Ducati Monster 400, 620
DUCATI MONSTER 400, 620 - WORKSHOP, 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. CONTENTS: WORKSHOP 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 DIAGRAMS - 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
Ducati Monster 400 620 - Service, Repair Manual - Manuale di Officina, Riparazione
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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