Ducati Monster 400 620 Workshop Manual 2006 Onwards
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:600+
DOWNLOADABLE:YES
FILE TYPE:PDF
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Ducati Monster 400 620 Workshop Manual 2006 Onwards
1 – HOW TO USE THE MANUAL:
This manual has been prepared for Ducati Authorized Service Centers and workshop personnel involved in the maintenance and repair of Ducati motorcycles. It gives fundamental information on how to work in perfect harmony with the concepts of “good technique” and “safety on work sites” for servicing or replacing of original spare parts both for chassis and engine concerning this motorcycle. All operations described in this manual must be carried out by senior skilled technicians, who are requested to strictly follow the Manufacturer’s instructions. Some information has been intentionally omitted, as, at our advice, a specialized technician must have this technical background. Additional information on how to install the different components is provided in the spare parts catalogue.
Manual layout:
This manual is divided in sections (1), each identified by a letter. Each section (1) includes several chapters (2), which are numbered consecutively. Each chapter (2) may include several paragraphs (3). The repair procedures described in this manual include the necessary disassembly and re-assembly instructions, i.e. the full procedure is detailed starting with the motorcycle fully assembled until bringing it back to the original condition.
TABLE OF CONTENTS:
Ducati Monster 400 620 Workshop Manual 2006 Onwards
DESCRIPTION 0
1 – HOW TO USE THE MANUAL 3
Manual layout 4
2 – SYMBOLS – ABBREVIATIONS –
REFERENCES 5
Product specifications 8
3 – DANGEROUS PRODUCTS –
WARNINGS 10
General safety rules 10
General maintenance indications 12
Section B
MODEL-SPECIFIC
INFORMATION 0
1 – IDENTIFICATION DATA 3
Identification data for Monster 400 i.e. 3
Identification data for Monster 620 i.e. 5
Section C
TECHNICAL SPECIFICATION 0
1.1 – TECHNICAL DATA 9
Description 9
Colors 10
Transmission assembly 10
Timing/valves 11
Cylinder / piston 11
Gearbox 12
Cooling system 12
Front wheel 12
Front suspension 12
Rear wheel 12
Rear suspension 13
Hydraulic brakes 13
Charging system / generator 13
Ignition system 14
Fuel system 14
Injection system 14
Lights / instrument panel 14
1.2 – DIMENSIONS 15
2 – FUELS AND LUBRICANTS 16
3 – TORQUE SETTINGS 24
Frame torque settings 24
Engine torque settings 28
4 – SERVICE TOOLS 31
Engine special tools 31
Frame special tool 36
Section D
USE AND MAINTENANCE 0
1 – PRELIMINARY CHECKS 3
Running-in precautions 3
Pre-ride checks 4
2 – STARTING – ENGINE WARM-UP 6
Starting the engine 6
3 – ROUTINE MAINTENANCE TABLE 10
4 – MAINTENANCE OPERATIONS 12
Checking the engine oil level 12
Changing the engine oil and filter cartridge 13
Checking valve clearances 14
Adjusting valve clearances 15
Changing and cleaning the air filters 16
Changing the brake fluid 17
Draining the braking circuit 19
Filling the brake circuit 20
Changing the clutch fluid 22
Draining the clutch circuit 23
Filling the clutch circuit 24
Adjusting steering bearings play 26
Adjusting chain tension 27
Checking brake pad wear. Changing brake pads 28
Adjusting the throttle and choke cables 31
Adjusting the position of the gear change and rear brake
pedals 33
Adjusting the rear shock absorber 34
