Ducati Monster 400, 620 - Service, Repair Manual - Manuale di Officina, Riparazione

DUCATI MONSTER 400, 620 - WORKSHOP, SERVICE, REPAIR MANUAL - MANUALE DI OFFICINA, RIPARAZIONE

- English Workshop Manual / Repair Manual, for motorcycles Ducati Monster 400, 620.
- Manuale di Officina in italiano, ai moto Ducati Monster 400, 620.
 

INDEX:

SERVICE MANUAL

GENERAL SUMMARY
A - Description
- 1 - HOW TO USE THE MANUAL
- Manual layout
- 2 - SYMBOLS - ABBREVIATIONS - REFERENCES
- Product specifications
- 3 - DANGEROUS PRODUCTS - WARNINGS
- General safety rules
- General maintenance indications
B - Model-specific information
- 1 - IDENTIFICATION DATA
- Identification data for Monster 400 i.e.
- Identification data for Monster 620 i.e.
C - Technical specification
- 1.1 - TECHNICAL DATA
- Description
- Colors
- Transmission assembly
- Timing/valves
- Cylinder / piston
- Gearbox
- Cooling system
- Front wheel
- Front suspension
- Rear wheel
- Rear suspension
- Hydraulic brakes
- Charging system / generator
- Ignition system
- Fuel system
- Injection system
- Lights / instrument panel
- 1.2 - DIMENSIONS
- 2 - FUELS AND LUBRICANTS
- 3 - TORQUE SETTINGS
- Frame torque settings
- Engine torque settings
- 4 - SERVICE TOOLS
- Engine special tools
- Frame special tool
D - Use and Maintenance
- 1 - PRELIMINARY CHECKS
- Running-in precautions
- Pre-ride checks
- 2 - STARTING - ENGINE WARM-UP
- Starting the engine
- 3 - ROUTINE MAINTENANCE TABLE
- 4 - MAINTENANCE OPERATIONS
- Checking the engine oil level
- Changing the engine oil and filter cartridge
- Checking valve clearances
- Adjusting valve clearances
- Changing and cleaning the air filters
- Changing the brake fluid
- Draining the braking circuit
- Filling the brake circuit
- Changing the clutch fluid
- Draining the clutch circuit
- Filling the clutch circuit
- Adjusting steering bearings play
- Adjusting chain tension
- Checking brake pad wear. Changing brake pads
- Adjusting the throttle and choke cables
- Adjusting the position of the gear change and rear brake pedals
- Adjusting the rear shock absorber
- 5 - DIAGNOSIS INSTRUMENTS
- Tester description
- Instrument power supply
- DDS diagnosis instrument
- Checking and adjusting timing belt tension
- Adjusting the throttle body
- Checking engine oil pressure
- Checking cylinder compression
- Checking fuel pressure
- Procedure to override the immobilizer system
- Guided diagnosis
- Checking the charging system
- Icons table
E - Fairing
- 1 - HEADLIGHT FAIRING (for 620 version only) - REAR-VIEW MIRRORS
- Disassembling the rear- view mirrors
- Refitting the rear-view mirrors
- Removing the headlight fairing (620 version only)
- Refitting the headlight fairing (620 version only)
- 3 - SEAT
- Removing the seat
- Refitting the seat
- Removing the splashguard
- Refitting the splashguard
- Removing the side body panels
- Refitting the side body panels
- 4 - FRONT AND REAR MUDGUARD
- Removing the front mudguard
- Refitting the front mudguard
- Removing the rear mudguard
- Refitting the rear mudguard
F - Controls - Devices
- 1 - THROTTLE CONTROL - CHOKE
- Adjusting the throttle and choke cables
- Disassembling the throttle control
- Reassembling the throttle control
- Removing the choke control
- Refitting the choke control
- 2 - CLUTCH HYDRAULIC CONTROL
- Removing the clutch master cylinder assembly
- Refitting the clutch master cylinder assembly
- Removing the clutch transmission unit
- Refitting the clutch transmission assembly
- 3 - FRONT BRAKE CONTROL
- Removing the front brake master cylinder
- Refitting the front brake master cylinder
- 4 - REAR BRAKE CONTROL
- Removing the rear brake master cylinder
- Disassembling the rear brake control
- Refitting the rear brake master cylinder
- 5 - GEAR CHANGE CONTROL
- Removing the gear change control
- Disassembling the gear change control
- Refitting the gear change control
- 6 - SEAT LOCK AND RELEASING MECHANISMS
- Removing the seat releasing mechanism
- Refitting the seat releasing mechanism
G - Wheels - Suspensions - Brakes
- 1 - FRONT WHEEL
- Removing the front wheel
- Overhauling the front wheel
- Refitting the front wheel
- 2 - FRONT FORK
- Removing the front fork
- Overhauling the front fork
- Refitting the front fork
- 3 - FRONT BRAKE (400)
- Braking system maintenance
- Removing the front brake system
- Removing the brake discs
- Overhauling the front brake components
- Refitting the brake discs
- Refitting the front brake system
- 3 - FRONT BRAKE (620/620Dark)
- Braking system maintenance
- Removing the front brake system
- Removing the brake discs
- Overhauling the front brake components
- Refitting the front brake system
- 4 - REAR WHEEL
- Removing the rear wheel
- Overhauling the rear wheel
- Refitting the rear wheel
- 5 - REAR SWINGARM
- Removing the swingarm
- Swingarm shaft inspection
- Checking swingarm end float
- Refitting the rear swingarm
- 6 - REAR BRAKE
- Removing the rear brake system
- Refitting the rear brake system
- 7 - REAR SUSPENSION
- Rear suspension
- Removing the monoshock absorber
- Overhauling the rear shock absorber
- Removing the rear suspension rocker arm
- Overhauling the rear suspension rocker arm
- Refitting the rear suspension
- 8 - FINAL DRIVE
- Final drive inspection
- Removing the chain sprocket
- Refitting the chain sprocket
- Removing the rear sprocket
- Refitting the rear sprocket
H - Frame
- 1 - HANDLEBAR
- Removing the handlebar
- Refitting the handlebar
- 2 - STEERING
- Adjusting steering bearing play
- Adjusting the steering angle
- Disassembling the steering tube components
- Refitting the steering tube components
- 4 - FOOTPEG SUPPORTS
- Removing the footpegs
- Refitting the footpegs
- 5 - STANDS
- Removing the side stand
- Refitting the side stand
- 6 - FRAME INSPECTION
- Removing the frame and related components
- Checking the frame
- Refitting frame and related components
- 7 - TAIL LIGHT AND NUMBER PLATE HOLDER
