Ducati Monster 796 Manuel d'instructions

1 - General

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01 - General

02 - Information about the model

03 - Technical data

04 - Maintenance operations

05 - Fairings

06 - Electric system and engine control system

07 - Chassis

08 - Fuel/Exhaust System

09 - Engine

0GENERAL INDEX

Section 1

01 - General

1 - How to use this manual 3

Layout of the manual 4

2 - Symbols - Abbreviations - References 5

Product specifications 6

3 - Hazardous Products - Warnings 8

General safety rules 8

General maintenance indications 9

Section 2

02 - Information about the model

1 - Identification data 3

Monster 796 / 796 ABS identification data 3

Section 3

03 - Technical data

1.1 - Technical specifications 3

General 3

Colours 4

Transmission 4

Timing system/valves 4

Exhaust system 5

Cylinder/Piston 5

Gearbox 6

Cooling system 6

Front wheel 6

Front suspension 6

Rear wheel 6

1 - General

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Rear suspension 7

Hydraulic brakes 7

Charging system/alternator 8

Ignition system 8

Fuel system 8

Injection system 8

Lights/instrument panel 8

1.2 - Dimensions 9

2 - Fuel, lubricants and other fluids 10

3 - Torque settings 11

Frame torque settings 11

Engine torque settings 17

4 - Service tools 20

Specific tools for the engine 20

Specific tools for the frame 25

Appropriate diagnosis tools 28

Section 4

04 - Maintenance operations

1 - Vehicle pre-delivery 3

2 - Routine maintenance table 4

Scheduled maintenance chart: operations to be carried out by the dealer 4

Scheduled maintenance chart: operations to be carried out by the customer 5

3 - Maintenance operations 6

Checking the engine oil level 6

Changing the engine oil and filter cartridge 6

Checking valve clearances 9

Changing and cleaning the air filters 14

Changing the brake fluid 16

Draining the brake circuit 21

Filling the brake system with fluid 23

Changing the clutch fluid 26

Draining the clutch hydraulic circuit 28

Filling the clutch circuit 30

Adjusting the steering head bearings 32

Adjusting the chain tension 34

Checking brake pad wear and changing brake pads 35

Adjusting the throttle cable 38

Adjusting the clutch lever and front brake lever 40

Adjusting the position of the gear change and rear brake pedals 41

Adjusting the rear shock absorber 42

Adjusting the exhaust valve bowden cable 44

Fitting a new motor and new cable 47

Fitting a new exhaust valve cable with used motor 53

Fitting a new exhaust valve motor with used cable 60

1 - General

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Section 5

05 - Fairings

1 - Headlight fairing - rear-view mirrors 3

Removal of the rear-view mirrors 4

Refitting the rear-view mirrors 4

Removal of the headlight fairing 5

Refit the headlight fairing 8

2 - Fairings 9

Removal of the fuel tank fairings 10

Refitting the fuel tank fairings 12

3 - Seat 16

Removal of the seat 17

Refitting the seat 18

Removal of the tool tray 18

Refitting the tool tray 19

4 - Front and rear mudguard 20

Removal of the front mudguard 21

Refitting the front mudguard 23

Removing the rear mudguard 25

Refitting the rear mudguard 25

Section 6

06 - Electric system and engine control system

1 - Wiring diagram 4

796 Wiring diagram 4

Key to wiring diagram 5

796 ABS Wiring diagram 6

Key to wiring diagram 7

Wiring diagram colour codes 7

Key to fuse box 8

Routing of wiring on frame 9

Table A 11

Table B 12

Table C 14

Table D 15

Table E 17

Table F 19

Table G 23

Table H 24

Table J 26

Table K 27

Table L 28

Table M 31

Table N 34

Table O 36

Table P 38

Table Q 42

Table R 43

1 - General

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Table S 44

Table T 45

Table U 46

Table V 47

2 - Battery charging system 48

Checking the battery charging system 48

Recharging the battery 49

Topping up the electrolyte 50

Battery 53

Battery support 56

Alternator 57

Rectifier-regulator 60

3 - Electric starting system 66

Electric starting system 66

Starter motor 67

Starter contactor 71

4 - Lights and indicating devices 76

Renewal of the headlight 76

Changing bulbs 81

High beam headlights relay 84

