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Ducati MONSTER 695 User Manual

Ducati MONSTER 695
628 pages
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How to use the manual
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 Manufacturers 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.
Caution
This manual also describes pre-delivery checks.
Ducati Motor Holding S.p.A. declines all responsibility for any technical errors or omissions in this
manual and reserves the right to make changes without prior notice.
The information given in this manual was correct at the time of going to print.
Caution
Reproduction and disclosure of all or part of the contents of this manual are strictly forbidden without
prior written authorization of Ducati Motor Holding S.p.A. All rights on this manual are reserved for
Ducati Motor Holding S.p.A. Applications for authorization must be submitted in writing and must
specify the reasons for reproduction or disclosure.
Ducati Motor Holding S.p.A.
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.
file:///C|/Documents%20and%20Settings/F4i/My%...0manual/wsm/usa/Mon695_MY07_A_1_3_00.3.1.html (1 of 2) [10/7/2008 8:41:32 PM]

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Ducati MONSTER 695 Specifications

General IconGeneral
Displacement695 cc
Compression Ratio10.5:1
Fuel SystemElectronic fuel injection, 45 mm throttle body
Transmission6-speed
FrameTubular steel trellis frame
Front Brakes2 x 300 mm discs, 2-piston calipers
Rear Brakes245mm disc, 2-piston caliper
Seat Height770mm (30.3 in)
Engine TypeL-Twin, 2 valves per cylinder Desmodromic
Bore x Stroke88 mm x 57.2 mm
Power54 kW @ 8, 500 rpm
Torque68 Nm @ 7750 rpm
Front Suspension43 mm upside-down fork
Dry Weight165 kg
Fuel Capacity14 litres (3.7 US gal)
Rear SuspensionProgressive linkage with preload adjustable monoshock

Summary

How to use the manual

Manual layout

Explains the manual's structure in sections, chapters, and paragraphs.

Symbols - abbreviations - references

Text references

Explains how to interpret numerical references to parts in text and figures.

Product specifications

Details threadlocker, sealant, and lubricant specifications with corresponding symbols.

Dangerous products – warnings

General safety rules

Provides fundamental safety advice for handling hazardous materials and operations.

Identification data

Data punched on frame

Details VIN structure for European and USA versions, including model year and plant of manufacture.

Data punched on engine

Explains the identification data format for the engine, including type and serial number.

Technical specifications

Vehicle dimensions

Lists key physical dimensions of the motorcycle including length, width, wheelbase, and seat height.

Frame

Details frame type, steering angles, trail, and rim specifications.

Engine

Provides engine type, bore, stroke, displacement, compression ratio, power, and torque specifications.

Colors

Transmission assembly

Details clutch, gearbox, primary drive, transmission ratio, final drive, and gear ratios.

Cylinder / piston

Gearbox

Lists standard and service limit values for gearbox shafts, drum, and selector fork clearances.

Front wheel

Front suspension

Details front fork type, travel, clevis pin, and oil quantity per leg.

Rear wheel

Lists minimum tread thickness, tyre pressure, swingarm shaft eccentricity, and wheel rim specifications.

Hydraulic brakes

Charging system / generator

Details battery voltage, charge, type, and generator capacity.

Ignition system

Fuel system

Specifies fuel type, throttle body diameter, and number of injectors.

Dimensions

Fuels and lubricants

Fuels

Specifies fuel type and tank capacity, including reserve.

Engine oil

Recommends using highly detergent engine oil with specific certifications for optimal engine properties.

Torque settings

Frame torque settings

Lists torque values for various frame components like chain, sprockets, and light units.

Front brake

Rear brake

Provides torque specifications for rear brake caliper, master cylinder, and hose clips.

Rear shock absorber

Front and rear mudguard

Specifies torque values for mudguard retaining screws and protection screws.

Seat

Engine torque settings

Provides torque specifications for engine components like blow-by valve, oil filter, and wet clutch drum nut.

Oil drain plug

Service Tools

Engine special tools

Lists specific tools for engine work, including belt roller ring nut tool and timing belt tensioner.