- Removing the tail light and number plate holder
- Refitting the tail light and number plate holder
L - Fuel / Exhaust System
- 1 - DESCRIPTION OF THE FUEL FEED SYSTEM
- 2 - PLASTIC FUEL TANK
- Removing the plastic fuel tank
- Removing the filler plug unit - plastic tank
- Refitting the filler plug unit - plastic tank
- Refitting the plastic fuel tank
- 3 - FUEL PUMP
- 4.1 - FUEL FILTER
- 4.2 - FUEL FILTER FOR PLASTIC FUEL TANK
- Replacing the fuel filter - plastic fuel tank
- 5 - PRESSURE REGULATOR
- 6 - THROTTLE BODY FOR PLASTIC TANK
- Removing the throttle body
- Refitting the throttle body
- 7 - AIRBOX
- Removing the airbox
- Refitting the airbox
- 8 - EXHAUST SYSTEM
- Catalytic converter operating principle
- Removing the exhaust system
- Refitting the exhaust system
- 10 - CANISTER FILTER
- Canister Filter System (for USA versions only)
- Removing the Canister filter
- Refitting the Canister Filter
M - Injection - ignition system
- 1 - DESCRIPTION OF THE FUEL INJECTION- IGNITION SYSTEM
- General information on the fuel injection-ignition system
- Fuel circuit
- Intake air circuit
- Operating stages
- 2 - SYSTEM DIAGRAM
- Fuel injection-ignition system diagram
- 3 - FUEL INJECTION- IGNITION SYSTEM COMPONENTS
- Electronic control unit
- Electric injector
- Air temperature / pressure sensor
- Spark plugs
- Coil
- Throttle position sensor
- Rpm/timing sensor
- Main and injection relays
N - Engine
- 1 - REMOVING - REASSEMBLING THE COMPLETE ENGINE
- Removing the engine
- Reassembling the engine
- 2.1 - LUBRICATION SYSTEM: OIL PUMP
- Lubrication system diagram
- Removing the oil pump
- Disassembling the oil pump
- Overhauling the oil pump
- Oil pump reassembly
- Refitting the oil pump
- 2.3 - LUBRICATION SYSTEM: OIL BREATHER TANK
- Removing the oil breather tank
- Refitting the oil breather tank
- 4.1 - HEAD UNIT: CHECKS AND ADJUSTMENTS
- Checking and adjusting valve clearance
- Checking engine timing
- 4.2 - CYLINDER HEADS: SIDE COVERS / TIMING SYSTEM
- Removing the timing system side covers
- Disassembling the timing system
- Reassembling the timing system
- Reassembling the side covers
- 4.3 - HEAD UNIT : CAMSHAFTS
- Removing the engine oil temperature sensor
- Refitting the engine oil temperature sensor
- Disassembling the intake manifold
- Refitting the intake manifolds
- Removing the cam covers
- Refitting the valve covers
- Removing the camshafts
- Checking the camshafts
- Checking the oil seals
- Checking the circlips
- Checking the bearings
- Refitting the camshaft
- Refitting the cam covers
- 4.4 - HEAD UNIT: VALVES - ROCKER ARMS
- Disassembling the engine heads
- Overhauling the head parts
- Reassembling the head
- 5 - CYLINDER / PISTON ASSY
- Removing cylinder / piston assy
- Overhauling the cylinder / piston assy
- Refitting cylinder / piston assy
- 6.1 - CLUTCH UNIT: WET CLUTCH
- Clutch unit
- Disassembling the clutch
- Clutch unit checks and overhaul
- Clutch reassembly
- 6.1 - CLUTCH UNIT: APTC WET CLUTCH
- APTC unit description
- Disassembling the APTC system
- Checking and overhauling the APTC unit
- Reassembling the APTC unit
- 6.2 - CLUTCH ASSEMBLY: CLUTCH COVER
- Removing the clutch cover
- Disassembling the clutch cover
- Reassembling the clutch cover
- Refitting the clutch cover
- 6.3 - CLUTCH ASSEMBLY: PRIMARY DRIVE GEARS
- Disassembling the primary drive gears
- Refitting the primary drive gear and checking meshing play
- 7.1 - GEARBOX: LEVER ASSEMBLY
- Removing the gear selector levers
- Disassembling the gear selector levers
- Removing the gear stopper and ratchet
- Reassembling gear stopper and ratchet
- Reassembling the gear selector lever
- Reassembling the gear selector lever
- 7.2 - GEARBOX: GEARBOX SHAFTS
- Removing the gearbox
- Disassembling the gearbox shafts
- Overhauling the gearbox
- Reassembling the gearbox shafts
- Inspecting the gear selector forks
- Inspecting the fork selector drum
- Reassembling the gearbox
- 8 - FLYWHEEL - GENERATOR
- Removing the generator cover
- Disassembling the generator cover
- Removing the flywheel - generator assembly
- Checking the flywheel - generator assembly
- Refitting flywheel / generator assembly
- Reassembling generator cover
- Checking the engine sensor air gap
- 9.1 - CASING: OUTER COMPONENTS
- Removing the outer components
- Reassembling the outer components
- Removing the timing lay gear
- Reassembling the timing lay gear
- Removing the starter motor driven gear
- Refitting the starter motor driven gear
- 9.2 - CASING UNIT: CRANKCASES
- Opening the casings
- Overhauling the casings
- Overhauling the main bearings
- Reassembling the casings
- Shimming the shafts
- Closing the casings
- 9.3 - CASING: CONNECTING RODS
- Removing the connecting rods
- Disassembling the connecting rods
- Overhauling the connecting rods
- Reassembling the connecting rods
- Refitting the connecting rod unit
P - Electric system
- 1 - WIRING DIAGRAM
- Wiring diagram key
- Wire color coding - wiring diagram
- Legend of fuse box
- Arrangement of wiring on frame
- Diagram A
- Diagram B
- Diagram C
- Diagram D
- Diagram E
- Diagram F
- Diagram G
- Diagram H
- Diagram J
- Diagram K
- Diagram L
- Diagram M
- Diagram N
- Diagram P
- Diagram Q
- 2 - CHARGING SYSTEM - BATTERY
- Checking the charging system
- Recharging the battery
- Adding electrolyte
- Battery
- Battery mount
- Generator
- Rectifier - regulator
- 3 - ELECTRIC STARTING
- Electric starting system
- Starter motor
- Starter contactor
- 4 - LIGHTING DEVICES
- Changing light bulbs
- Beam setting
- 5 - INDICATORS AND LIGHTING SYSTEM
- Checking the indicators and lighting system components
- Changing light bulbs
- 6 - PROTECTION AND SAFETY DEVICES
- Checking protection and safety devices components
- Checking the fuses
- 7 - WARNING LIGHTS AND INDICATORS
- Instrument panel
- 8 - IMMOBILIZER AND TRANSPONDER
- 9 - TESTERS
- How to use the multimeter to check electric systems
Subject index


