Page 551 Wiring diagram Diagram B Immobilizer antenna Diagram B Key switch connector Diagram B Immobilizer antenna connector Diagram B Horn connectors Diagram C Horizontal coil connectors Diagram C Injection/lights relays Diagram C Diagram D Side stand Diagram C Vertical injector connector Diagram D Generator cable Diagram C...
Page 552 Wiring diagram Diagram P Headlight connector Diagram P Front left turn indicator connection Diagram P Front brake light switch connection Diagram P Right switch connector Diagram P Front right turn indicator connection Diagram P Rear brake switch Diagram Q Speed sensor connector Diagram Q Speed sensor Diagram J...
Page 553: Diagram A
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Page 554: Diagram B
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Page 556: Diagram C
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Page 557: Diagram D
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Page 559: Diagram E
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Page 560: Diagram F
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Page 562: Diagram G
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Page 563: Diagram H
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Page 564: Diagram J
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Page 566: Diagram K
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Page 567: Diagram L
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Page 568: Diagram M
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Page 570: Diagram N
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Page 571: Diagram P
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Page 573 Charging system – battery 2 - Charging system – battery Checking the charging system To check the current flow in the charging circuit, use the "DDS" tester with the supplied inductive clamp-type amperemeter. Please refer to indications given under “Checking the charging system”...
Page 574 Charging system – battery Charge battery if open circuit voltage is lower than 12.8 V. Leaving the battery discharged for more than one month could damage the battery itself. Check battery charge with a voltmeter. Always check battery condition before charging and 1 - 2 hours after charging. Caution Strictly follow the recharging time indications.
Page 575 Charging system – battery Set the battery on a flat surface. Remove the protective film (1). Warning Ensure that the fluid is suitable for your battery. Take the fluid container off the vinyl case. Remove the cap bar (3) from the container (2). Caution Keep the cap bar (3) at hand because it will be used to plug the battery cells.
Page 576 Charging system – battery Warning Do not graze or pierce the sealed areas. Set the fluid container (2) upside-down. Ensure the six sealed elements match the six filler holes on the battery. Push down the container (2) and break the seals so that fluid can flow out. Note Do not tilt the fluid container or the flow might stop.
Page 577 Charging system – battery 3 -12 AH batteries: allow at least 30 min. >12 AH batteries: allow at least 1 hour. Install the cap bar on filler holes, do not fix it yet. Charge the battery as described under Recharging the battery.
Page 578 Charging system – battery Battery Battery safety rules Warning Carefully read the relevant safety rules before making any intervention on the battery (Sect. A 3, General safety rules). When under charge, batteries produce explosive gases. Keep batteries away from heat sources or open flames. Instructions for use of the battery This is a sealed-type maintenance-free battery, ready for installation to the vehicle.
Page 579 Charging system – battery Note References (16) and (19) are the same as those of diagrams under “Arrangement of wiring on frame” of this section. Remove the seat (Sect. E 3, Removing the seat). Lift the fuel tank (Sect. L 2, Removing the fuel tank).
Page 580 Charging system – battery Installation is a reversal of the removal procedure. Make sure to tighten the screws to the specified torque (Sect. C 3, Frame torque settings). Generator The generator is a 12V, 520W alternator, consisting of a fixed stator (A) located in the generator cover and a rotor (B) fixed to the crankshaft.
Page 581 Charging system – battery Warning To check operation of the battery charging system, use the DDS, please refer to "Checking the charging system" (Sect. D 5). Absolute value of voltage measured across the terminals of two of the three yellow cables (measured value will be the same whichever the combination) must be within the range indicated in the table below.
Page 582 Charging system – battery Fit rotor (B), stator (A) and generator cover. Connect the generator-side electrical cables (see diagram in "Arrangement of wiring on frame", Sect. P 1). Rectifier - regulator The rectifier-regulator (1) is fixed to the oil breather tank (2) and to motorcycle frame. The rectifier-regulator consists of an aluminium casing containing the diodes that rectify the current produced by the generator.
Page 583 Charging system – battery Note To correctly position the regulator cable (14), follow the instructions of diagram E in Arrangement of wiring on frame under Sect. P 1. Install the fuel tank (Sect. L 2, Refitting the plastic fuel tank). Install the seat (Sect.
Page 584 Charging system – battery To prevent short circuits, ensure that the ignition key is in the OFF position before changing a fuse. Warning Use only fuses with the specified amperage. Using fuses with the incorrect amperage may damage the electrical system and cause fires.
