Ducati Monster 796 - Service Manual - Reparation - Werkstatthandbuch - Manuale di Servizio - Taller

DUCATI MONSTER 796 - SERVICE MANUAL - MANUALE DI SERVIZIO - MANUEL DE REPARATION - REPARATURANLEITUNG - MANUAL DE TALLER


- English, Italiano, French, Spanish, German, Portuguese and Japanese Service Manual for motorcycles Ducati Monster 796.

 
INDEX:

1 - GENERAL

    1 - How to use this manual

    -     Layout of the manual

    2 - Symbols - Abbreviations - References

    -     Product specifications

    3 - Hazardous Products - Warnings

    -     General safety rules

    -     General mainten

2 - INFORMATION ABOUT THE MODEL

    1 - Identification data

    -     Monster 796 / 796 ABS identification data

3 - TECHNICAL DATA

    1.1 - Technical specifications

    -     General

    -     Colours

    -     Transmission

    -     Timing system/valves

    -     Exhaust system

    -     Cylinder/Piston

    -     Gearbox

    -     Cooling system

    -     Front wheel

    -     Front suspension

    -     Rear wheel

    -     Rear suspension

    -     Hydraulic brakes

    -     Charging system/alternator

    -     Ignition system

    -     Fuel system

    -     Injection system

    -     Lights/instrument panel


    1.2 - Dimensions


    2 - Fuel, lubricants and other fluids


    3 - Torque settings

    -     Frame torque settings

    -     Engine torque settings


    4 - Service tools

    -     Specific tools for the engine

    -     Specific tools for the frame

    -     Appropriate diagnosis tools

4 - MAINTENANCE OPERATIONS

    1 - Vehicle pre-delivery


    2 - Routine maintenance table

    -     Scheduled maintenance chart: operations to be carried out by the dealer

    -     Scheduled maintenance chart: operations to be carried out by the customer


    3 - Maintenance operations

    -     Checking the engine oil level

    -     Changing the engine oil and filter cartridge

    -     Checking valve clearances

    -     Changing and cleaning the air filters

    -     Changing the brake fluid

    -     Draining the brake circuit

    -     Filling the brake system with fluid

    -     Changing the clutch fluid

    -     Draining the clutch hydraulic circuit

    -     Filling the clutch circuit

    -     Adjusting the steering head bearings

    -     Adjusting the chain tension

    -     Checking brake pad wear and changing brake pads

    -     Adjusting the throttle cable

    -     Adjusting the clutch lever and front brake lever

    -     Adjusting the position of the gear change and rear brake pedals

    -     Adjusting the rear shock absorber

    -     Adjusting the exhaust valve bowden cable

    -     Fitting a new motor and new cable

    -     Fitting a new exhaust valve cable with used motor

    -     Fitting a new exhaust valve motor with used cable

5 - FAIRINGS

    1 - Headlight fairing - rear-view mirrors

    -     Removal of the rear-view mirrors

    -     Refitting the rear-view mirrors

    -     Removal of the headlight fairing

    -     Refit the headlight fairing


    2 - Fairings

    -     Removal of the fuel tank fairings

    -     Refitting the fuel tank fairings


    3 - Seat

    -     Removal of the seat

    -     Refitting the seat

    -     Removal of the tool tray

    -     Refitting the tool tray


    4 - Front and rear mudguard

    -     Removal of the front mudguard

    -     Refitting the front mudguard

    -     Removing the rear mudguard

    -     Refitting the rear mudguard

6 - ELECTRIC SYSTEM AND ENGINE CONTROL SYSTEM

    1 - Wiring diagram

    -     796 Wiring diagram

    -     Key to wiring diagram

    -     796 ABS Wiring diagram

    -     Key to wiring diagram

    -     Wiring diagram colour codes

    -     Key to fuse box

    -     Routing of wiring on frame

    -     Table A

    -     Table B

    -     Table C

    -     Table D

    -     Table E

    -     Table F

    -     Table G

    -     Table H

    -     Table J

    -     Table K

    -     Table L

    -     Table M

    -     Table N

    -     Table O

    -     Table P

    -     Table Q

    -     Table R

    -     Table S

    -     Table T

    -     Table U

    -     Table V


    2 - Battery charging system

    -     Checking the battery charging system

    -     Recharging the battery

    -     Topping up the electrolyte

    -     Battery

    -     Battery support

    -     Alternator

    -     Rectifier-regulator


    3 - Electric starting system

    -     Electric starting system

    -     Starter motor

    -     Starter contactor


    4 - Lights and indicating devices

    -     Renewal of the headlight

    -     Changing bulbs

    -     High beam headlights relay

    -     Headlight aim


    5 - Indicating devices

    -     Checking the indicating devices

    -     Changing light bulbs


    6 - Protection and safety devices

    -     Checking protection and safety device components

    -     Checking the fuses


    7 - Instruments

    -     Instrument panel

    -     Instrument panel system

    -     Display settings and functions


    8 - immobilizer and transponder


    10 - Description of the system

    -     General information on the fuel injection-ignition system

    -     Fuel circuit

    -     Intake air circuit

    -     Operating phases


    11 - Fuel injection - ignition system


    12 - System components

    -     Electronic Control Unit (ECU)