Timing degree wheel

0.1 mm fork feeler gauge

Crankshaft locking tool

Chain joint

Front wheel shaft tool

Preliminary checks

Running-in precautions

Provides guidelines for engine break-in, including RPM limits and driving recommendations.

Fuel level in the tank

Engine oil level

Details how to check engine oil level via sight glass and topping up if necessary.

Starting – engine warm-up

Starting the engine

Provides step-by-step instructions for starting the engine in cold ambient conditions.

Routine maintenance table

Scheduled maintenance chart: operations to be performed by the dealer

Outlines periodic maintenance tasks for dealers based on mileage or time intervals.

Scheduled maintenance chart: operations to be performed by the customer

Lists basic maintenance tasks for the owner to perform at set intervals.

Maintenance operations

Checking the engine oil level

Details how to check the engine oil level using the sight glass and topping up if required.

Changing the engine oil and filter cartridge

Provides instructions for draining old oil, replacing the filter cartridge, and refilling with new oil.

Checking valve clearances

Explains how to measure valve clearances for intake and exhaust using feeler gauges.

Changing and cleaning the air filters

Guides on replacing or cleaning the air filter at specified intervals for optimal engine performance.

Changing the brake fluid

Provides instructions for changing brake fluid, including warnings about spills and safety precautions.

Filling the front brake circuit

Details the procedure for filling the front brake circuit with fresh fluid and bleeding the system.

Draining the braking circuit

Explains how to drain the hydraulic braking system, emphasizing safety precautions for brake fluid.

Filling the brake circuit

Guides on filling the brake circuit with specified fluid, ensuring proper topping up and air removal.

Changing the clutch fluid

Provides instructions for changing clutch fluid, including safety warnings related to clutch fluid.

Suck the oil up from the reservoir

Instructs on using a suction method to remove oil from the reservoir.

Let oil flow off from the bleed valve

Details how to let oil flow from the bleed valve until a different color is observed.

Draining the clutch circuit

Explains how to drain the clutch circuit, including safety warnings for clutch fluid.

Push in the piston to expel all fluid inside the unit

Describes how to push the piston to expel all fluid from the unit.

Operate the clutch lever several times

Instructs to operate the clutch lever multiple times to reach all circuit points and expel any air.

Adjusting steering bearings play

Details how to adjust steering head bearings to eliminate play and ensure proper steering.

Adjusting chain tension

Guides on adjusting chain tension by finding the tightest position and adjusting nuts.

Checking brake pad wear. Changing brake pads

Explains how to check brake pad wear and provides instructions for changing the pads.

Change the brake pads as follows

Provides step-by-step instructions for changing brake pads, including removing split pins and retaining pins.

Checking rear brake pad wear

Instructs on checking rear brake pad wear through the caliper slot for minimum friction material.

Adjusting the throttle and choke cables

Explains how to adjust throttle and choke cables for proper operation and mentions potential impact on throttle body adjustments.

Fine adjustment can be made by turning the adjuster

Describes how to make fine adjustments to the throttle cable using the adjuster on the handlebar.

Adjusting the rear shock absorber

Details how to adjust rear shock absorber settings for rebound damping and spring preload.

Testers

DDS (Ducati Diagnosis System) base unit

Details the DDS base unit, its components, and its function in diagnosing injection-ignition systems.

Tester description

Describes the DDS diagnostic system, its features for testing motorcycle devices, and measurement capabilities.

Instrument power supply

Explains how to power the DDS instrument using mains or vehicle battery.

Connection to the bike

Provides instructions on connecting the DDS to the motorcycle battery, ensuring correct voltage supply.

DDS diagnosis instrument

Outlines the functions of the DDS, including error reading, parameter reading, and active diagnosis.

Checking and adjusting timing belt tension

Details the procedure for checking and adjusting timing belt tension using the DDS and related tools.

Zero setting the throttle position sensor (TPS)

Guides on resetting the throttle position sensor for proper system operation after component replacement.

Adjusting idling condition

Explains how to adjust idle speed and CO level using bypass screws and a gas analyser.

Adjusting the choke

Describes how to adjust the choke control lever for smooth operation.