Page 585 Electric starting 3 - Electric starting Note Items reference numbers refer to “Wiring diagram” in Section P 1. Electric starting system The key components of the electric starting system are a starter contactor (7) and a starter motor (6) fed by the battery (8). ECU (28) has total control on motorcycle ignition procedure.
Page 586 Electric starting Starter motor Power: 700 W with 12V power supply Direction of rotation: counterclockwise viewed from power take-off side. As the starter motor is reliable and compact, it usually does not fail. In case of troubles, ensure that the starter motor cable terminal is properly tightened under the nut and shows no oxidation. If the terminal is properly tightened and free from oxidation, remove the starter motor and test it under loadless conditions (no load applied to the shaft).
Page 587 Electric starting Removing the starter motor Remove generator cover (Sect. N 8, Removing the generator cover). In the event the whole starting gear unit needs replacing, remove timing intermediate gears and starter motor intermediate gear (Sect. N 9.1, Removing the starter motor driven gear).
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Electric starting Note Starter motor retaining screws are originally assembled with threadlocker. Slide out starter motor and gasket (2). Refitting the starter motor Visually inspect gasket (2) for wear. Replace if necessary. Place gasket (2) and starter motor on casing and tighten screws (1) to the specified torque (Sect. C 3, Frame torque settings).
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Electric starting Starter contactor (1) is elastically connected to the frame. Disconnect the battery (Sect. P 2, Battery). Remove the starter contactor from its housing. Undo the nuts (4) and collect the spring washers (3). Remove the contactor-starter motor cable (2). Remove the contactor-battery cable (5).
Page 590 Electric starting At reassembly, check that contacts (C) and (D) are not oxidized and use waterproof spray. Tighten the nuts (4) to the specified torque (Sect. C 3, Frame torque settings). Reconnect connector (2) to wiring. file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_P_3_9_00.80.1.html (6 of 6) [10/7/2008 8:47:02 PM]...
Page 591 Lighting devices 4 - Lighting devices Changing light bulbs Changing the headlight bulbs Before replacing a burnt-out bulb, make sure that the new bulb complies with the specified voltage and wattage (Sect. C 1.1, Lights / instrument panel). Warning Headlamp halogen bulbs become hot when turned on and stay hot for some time after they are switched off.
Page 592 Lighting devices Release the bulb retaining clip (3) and take bulb out of mount. Fit a bulb of equal rating (Sect. C 1.1, Lights / instrument panel). Note Be careful to hold the new bulb at the base only. Never touch the transparent body with your fingers or it will blacken resulting in reduced bulb brilliancy.
Page 593 Lighting devices Position the new bulb. Press and turn counterclockwise until it becomes properly seated with an audible click. Refit the connector and secure the rim/reflector assembly in place. Replacing the number plate light bulbs Remove the bulb holder from the inside of the number plate holder to gain access to the number plate bulb (5).
Page 594 Lighting devices To remove the headlight, loosen the screws (1), collect caps (2). Disconnect connector (3) from front wiring. Loosen screws (4) to remove turn indicators. file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_P_4_9_00.81.1.html (4 of 8) [10/7/2008 8:47:05 PM]...
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Lighting devices Headlight support (5) is secured to the steering head by means of threaded vibration dampers (6). Vibration dampers (6) and screws (7) secure the instrument panel to the steering head. Headlight support (5) is secured to the bottom yoke by means of screws (8). file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_P_4_9_00.81.1.html (5 of 8) [10/7/2008 8:47:05 PM]...
Page 596 Lighting devices High beam relay It is located next to the batteries and secured to battery mount. To gain access to this component it is necessary to lift the fuel tank (Sect. L2, Removing the fuel tank). High beam relay (1) was added to the system in order to control the light automatic switch-off strategy, i.e.: If on after normal use, lights go off 60 seconds after engine is stopped by means of "Engine kill button“...
Page 597 Lighting devices If this strategy is not working, check system operation. Checking high beam relay operation Remove relay (1) from its support and power contacts (86) and (85) (small contacts) with 12 V (battery). The electric magnet must click. Connect a multimeter across contacts (30) and (87) (large contacts) and ensure it reaches full scale (analog multimeter) or beeps (digital multimeter).
Page 598 Lighting devices Note This is the procedure specified by Italian standards to check the maximum height of the light beam. To adjust the height of the light beam, turn the adjusting screws (1) that retain the headlamp to the side supports. file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_P_4_9_00.81.1.html (8 of 8) [10/7/2008 8:47:05 PM]...