5 – DIAGNOSIS INSTRUMENTS 35
Tester description 36
Instrument power supply 37
DDS diagnosis instrument 39
Checking and adjusting timing belt tension 40
Adjusting the throttle body 43
Checking engine oil pressure 57
Checking cylinder compression 60
Checking fuel pressure 62
Procedure to override the immobilizer system 64
Guided diagnosis 67
Checking the charging system 69
Icons table 71
Section E
FAIRING 0
1 – HEADLIGHT FAIRING (FOR 620
VERSION
ONLY) – REAR-VIEW MIRRORS 3
Disassembling the rear-view mirrors 4
Refitting the rear-view mirrors 4
Removing the headlight fairing (620 version only) 5
Refitting the headlight fairing (620 version only) 5
3 – SEAT 6
Removing the seat 7
Refitting the seat 8
Removing the splashguard 9
Refitting the splashguard 9
Removing the side body panels 10
Refitting the side body panels
4 – FRONT AND REAR MUDGUARD 11
Removing the front mudguard 12
Refitting the front mudguard 12
Removing the rear mudguard 13
Refitting the rear mudguard 13
Section F
CONTROLS – DEVICES 0
1 – THROTTLE CONTROL – CHOKE 3
Adjusting the throttle and choke cables 4
Disassembling the throttle control 4
Reassembling the throttle control 4
Removing the choke control 5
Refitting the choke control 6
2 – CLUTCH HYDRAULIC CONTROL 8
Removing the clutch master cylinder assembly 9
Refitting the clutch master cylinder assembly 10
Removing the clutch transmission unit 11
Refitting the clutch transmission assembly 12
3 – FRONT BRAKE CONTROL 14
Removing the front brake master cylinder 15
Refitting the front brake master cylinder 15
4 – REAR BRAKE CONTROL 16
Removing the rear brake master cylinder 17
Disassembling the rear brake control 18
Refitting the rear brake master cylinder 18
5 – GEAR CHANGE CONTROL 20
Removing the gear change control 21
Disassembling the gear change control 21
Refitting the gear change control 21
6 – SEAT LOCK AND RELEASING
MECHANISMS 22
Removing the seat releasing mechanism 23
Refitting the seat releasing mechanism 23
Section G
WHEELS – SUSPENSIONS –
BRAKES 0
1 – FRONT WHEEL 3
Removing the front wheel 4
Overhauling the front wheel 6
Refitting the front wheel 8
2 – FRONT FORK 10
Removing the front fork 11
Overhauling the front fork 12
Refitting the front fork 18
3 – FRONT BRAKE (400) 19
Braking system maintenance 20
Removing the front brake system 20
Removing the brake discs 21
Overhauling the front brake components 21
Refitting the brake discs 22
Refitting the front brake system 22
3 – FRONT BRAKE (620/620DARK) 24
Braking system maintenance 25
Removing the front brake system 25
Removing the brake discs 26
Overhauling the front brake components 26
Refitting the front brake system 27
4 – REAR WHEEL 29
Removing the rear wheel 30
Overhauling the rear wheel 31
Refitting the rear wheel 32
5 – REAR SWINGARM 33
Removing the swingarm 34
Swingarm shaft inspection 35
Checking swingarm end float 35
Refitting the rear swingarm 36
6 – REAR BRAKE 37
Removing the rear brake system 38
Refitting the rear brake system 39
7 – REAR SUSPENSION 40
Rear suspension 41
Removing the monoshock absorber 41
Overhauling the rear shock absorber 42
Removing the rear suspension rocker arm 43
Overhauling the rear suspension rocker arm 44
Refitting the rear suspension 45
8 – FINAL DRIVE 46
Final drive inspection 47
Removing the chain sprocket 48
Refitting the chain sprocket 48
Removing the rear sprocket 49
Refitting the rear sprocket 49
Section H
FRAME 0