Headlight aim 86

5 - Indicating devices 87

Checking the indicating devices 87

Changing light bulbs 92

6 - Protection and safety devices 93

Checking protection and safety device components 93

Checking the fuses 95

7 - Instruments 97

Instrument panel 97

Instrument panel system 98

Display settings and functions 100

8 - immobilizer and transponder 129

10 - Description of the system 132

General information on the fuel injection-ignition system 132

Fuel circuit 135

Intake air circuit 136

Operating phases 138

11 - Fuel injection - ignition system 139

12 - System components 140

Electronic Control Unit (ECU) 140

Fuel injectors 142

Stepper motor 143

Lambda sensor 144

Air pressure sensor 146

Temperature sensor 148

Spark plug 150

1 - General

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Coil 152

Throttle Position Sensor (TPS) 155

Timing/rpm sensor 156

Injection and main relay 157

13 - Diagnostic instruments 158

Using a multimeter to check the electrical systems 158

Description of the Ducati Diagnostic System tester 160

Tester power supply 162

DDS diagnosis instrument 165

Checking and adjusting timing belt tension 165

Self-adaptation of the throttle position sensor (TPS) 170

Adjusting the idle speed 174

Check the engine oil pressure 179

Cylinder compression test 183

Fuel pressure test 186

Immobilizer override procedure 192

Guided diagnosis 196

Testing the battery charging system 199

ABS diagnosis 201

Icons table 202

Section 7

07 - Chassis

1 - Front wheel 5

Removal of the front wheel 6

Overhauling the front wheel 8

Refitting the front wheel 10

2 - Rear wheel 13

Removal of the rear wheel 14

Overhauling the rear wheel 15

Refitting the rear wheel 16

3 - Front brake control 18

Removal of the front brake master cylinder 19

Refitting the front brake master cylinder 20

Maintenance operations 22

Removal of the front brake system 22

Removal of the brake discs 24

Overhauling the front brake components 24

Refitting the brake discs 24

Refitting the front brake system 25

4 - Rear brake control 29

Removal of the rear brake lever 30

Disassembly of the rear brake control 32

Refitting the rear brake control 33

Removal of the rear brake calliper 37

Refitting the rear brake calliper 39

5 - ABS system information 41

Operating principle 41

1 - General

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ABS system operating information 42

ABS system deactivation 44

6 - System components 45

Replacing the front phonic wheel sensor 46

Replacing the rear phonic wheel sensor 48

Removing of the ABS control unit 49

Refitting the ABS control unit 50

Flexible wiring/hoses positioning 53

Table A 54

Table B 55

Table C 57

Table D 59

Table E 60

Table F 63

7 - ABS components maintenance 65

Adjusting of the AIR-GAP phonic wheel sensor 65

Bleeding of the ABS hydraulic system 67

8.1 - Handlebar unit: Throttle twistgrip 68

Removal of the handlebar 69

Refitting the handlebar 70

Adjusting the throttle cable 71

Removal of the throttle twistgrip 71

Refitting the throttle twistgrip 73

8.2 - Handlebar unit: clutch lever 74

Removal of the clutch master cylinder assembly 75

Refitting the clutch master cylinder assembly 76

Removal of the clutch transmission unit 78

Refitting the clutch transmission unit 79

9 - Gearchange mechanism 84

Removal of the gearchange control 85

Disassembly of the gearchange control 86

Refitting the gearchange mechanism 87

10.1 - Fork - steering head: front fork 88

Removal of the front forks 89

Overhauling the front forks 90

Refitting the front forks 103

10.2 - Fork - steering head: Steering 104

Adjusting the steering head bearings 105

Steering angle adjustment 106

Removal of the steering head components 107

Refitting the steering head components 113

12 - Rear shock absorber assembly 117

Rear suspension system 118

Removal of the rear shock absorber 118

Overhauling the rear shock absorber 119

Refitting the rear shock absorber 122

13 - Rear swingarm 123

Removal of the rear wheel eccentric hub and rear wheel shaft 125

1 - General

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Removal of the rear brake disc 127