Checking engine oil pressure

Details how to take oil circuit pressure readings using the DDS and pressure sensor.

Oil pressure test values

Provides test values for oil pressure at different RPMs and warns about maximum pressure limits.

Checking cylinder compression

Explains the importance of compression and how to check it, noting factors affecting performance.

Screw the cylinder compression cable

Details connecting the cylinder compression cable to the spark plug hole and pressure sensor.

Crank the engine using the starter motor

Instructs to crank the engine with the starter motor until pressure reading stops rising for compression check.

Checking fuel pressure

Guides on checking fuel pressure by connecting a pressure sensor to the fuel delivery hose.

Connect the pressure sensor to port (A) or (C)

Details connecting the pressure sensor to specific ports on the cable for measurement.

Values can be displayed in three ways

Explains how measured values can be displayed as numbers or graphs on the DDS.

Procedure to override the immobilizer system

Provides emergency steps to start the engine if the immobilizer is faulty.

Enter the general functions menu

Guides on navigating the DDS menu to select vehicle model, version, and enter self-diagnosis.

Press "Actuators" (C) to display actuators

Instructs to press 'Actuators' to view connected ECU components for diagnosis.

Guided diagnosis

Explains how the DDS guides the operator through diagnosis stages and provides component information.

Press the "Vehicle selection" icon

Guides on selecting the vehicle model and version within the DDS for diagnosis.

Press "Step-by-step diagnosis" icon (C)

Instructs to use the 'Step-by-step diagnosis' function for detailed diagnostic procedures.

The DDS queries the control unit

Explains that DDS queries ECU and displays elements with their values.

Checking the charging system

Explains how to check the charging system using the DDS and an ammeter clamp.

Connect the ammeter clamp to socket (E)

Details connecting the ammeter clamp to the DDS power and diagnosis cable for current measurement.

If polarity is reversed

Warns about reversed polarity affecting ammeter readings and leading to wrong diagnosis.

Use and maintenance operations

Preliminary checks

Covers essential pre-ride checks for safe operation, including fluid levels and controls.

Starting – engine warm-up

Provides step-by-step instructions for starting the engine in cold ambient conditions.

Routine maintenance table

Outlines periodic maintenance tasks for dealers based on mileage or time intervals.

Maintenance operations

Covers various maintenance tasks like oil changes, valve clearance checks, and filter replacement.

Testers

Details diagnostic tools like DDS and multimeters for checking electrical systems.

Fairing

Rear-view mirrors

Explains the disassembly and refitting procedure for rear-view mirrors.

Seat

Covers seat removal, refitting, splash guard, and side body panel procedures.

Front and rear mudguard

Details removal and refitting procedures for front and rear mudguards.

Controls - Devices

Throttle control – choke

Details throttle and choke cable adjustments, disassembly, and reassembly.

Clutch hydraulic control

Covers clutch master cylinder and transmission unit removal and refitting.

Front brake control

Explains removal and refitting of the front brake master cylinder and system.

Rear brake control

Covers rear brake system removal and refitting, including master cylinder and caliper.

Gear change control

Details removal, disassembly, and refitting of the gear change control mechanism.

Seat lock and releasing mechanisms

Explains removal and refitting of the seat lock and releasing mechanism.

Wheels - Suspensions - Brakes

Front wheel

Covers front wheel removal, overhauling, and refitting procedures.

Front fork

Details front fork removal, overhauling, and refitting procedures.

Front brake

Covers braking system maintenance, removal, and refitting of front brake system components.

Rear wheel

Covers rear wheel removal, overhauling, and refitting procedures.

Rear swingarm

Details swingarm removal, inspection, and refitting procedures.

Rear brake

Covers rear brake system removal and refitting, including caliper and hose connections.

Rear suspensions

Details rear suspension components and overhaul procedures for shock absorber and rocker arm.

Final drive

Covers final drive inspection, chain sprocket removal, and refitting.

Frame

Handlebar

Explains the removal and refitting procedures for the motorcycle handlebar.

Steering

Details steering bearing play adjustment and steering tube disassembly/refitting.

Footpeg supports

Covers removal and refitting procedures for footpegs and footpeg plates.