Page 599 Indicators and lighting system 5 - Indicators and lighting system Checking the indicators and lighting system components In the event of a fault, the internal connections of the device must be checked in all operating positions. To do this, disconnect the switch connector from main wiring (Sect. P 1, Arrangement of wiring on frame).
Page 600 Indicators and lighting system Low and high beam (DIMMER) Test method is the same. Connect meter as follows: Low beam (LO) (Blue/Yellow and Red/Yellow cables) High beam (HI) (Red/Black and Blue/Yellow cables). Flasher (PASSING) Check for continuity across the Red/Black and Grey cables. Fit the left switch, tighten the screws (1) to the specified torque (Sect.
Page 601 Indicators and lighting system Checking the right switch Undo the screws (1) and disconnect the right switch from the electric system to remove it. Colours mentioned in the descriptions refer to the colour of wires from the switch and not to the colour of wires of the main electric system.
Page 602 Indicators and lighting system Checking front and rear STOP switches, neutral switch, oil pressure switch and clutch switch STOP switches Check for electric continuity (Pos. A) between the switch terminals of front STOP switch (1) and rear STOP switch (2) with a multimeter (Sect. P 9, Testerson multimeter operation) when either front or rear brake is enabled.
Page 603 Indicators and lighting system Neutral light Proceed as follows to check the neutral light switch (3): the neutral light on the instrument panel does not turn on. Remove the electric terminal connected to the neutral switch. Position the ignition key to ON to switch on the instrument panel and ensure that the light turns on when the terminal is grounded.
Page 604 Indicators and lighting system the sensor should be replaced. If the warning light stays off, use a multimeter and check for electric continuity in the section between sensor and warning light on the instrument panel. Check with ignition key positioned to OFF (instrument panel off). If engine oil pressure value is within the allowed operating range and the warning light "engine oil pressure low"...
Page 605 Indicators and lighting system Replacing the stop light bulbs To replace the stop and parking light bulbs, unscrew the two screws (4) that fasten the lens (5) and remove. The bulb has a bayonet fitting. Press and twist clockwise to extract. Fit a new bulb.
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Page 607 Protection and safety devices 6 - Protection and safety devices Checking protection and safety devices components Checking the key-operated switch Disconnect the key-operated switch (A) from the electric system (see chapter "Arrangement of wiring frame" under Sect. P 1) and check for electric continuity of inner connections with a multimeter as follows: set the ignition key to OFF and connect a multimeter to contacts (1) and (4) to check for electric continuity (Section P 9,...
Page 608 Protection and safety devices Note The same test may be done using the “DDS” tester (Sect. D 5, DDS diagnosis instrument). Checking the side stand switch Remove switch from side stand (Sect. H 5, Removing the side stand) and disconnect it from the main wiring harness (refer to “Arrangement of wiring on frame”...
Page 609 Protection and safety devices Note The same test may be done using the “DDS” (Sect. D 5, DDS diagnosis instrument). Pin pos. (A) El. items Val. Multimeter pos. Green/ Green/ Green Yellow White Black 0 = Open contact X = Closed contact Checking the fuses The main fuse box (1) is located on the right-hand side of the battery mount.
Page 610 Protection and safety devices Caution To prevent short circuits, ensure that the ignition key is in the OFF position before changing a fuse. Warning Use only fuses with the specified amperage. Using fuses with the incorrect amperage may damage the electrical system and cause fires.
Page 611 Warning lights and indicators 7 - Warning lights and indicators Instrument panel Unscrew the two screws (A) with washers that retain instrument panel to steering head and remove. Disconnect main wiring connector (B) (see diagrams in “Arrangement of wiring on frame”...
Page 612 Warning lights and indicators 3 Yellow light Low fuel. Fuel reserve is about 3.5 litres. 4 Green light Neutral light. 5 Red light Low oil pressure. It turns on briefly when the ignition switch is switched ON. It should turn off a few seconds after engine has started.
Page 613 Warning lights and indicators LCD unit operation On starting (key is turned from OFF to ON), the instrument panel runs an overall instrument check routine (gauges, display, warning lights). Operation of LCD unit (9) Press the button (12) with key ON to toggle between trip meter and odometer and, if fuel reserve light is on, distance covered since fuel reserve is used (trip fuel function).
Page 614 Warning lights and indicators Oil temperature warning When oil temperature falls below 50 °C, the wording "LO" is displayed. Oil temperature rising above 170 °C turns on a "HI" warning. Low fuel warning When the reserve light is on, the Display (L11) shows "FUEL" and the trip fuel function is activated. Maintenance counter The word "MAInt"...