1 – HANDLEBAR 3
Removing the handlebar 4
Refitting the handlebar 4
2 – STEERING 5
Adjusting steering bearing play 6
Adjusting the steering angle 6
Disassembling the steering tube components 7
Refitting the steering tube components 8
4 – FOOTPEG SUPPORTS 10
Removing the footpegs 11
Refitting the footpegs 12
5 – STANDS 13
Removing the side stand 14
Refitting the side stand 14
6 – FRAME INSPECTION 15
Removing the frame and related components 16
Checking the frame 20
Refitting frame and related components
7 – TAIL LIGHT AND NUMBER PLATE
HOLDER 21
Removing the tail light and number plate holder 22
Refitting the tail light and number plate holder 22
Section L
FUEL SYSTEM – EXHAUST
SYSTEM 0
1 – DESCRIPTION OF THE FUEL FEED
SYSTEM 3
2 – PLASTIC FUEL TANK 6
Removing the plastic fuel tank 7
Removing the filler plug unit – plastic tank 8
Refitting the filler plug unit – plastic tank 8
Refitting the plastic fuel tank 9
3 – FUEL PUMP 12
4.1 – FUEL FILTER 13
4.2 – FUEL FILTER FOR PLASTIC FUEL
TANK 14
Replacing the fuel filter – plastic fuel tank 15
5 – PRESSURE REGULATOR 16
6 – THROTTLE BODY FOR PLASTIC
TANK 17
Removing the throttle body 18
Refitting the throttle body 19
7 – AIRBOX 21
Removing the airbox 22
Refitting the airbox 24
8 – EXHAUST SYSTEM 27
Catalytic converter operating principle 28
Removing the exhaust system 30
Refitting the exhaust system 32
10 – CANISTER FILTER 34
Canister Filter System (for USA versions only) 35
Removing the Canister filter 36
Refitting the Canister Filter 36
Section M
INJECTION – IGNITION SYSTEM0
1 – DESCRIPTION OF THE FUEL
INJECTION-IGNITION SYSTEM 3
General information on the fuel injection-ignition system 3
Fuel circuit 6
Intake air circuit 7
Operating stages 8
2 – SYSTEM DIAGRAM 9
Fuel injection-ignition system diagram 9
– FUEL INJECTION-IGNITION
SYSTEM COMPONENTS 11
Electronic control unit 11
Electric injector 14
Air temperature / pressure sensor 15
Spark plugs 16
Coil 17
Throttle position sensor 18
Rpm/timing sensor 18
Main and injection relays 19
Section N
ENGINE 0
1 – REMOVING – REASSEMBLING
THE COMPLETE ENGINE 4
Removing the engine 6
Reassembling the engine 8
2.1 – LUBRICATION SYSTEM: OIL PUMP 9
Lubrication system diagram 10
Removing the oil pump 13
Disassembling the oil pump 13
Overhauling the oil pump 14
Oil pump reassembly 14
Refitting the oil pump 15
2.3 – LUBRICATION SYSTEM:
OIL BREATHER TANK 16
Removing the oil breather tank 17
Refitting the oil breather tank 17
4.1 – HEAD UNIT: CHECKS AND
ADJUSTMENTS 18
Checking and adjusting valve clearance 19
Checking engine timing 23
4.2 – CYLINDER HEADS: SIDE COVERS /
TIMING SYSTEM 25
Removing the timing system side covers 26
Disassembling the timing system 27
Reassembling the timing system 30
Reassembling the side covers 35
4.3 – HEAD UNIT : CAMSHAFTS 36
Removing the engine oil temperature sensor 38
Refitting the engine oil temperature sensor 38
Disassembling the intake manifold 39
Refitting the intake manifolds 39
Removing the cam covers 40
Refitting the valve covers 41
Removing the camshafts 42
Checking the camshafts 44
Checking the oil seals 44
Checking the circlips 44
Checking the bearings 45
Refitting the camshaft 46
Refitting the cam covers 48
4.4 – HEAD UNIT: VALVES –
ROCKER ARMS 49
Disassembling the engine heads 50
Overhauling the head parts 54
Reassembling the head 60
5 – CYLINDER / PISTON ASSY 66
Removing cylinder / piston assy 67