Stands

Guides on removing and refitting the side stand.

Frame inspection

Explains how to check frame dimensions and handle damaged frames.

Tail light and number plate holder

Details removal and refitting of the tail light and number plate holder.

Fuel system / Exhaust system

Fuel system description

Describes the fuel system, including the plastic fuel tank, throttle body, airbox, and exhaust.

Throttle body for plastic tank

Details throttle body removal, refitting, and injector procedures.

Airbox

Covers airbox removal, filter element replacement, and refitting procedures.

Exhaust system

Explains catalytic converter operation, precautions, and removal/refitting of the exhaust system.

Canister Filter

Details the Canister Filter System for USA versions, including removal and refitting.

Injection - ignition system

Description of the fuel injection-ignition system

Provides general information on the fuel injection-ignition system and its circuits.

Injection - ignition system

Lists components of the injection-ignition system.

Fuel injection-ignition system components

Describes ECU, sensors, injectors, coils, and spark plugs.

Engine

Removing - reassembling the complete engine

Covers engine removal and reassembly procedures, referencing other sections.

Lubrication system: oil pump

Details oil pump components, operation, removal, disassembly, and reassembly.

Lubrication system: oil breather reservoir

Covers removal and refitting of the oil breather tank and valve.

Head unit: checks and adjustments

Details checks and adjustments for valve clearance, engine timing, and camshafts.

Cylinder heads: side covers / timing system

Covers removal, disassembly, and reassembly of timing side covers and system.

Head unit: camshafts

Details removal, overhaul, and refitting of camshafts, including checking bearings and oil seals.

Head unit: valves - rocker arms

Covers disassembly and reassembly of valves, rocker arms, and related components.

Cylinder / piston assy

Details removal, overhauling, and refitting of cylinder and piston assembly.

Clutch unit: APTC wet clutch

Describes APTC wet clutch unit, its advantages, and disassembly/reassembly procedures.

Clutch unit: clutch cover

Covers removal, disassembly, and refitting of the clutch cover.

Clutch unit: primary gears

Details disassembly and refitting of primary drive gears and checking meshing play.

Gearbox assembly: gear selector levers

Covers removal, disassembly, and refitting of gear selector levers.

Gearbox assembly: gearbox shafts

Details gearbox shaft removal, disassembly, overhauling, and reassembly.

Flywheel - generator

Covers generator cover, flywheel, and rotor removal, disassembly, and reassembly.

Casing unit: outer components

Details removal and refitting of outer components like engine, lubrication system, and head unit.

Casing unit: crankcases

Covers opening, overhauling, shimming, and closing crankcases.

Casing unit: connecting rods

Details removal, disassembly, overhauling, and reassembly of connecting rods.

Wiring diagram

Wiring diagram key

Lists electrical components of the wiring system with reference numbers.

Wire color coding - wiring diagram

Provides wire color codes used in the wiring diagram.

Legend of fuse box

Explains the legend for the fuse box positions, descriptions, and ratings.

Arrangement of wiring on frame

Details the optimized routing of wiring on the frame to ensure minimum obstruction.

Diagram A

Shows the wiring harness routing from the ignition switch to various components.

Diagram B

Illustrates connections related to the ignition switch and handlebar controls.

Diagram C

Shows wiring connections for the engine control unit and related sensors.

Diagram E

Illustrates wiring connections for the regulator and its components.

Diagram G

Shows wiring connections for the throttle body, injectors, and position sensor.

Diagram H

Illustrates wiring connections for the engine control unit and related components.

Diagram J

Shows wiring connections for the neutral switch, stop switches, and instrument panel.

Diagram K

Illustrates wiring connections for turn indicators and lighting system components.

Diagram L

Shows wiring connections for the air temperature sensor.

Diagram M

Illustrates wiring connections for the headlight and related components.

Diagram N

Shows wiring connections for the side stand switch and related components.

Diagram P

Illustrates wiring connections for the headlight support and instrument panel.

Diagram Q

Shows wiring connections for the speed sensor.

Charging system – battery

Checking the charging system

Explains how to check the charging system using the DDS tester and multimeter.