Refitting the rear brake disc 128

Refitting the rear wheel eccentric hub and rear wheel shaft 129

Removal of the swingarm 133

Inspecting the swingarm pivot 136

Checking swingarm end float 137

Refitting the swingarm 138

14 - Final drive 142

Inspecting the final drive 143

Removing of the front sprocket 144

Refitting the front sprocket 146

Replacing of the rear sprocket 148

Refitting the rear sprocket 149

Washing the chain 150

Lubricating the chain 150

15 - Footrest brackets 151

Removal of the footrest brackets 152

Refitting the footrest brackets 155

16 - Stands 161

Removing of the side stand 162

Refitting the side stand 164

17 - Frame inspection 165

Disassembly of structural components and the frame 166

Removal of the frame 168

Removal of the rear subframe 171

Checking the frame 173

Reassembly of the rear subframe 174

Refitting the rear subframe 176

18 - Tail light-number plate holder and locks 177

Removal of the tail light-protection-number plate holder assembly 178

Refitting the tail light-protection-number plate holder assembly 182

Removal of the seat release mechanism 186

Refitting the seat release mechanism 187

Removal of the number plate holder 189

Refitting the number plate holder 190

Section 8

08 - Fuel/Exhaust System

2 - Fuel tank 3

Removal of the fuel tank 4

Removal of the fuel tank filler cap 7

Refitting the filler cap 7

Removal of the fuel tank flange 8

Refitting the fuel tank flange 9

Refitting the fuel tank 10

6 - Throttle body 19

Removal of the throttle body 20

1 - General

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Refitting the throttle body 25

7 - Air intake 31

Removal of the airbox 32

Removal of the oil breather valve 37

Refitting the oil breather valve 37

Refitting the airbox 38

8 - Exhaust system 44

Operating principle of the catalytic converter 46

Removal of the exhaust system 47

Refitting the exhaust system 52

10 - Evaporative emissions canister 58

Evaporative emissions canister system (USA versions only) 59

Removal of the evaporative emissions canister 60

Refitting the evaporative emissions canister 62

Section 9

09 - Engine

1 - Removal–refitting of the engine assembly 4

Removal of the engine 5

Refitting the engine 7

2.1 - Lubrication system: oil pump 9

Removal of the oil pump 10

Disassembly of the oil pump 11

Reassembly of the oil pump 12

Refitting the oil pump 13

2.2 - Lubrication system: oil cooler 14

Removal of the oil cooler 15

Oil cooler inspection 18

Refitting the oil cooler 18

4.1 - Cylinder head assemblies: checks and adjustments 22

Checking and adjusting valve clearances 23

Checking the engine timing 27

4.2 - Cylinder head assemblies: timing belt covers/timing system 29

Removal of the timing belt covers 30

Removal of the timing system assembly 31

Disassembly and reassembly of the timing pulleys 34

Refitting the timing system assembly 35

Refitting the timing belt covers 44

4.3 - Cylinder head assemblies: camshafts 45

Removal of the intake manifolds 47

Refitting the intake manifolds 49

Removal of the side covers 51

Removal of the valve covers 53

Refitting the valve covers 54

Removal of the camshafts 55

1 - General

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Inspecting the camshafts 57

Checking the oil seals 57

Refitting the camshafts 58

Refitting side covers 61

4.4 - Cylinder head assemblies: valves - rocker arms 63

Removal of the cylinder head assembly 64

Overhaul of cylinder head components 68

Refitting the cylinder head assembly 76

Refitting the cylinder heads 82

5 - Cylinder/piston assemblies 84

Removal of the cylinder/piston assembly 85

Overhaul of the cylinder barrel/piston components 88

Refitting the cylinder/piston assembly 94

6.1 - Clutch assembly: APTC wet clutch 98

Description of the APTC clutch assembly 99

Removal of the APTC clutch 100

Disassembly of the clutch hub-plates-centre assembly 102

Overhaul and inspection of the APTC clutch components 103

Reassembly of the clutch hub-plates-centre assembly 105

Refitting the APTC clutch 107

6.2 - Clutch assembly: clutch cover 110

Removal of the clutch cover 111

Disassembly of the clutch cover 112

Reassembly of the clutch cover 113

Refitting the clutch cover 114

6.3 - Clutch assembly: primary drive gears 116

Removal of the primary drive gear 117

Refitting the primary drive gears and checking backlash 119

7.1 - Gearbox assembly: gearchange mechanism 122

Removal of the gear selector lever 123

Disassembly of gear interlock plunger and pawl assembly 126

Refitting the pawl assembly and the gear interlock plunger 127

Refitting the gear selector lever 129

7.2 - Gearbox assembly: gearbox shafts 131

Removal of the gearbox assembly 132

Disassembly of the gearbox shafts 134

Overhaul of the gearbox 144

Inspection of the gear selector forks 145

Inspection of the gear selector drum 146

Reassembly of the gearbox shafts 147

Reassembly of the gearbox 151

8 - Flywheel - alternator 152

Removal of the generator cover 154

Disassembly of the generator cover 156

Removal of the flywheel/alternator assembly 157

Checking the flywheel/alternator assembly 159

Refitting the flywheel-alternator assembly 164

Reassembly of the generator cover 166

Refitting the generator cover 167

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