    -     Fuel injectors

    -     Stepper motor

    -     Lambda sensor

    -     Air pressure sensor

    -     Temperature sensor

    -     Spark plug

    -     Coil

    -     Throttle Position Sensor (TPS)

    -     Timing/rpm sensor

    -     Injection and main relay


    13 - Diagnostic instruments

    -     Using a multimeter to check the electrical systems

    -     Description of the Ducati Diagnostic System tester

    -     Tester power supply

    -     DDS diagnosis instrument

    -     Checking and adjusting timing belt tension

    -     Self-adaptation of the throttle position sensor (TPS)

    -     Adjusting the idle speed

    -     Check the engine oil pressure

    -     Cylinder compression test

    -     Fuel pressure test

    -     Immobilizer override procedure

    -     Guided diagnosis

    -     Testing the battery charging system

    -     ABS diagnosis

    -     Icons table

7 - CHASSIS

    1 - Front wheel

    -     Removal of the front wheel

    -     Overhauling the front wheel

    -     Refitting the front wheel


    2 - Rear wheel

    -     Removal of the rear wheel

    -     Overhauling the rear wheel

    -     Refitting the rear wheel


    3 - Front brake control

    -     Removal of the front brake master cylinder

    -     Refitting the front brake master cylinder

    -     Maintenance operations

    -     Removal of the front brake system

    -     Removal of the brake discs

    -     Overhauling the front brake components

    -     Refitting the brake discs

    -     Refitting the front brake system


    4 - Rear brake control

    -     Removal of the rear brake lever

    -     Disassembly of the rear brake control

    -     Refitting the rear brake control

    -     Removal of the rear brake calliper

    -     Refitting the rear brake calliper


    5 - ABS system information

    -     Operating principle

    -     ABS system operating information

    -     ABS system deactivation


    6 - System components

    -     Replacing the front phonic wheel sensor

    -     Replacing the rear phonic wheel sensor

    -     Removing of the ABS control unit

    -     Refitting the ABS control unit

    -     Flexible wiring/hoses positioning

    -     Table A

    -     Table B

    -     Table C

    -     Table D

    -     Table E

    -     Table F


    7 - ABS components maintenance

    -     Adjusting of the AIR-GAP phonic wheel sensor

    -     Bleeding of the ABS hydraulic system


    8.1 - Handlebar unit: Throttle twistgrip

    -     Removal of the handlebar

    -     Refitting the handlebar

    -     Adjusting the throttle cable

    -     Removal of the throttle twistgrip

    -     Refitting the throttle twistgrip


    8.2 - Handlebar unit: clutch lever

    -     Removal of the clutch master cylinder assembly

    -     Refitting the clutch master cylinder assembly

    -     Removal of the clutch transmission unit

    -     Refitting the clutch transmission unit


    9 - Gearchange mechanism

    -     Removal of the gearchange control

    -     Disassembly of the gearchange control

    -     Refitting the gearchange mechanism


    10.1 - Fork - steering head: front fork

    -     Removal of the front forks

    -     Overhauling the front forks

    -     Refitting the front forks


    10.2 - Fork - steering head: Steering

    -     Adjusting the steering head bearings

    -     Steering angle adjustment

    -     Removal of the steering head components

    -     Refitting the steering head components


    12 - Rear shock absorber assembly

    -     Rear suspension system

    -     Removal of the rear shock absorber

    -     Overhauling the rear shock absorber

    -     Refitting the rear shock absorber


    13 - Rear swingarm

    -     Removal of the rear wheel eccentric hub and rear wheel shaft

    -     Removal of the rear brake disc

    -     Refitting the rear brake disc

    -     Refitting the rear wheel eccentric hub and rear wheel shaft

    -     Removal of the swingarm

    -     Inspecting the swingarm pivot

    -     Checking swingarm end float

    -     Refitting the swingarm


    14 - Final drive

    -     Inspecting the final drive

    -     Removing of the front sprocket

    -     Refitting the front sprocket

    -     Replacing of the rear sprocket

    -     Refitting the rear sprocket

    -     Washing the chain

    -     Lubricating the chain


    15 - Footrest brackets

    -     Removal of the footrest brackets

    -     Refitting the footrest brackets


    16 - Stands

    -     Removing of the side stand

    -     Refitting the side stand


    17 - Frame inspection

    -     Disassembly of structural components and the frame

    -     Removal of the frame

    -     Removal of the rear subframe

    -     Checking the frame

    -     Reassembly of the rear subframe

    -     Refitting the rear subframe


    18 - Tail light-number plate holder and locks

    -     Removal of the tail light-protection-number plate holder assembly

    -     Refitting the tail light-protection-number plate holder assembly

    -     Removal of the seat release mechanism

    -     Refitting the seat release mechanism