Recharging the battery

Provides instructions for recharging the battery, including charge types and safety precautions.

Adding electrolyte

Guides on adding electrolyte to the battery, including safety warnings and precautions.

Battery

Details battery safety rules, instructions for use, and precautions.

Battery mount

Covers battery removal and refitting, including regulator fuse and ECU.

Generator

Describes the generator as a 12V, 520W alternator with stator and rotor.

Rectifier - regulator

Explains the function of the rectifier-regulator and its connection to the motorcycle frame.

Electric starting

Electric starting system

Details key components of the electric starting system: starter contactor, motor, and ECU.

Starter motor

Describes the starter motor power, direction of rotation, and troubleshooting steps.

Removing the starter motor

Guides on removing the starter motor by disconnecting cables and undoing retaining screws.

Refitting the starter motor

Details refitting the starter motor, including inspecting gasket and tightening screws.

Starter contactor

Explains the starter contactor's connection to the frame and its operational check.

Lighting devices

Changing light bulbs

Provides instructions for changing headlight and number plate light bulbs.

Changing the headlight

Guides on removing and refitting the headlight assembly.

High beam relay

Details the location and function of the high beam relay and its strategy.

Beam setting

Explains the procedure for setting the headlight beam height against a wall.

Indicators and lighting system

Checking the indicators and lighting system components

Guides on checking components like switches and indicators for electric continuity.

Checking the left switch

Details checking the left switch for continuity and wire colors.

HORN button

Explains how to check HORN button continuity using a multimeter.

Turn indicator switch

Guides on checking turn indicator switch continuity using a multimeter.

Checking the right switch

Details checking the right switch for continuity and wire colors.

Engine stop button

Explains how to check the engine stop switch continuity.

Starter button

Guides on checking the starter button continuity using a multimeter.

Parking light/low beam switch

Details checking the parking light/low beam switch continuity.

Checking front and rear STOP switches

Explains how to check STOP switches for electric continuity.

Neutral light

Guides on checking the neutral light switch operation.

Oil pressure sensor

Details how to check the oil pressure sensor for proper operation using DDS.

Clutch switch

Provides instructions for checking the clutch switch, similar to STOP switches.

Changing light bulbs

Guides on replacing stop and parking light bulbs.

Protection and safety devices

Checking the key-operated switch

Guides on checking the key-operated switch for electric continuity in different positions.

Checking the side stand switch

Explains how to check the side stand switch operation using a multimeter.

Checking the fuses

Details checking fuses in the main fuse box and the regulator fuse.

Warning lights and indicators

Instrument panel

Describes instrument panel operations, including LCD unit, clock setting, and light indicators.

Oil temperature warning

Explains oil temperature warning indications (LO and HI).

Low fuel warning

Details the low fuel warning indication and trip fuel function.

Maintenance counter

Explains the maintenance warning display and how to cancel it.

Panel light setting

Guides on setting the instrument panel light brightness.

Light automatic switch-off strategy

Describes the system's strategy for automatic switch-off and reactivation of lights.

Immobilizer and Transponder

Transponder keys

Describes the different types of keys (red and black) and their functions.

Programming the immobilizer

Provides step-by-step instructions for programming the immobilizer system.

Checking for correct immobilizer programming

Explains LED indications for programming status and troubleshooting faults.

Emergency procedure to override the immobilizer system

Details the emergency procedure to start the engine if the immobilizer is faulty.

Removing the immobilizer

Guides on removing the immobilizer antenna and switch.

Refitting the immobilizer

Details refitting the immobilizer antenna, switch, and related components.

Dismantling the red key with transponder

Explains how to dismantle the red key and transponder.

Testers

How to use the multimeter to check electric systems

Provides guidance on using multimeters for checking resistance, voltage, and current.

How to measure voltage

Details connecting multimeter terminals in parallel to measure voltage.

How to measure current

Explains connecting multimeter terminals in series to measure current.

How to measure resistance and electric continuity

Guides on measuring resistance and checking electric continuity.

Protections and precautions for a proper use of the multimeter

Provides precautions for using the multimeter, including handling fuses and batteries.

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