Overhauling the cylinder / piston assy 69
Refitting cylinder / piston assy 74
6.1 – CLUTCH UNIT: WET CLUTCH 76
Clutch unit 77
Disassembling the clutch 79
Clutch unit checks and overhaul 81
Clutch reassembly 82
6.1 – CLUTCH UNIT: APTC WET CLUTCH 84
APTC unit description 85
Disassembling the APTC system 87
Checking and overhauling the APTC unit 89
Reassembling the APTC unit 91
6.2 – CLUTCH ASSEMBLY:
CLUTCH COVER 93
Removing the clutch cover 94
Disassembling the clutch cover 95
Reassembling the clutch cover 96
Refitting the clutch cover 97
6.3 – CLUTCH ASSEMBLY: PRIMARY
DRIVE GEARS 98
Disassembling the primary drive gears 99
Refitting the primary drive gear and checking
meshing play 102
7.1 – GEARBOX: LEVER ASSEMBLY 104
Removing the gear selector levers 105
Disassembling the gear selector levers 105
Removing the gear stopper and ratchet 106
Reassembling gear stopper and ratchet 106
Reassembling the gear selector lever 107
Reassembling the gear selector lever 109
7.2 – GEARBOX: GEARBOX SHAFTS 110
Removing the gearbox 112
Disassembling the gearbox shafts 113
Overhauling the gearbox 117
Reassembling the gearbox shafts 119
Inspecting the gear selector forks 121
Inspecting the fork selector drum 121
Reassembling the gearbox 122
8 – FLYWHEEL – GENERATOR 123
Removing the generator cover 125
Disassembling the generator cover 126
Removing the flywheel – generator assembly 127
Checking the flywheel – generator assembly 128
Refitting flywheel / generator assembly 130
Reassembling generator cover 131
Checking the engine sensor air gap 132
9.1 – CASING: OUTER COMPONENTS 133
Removing the outer components 134
Reassembling the outer components 136
Removing the timing lay gear 137
Reassembling the timing lay gear 137
Removing the starter motor driven gear 138
Refitting the starter motor driven gear 138
9.2 – CASING UNIT: CRANKCASES 139
Opening the casings 140
Overhauling the casings 142
Overhauling the main bearings 143
Reassembling the casings 144
Shimming the shafts 145
Closing the casings 152
9.3 – CASING: CONNECTING RODS 156
Removing the connecting rods 157
Disassembling the connecting rods 157
Overhauling the connecting rods 158
Reassembling the connecting rods 162
Refitting the connecting rod unit 163
Section P
ELECTRIC SYSTEM 0
1 – WIRING DIAGRAM 3
Wiring diagram key 4
Wire color coding – wiring diagram 4
Legend of fuse box 5
Arrangement of wiring on frame 5
Diagram A 8
Diagram B 9
Diagram C 10
Diagram D 11
Diagram E 11
Diagram F 12
Diagram G 13
Diagram H 14
Diagram J 14
Diagram K 15
Diagram L 15
Diagram M 16
Diagram N 17
Diagram P 18
Diagram Q 18
2 – CHARGING SYSTEM – BATTERY 19
Checking the charging system 19
Recharging the battery 20
Adding electrolyte 21
Battery 24
Battery mount 25
Generator 26
Rectifier – regulator 27
3 – ELECTRIC STARTING 29
Electric starting system 30
Starter motor 32
Starter contactor 34
4 – LIGHTING DEVICES 35
Changing light bulbs 35
Beam setting 38
5 – INDICATORS AND
LIGHTING SYSTEM 39
Checking the indicators and lighting system
components 39
Changing light bulbs 44
6 – PROTECTION AND SAFETY
DEVICES 45
Checking protection and safety devices components 45
Checking the fuses 47
7 – WARNING LIGHTS AND
INDICATORS 48
Instrument panel 48
8 – IMMOBILIZER AND
TRANSPONDER 51
9 – TESTERS 61
How to use the multimeter to check electric systems 61
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
Jasper Vincenzo –
Augustine Pablo –