    -     Removal of the number plate holder

    -     Refitting the number plate holder

8 - FUEL/EXHAUST SYSTEM

    2 - Fuel tank

    -     Removal of the fuel tank

    -     Removal of the fuel tank filler cap

    -     Refitting the filler cap

    -     Removal of the fuel tank flange

    -     Refitting the fuel tank flange

    -     Refitting the fuel tank


    6 - Throttle body

    -     Removal of the throttle body

    -     Refitting the throttle body


    7 - Air intake

    -     Removal of the airbox

    -     Removal of the oil breather valve

    -     Refitting the oil breather valve

    -     Refitting the airbox


    8 - Exhaust system

    -     Operating principle of the catalytic converter

    -     Removal of the exhaust system

    -     Refitting the exhaust system

9 - ENGINE

    1 - Removal–refitting of the engine assembly

    -     Removal of the engine

    -     Refitting the engine


    2.1 - Lubrication system: oil pump

    -     Removal of the oil pump

    -     Disassembly of the oil pump

    -     Reassembly of the oil pump

    -     Refitting the oil pump


    2.2 - Lubrication system: oil cooler

    -     Removal of the oil cooler

    -     Oil cooler inspection

    -     Refitting the oil cooler


    4.1 - Cylinder head assemblies: checks and adjustments

    -     Checking and adjusting valve clearances

    -     Checking the engine timing


    4.2 - Cylinder head assemblies: timing belt covers/timing system

    -     Removal of the timing belt covers

    -     Removal of the timing system assembly

    -     Disassembly and reassembly of the timing pulleys

    -     Refitting the timing system assembly

    -     Refitting the timing belt covers


    4.3 - Cylinder head assemblies: camshafts

    -     Removal of the intake manifolds

    -     Refitting the intake manifolds

    -     Removal of the side covers

    -     Removal of the valve covers

    -     Refitting the valve covers

    -     Removal of the camshafts

    -     Inspecting the camshafts

    -     Checking the oil seals

    -     Refitting the camshafts

    -     Refitting side covers


    4.4 - Cylinder head assemblies: valves - rocker arms

    -     Removal of the cylinder head assembly

    -     Overhaul of cylinder head components

    -     Refitting the cylinder head assembly

    -     Refitting the cylinder heads


    5 - Cylinder/piston assemblies

    -     Removal of the cylinder/piston assembly

    -     Overhaul of the cylinder barrel/piston components

    -     Refitting the cylinder/piston assembly


    6.1 - Clutch assembly: APTC wet clutch

    -     Description of the APTC clutch assembly

    -     Removal of the APTC clutch

    -     Disassembly of the clutch hub-plates-centre assembly

    -     Overhaul and inspection of the APTC clutch components

    -     Reassembly of the clutch hub-plates-centre assembly

    -     Refitting the APTC clutch


    6.2 - Clutch assembly: clutch cover

    -     Removal of the clutch cover

    -     Disassembly of the clutch cover

    -     Reassembly of the clutch cover

    -     Refitting the clutch cover


    6.3 - Clutch assembly: primary drive gears

    -     Removal of the primary drive gear

    -     Refitting the primary drive gears and checking backlash


    7.1 - Gearbox assembly: gearchange mechanism

    -     Removal of the gear selector lever

    -     Disassembly of gear interlock plunger and pawl assembly

    -     Refitting the pawl assembly and the gear interlock plunger

    -     Refitting the gear selector lever


    7.2 - Gearbox assembly: gearbox shafts

    -     Removal of the gearbox assembly

    -     Disassembly of the gearbox shafts

    -     Overhaul of the gearbox

    -     Inspection of the gear selector forks

    -     Inspection of the gear selector drum

    -     Reassembly of the gearbox shafts

    -     Reassembly of the gearbox


    8 - Flywheel - alternator

    -     Removal of the generator cover

    -     Disassembly of the generator cover

    -     Removal of the flywheel/alternator assembly

    -     Checking the flywheel/alternator assembly

    -     Refitting the flywheel-alternator assembly

    -     Reassembly of the generator cover

    -     Refitting the generator cover


    9.1 - Crankcase assembly: external components

    -     Removing outer components

    -     Refitting the external components

    -     Removal of the timing gears

    -     Refitting the timing gears

    -     Removal of the starter motor idler gear

    -     Refitting the starter motor gear


    9.2 - Crankcase assembly: crankcase halves

    -     Separation of the crankcase halves

    -     Overhaul of the crankcase halves

    -     Overhauling the main bearings

    -     Reassembly of the crankcase halves

    -     Shimming the shafts

    -     Reassembly of the crankcase halves


    9.3 - Crankcase assembly: crankshaft/connecting rods assembly

    -     Removal of the crankshaft/connecting rods assembly

    -     Disassembly of the crankshaft/connecting rods assembly

    -     Overhaul of the connecting rods

    -     Reassembly of the connecting rods

    -     Refitting the crankshaft/connecting rod assembly