WIRING SCHEMATICS

- Fuses
- Wire color coding
Legend
- 1) Right switch
- 2) Transponder antenna
- 3) Ignition switch
- 4) Main relay
- 5) Fuse box
- 6) Starter motor
- 7) Solenoid starter
- 8) Battery
- 9) Regulator fuse
- 10) Regulator
- 11) Generator
- 12) RH rear turn indicator
- 13) Tail light
- 14) Number plate light
- 15) LH rear turn indicator
- 16) Fuel tank
- 17) Self-diagnosis connector
- 18) Speed sensor
- 19) Horizontal cylinder coil
- 20) Vertical cylinder coil
- 21) Horizontal cylinder spark plug
- 22) Vertical cylinder spark plug
- 23) Horizontal cylinder injector
- 24) Vertical cylinder injector
- 25) Throttle position sensor
- 26) Timing/rpm sensor
- 27) Side stand switch
- 28) ECU
- 29) Injection relay
- 30) Neutral switch
- 31) Oil pressure switch
- 32) Rear stop switch
- 33) Front stop switch
- 34) Left switch
- 35) Air temperature/pressure sensor
- 36) Instrument panel
- 37) LH front turn indicator
- 38) Horn
- 39) Headlight
- 40) RH front turn indicator
- 41) Oil temperature sensor (control unit)
- 42) Oil temperature sensor (instrument)
- 43) Clutch switch