Page 615 Warning lights and indicators Light automatic switch-off strategy This strategy allows you to save battery power and is activated only when ignition switch is ON and engine is off. The system activates and deactivates the lights as follows: Lights switch Engine state Lights (IN3 input state)
Page 616 Immobilizer and Transponder 8 - Immobilizer and Transponder The Immobilizer allows the vehicle to be started only if the rider uses the special ignition key which sends the identification code to a decoder fitted into the instrument panel. The emitting - receiving system is made of a TRANSPONDER fitted into the ignition key heads and an antenna close to the ignition lock.
Page 617 Immobilizer and Transponder Operating principle of the immobilizer When the ignition key is positioned to ON, the decoder into the instrument panel energises the antenna, which generates an electromagnetic field power-supplying the key transponder. The Transponder sends the code stored into its ROM, which is received by the antenna and sent to the decoder.
Page 618 Immobilizer and Transponder At least three keys (included the RED key) are necessary to program the immobilizer up to max. 8 keys (included the RED key). Programming the immobilizer If one or more parts of the immobilizer are replaced, such as black keys, decoder or engine control unit, system must be reprogrammed.
Page 619 Immobilizer and Transponder - ensure that countdown has started and turn the key to OFF before it reaches zero remove the black key, insert the red key and set the switch to ON within the next 15 seconds (display shows the number of keys inserted, in this instance 4, with the countdown from 30 to 0 at the side) ensure that the countdown has begun and set the key to OFF before it reaches zero.
Page 620 Immobilizer and Transponder indication for correct immobilizer programming. Checking for correct immobilizer programming Insert the red key in the ignition switch. Set it to ON. The led (1) on the instrument panel will flash (see further below for details of LED indications). And then led (1) turns off. First flashing indication: if the led flashes for two seconds, it means that the immobilizer is not programmed, maybe because the programming procedure has not been strictly followed.
Page 621 Immobilizer and Transponder 4 Release the throttle when the EOBD light goes off. 5 Repeat operations described in steps 3 and 4 until you enter the last digit. After releasing the throttle twistgrip and if the entered code is correct, the EOBD light will flash for 4 seconds to indicate that the immobilizer is now disabled.
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Immobilizer and Transponder Remove the immobilizer antenna wire ties. Undo the two nuts (1) retaining the Immobilizer antenna guard. Remove the cover (2) and lift the Immobilizer antenna (3) clear of the key-operated switch. Remove the special screws (6). Remove the key-operated switch (9) complete with plate (8) from the frame. Separate plate (8) and key-operated switch (9).
Page 623 Immobilizer and Transponder Dismantling the red key with transponder Vice the key grip (1). Make sure the vice jaws are protected. Use pliers to extract the key (2), the protections (3) and the transponder (4). Change any damaged components and reverse the dismantling procedure to reassemble. file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_P_8_9_00.85.1.html (8 of 9) [10/7/2008 8:47:22 PM]...
Page 624 Immobilizer and Transponder file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_P_8_9_00.85.1.html (9 of 9) [10/7/2008 8:47:22 PM]...
Page 625 Testers 9 - Testers Please refer to Section D 5, DDS diagnosis instrument, as far as “DDS” tester is concerned. How to use the multimeter to check electric systems Multimeter operation This instrument can take resistance, voltage and current values. Multimeters are usually gathered into two big families: analogue and digital display multimeter.
Page 626 Testers How to measure current Always connect multimeter terminals in series with the power supplied part. For example: disconnect a wire powering a lamp and connect a terminal with the end of the disconnected wire and the other terminal with the lamp. Position the light switch to on, the lamp will turn on and the instrument will show the value for absorbed current, that is the value for the current flowing into the wire.
Page 627 Electric system 0Electric system 1 - Wiring diagram Wiring diagram key 4 Wire color coding - wiring diagram 4 Legend of fuse box 5 Arrangement of wiring on frame 6 Diagram A 8 Diagram B 9 Diagram C 10 Diagram D 11 Diagram E 12 Diagram F 13 Diagram G 14...
Page 628 Electric system Changing light bulbs 38 High beam relay 43 Beam setting 44 5 - Indicators and lighting system Checking the indicators and lighting system components 45 Changing light bulbs 50 6 - Protection and safety devices Checking protection and safety devices components 52 Checking the fuses 54 7 - Warning lights and indicators Instrument panel 55...

Ducati Monster 695 User Manual

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