Ducati MONSTER 821 Instruction manual
DUCATI MONSTER 821 Workshop
Manual 2015
M.01 - General
How to use this manual
Layout of the manual
Symbols - Abbreviations - References
Product specifications
Hazardous Products - Warnings
General maintenance instructions
General safety rules
M.02 - Information about the model
Model identification data
Identification data
M.03 - Technical data
Technical specifications
Injection system
Cooling system
Gearbox
Crankshaft
Lights/instrument panel
Fuel system
Injection-ignition system
Charging system/generator
Hydraulic brakes
Rear suspension
Rear wheel
Front suspension
Front wheel
Cylinder/Piston
Timing system/valves
Transmission
Colours
General
Dimensions
Dimensions
Dimensions
Fuel, lubricants and other fluids
Fuel, lubricants and other fluids
Torque settings
Engine tightening torque values
Frame tightening torque values
Service tools
Special diagnosis equipment
Special tools for the frame
Specific tools for the engine
M.04 - Maintenance operations
Vehicle pre-delivery
Vehicle pre-delivery
Scheduled maintenance chart
Operations to be carried out by the customer
Operations to be carried out by the dealer
Maintenance operations
Adjusting the steering head bearing play
Changing the timing belts
Adjusting the rear shock absorber
Adjusting the position of the gear change and rear brake pedals
Adjusting the front brake lever
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Checking the rear brake pad wear and changing the brake pads
Checking the front brake pad wear and changing the brake pads
Adjusting the chain tension
Adjusting the clutch control cable
Changing the fluid in the rear brake system
Changing the fluid in the front brake system
Changing the coolant
Checking the coolant level
Changing and cleaning the air filters
Spark plugs replacement
Checking valve clearance
Changing the engine oil and filter cartridge
Check engine oil level
M.05 - Fairings
Panel - headlight fairing
Refitting the panel
Removing the panel
Gruppo cruscotto
Rimontaggio gruppo cruscotto
Smontaggio gruppo cruscotto
Seat - side panels
Rimontaggio cover fondo sella
Smontaggio cover fondo sella
Rimontaggio maniglie posteriori
Smontaggio maniglie posteriori
Refitting the seat release mechanism
Removal of the seat release mechanism
Refitting the seat
Removing the seat
Front and rear mudguard
Refitting the rear mudguard
Removing the rear mudguard
Refitting the front mudguard
Removing the front mudguard
M.06 - Electric system and engine management
Wiring diagram
Table V
Table U
Table T
Table S
Table R
Table Q
Table P
Table O
Table N
Table M
Table L
Table K
Table J
Table I
Table H
Table G
Table F
Table E
Table D
Table C
Table B
Table A
Routing of wiring on frame
Key to fuse box
Wiring diagram colour codes
Key to wiring diagram
Battery charging system
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Rectifier-regulator
Generator
Battery
Topping up the electrolyte
Recharging the battery
Checking the battery charging system
Electric starting
Solenoid starter
Starter motor
Electric starting system
LightsHeadlight aim
Changing bulbs
Instruments
Instantaneous fuel consumption
VIN Code
Activations through DDS 2
Software remote update
Light control
Setting the unit of measurement
Engine rpm indication (RPM)
Changing the PIN CODE
Pin Code
Clock setting
LAP
Backlighting adjustment
Battery voltage
Customizing the Riding Mode: Restoring default settings
Customizing the Riding Mode: restoring default settings (ALL DEFAULT)
Customizing the Riding Mode: ABS setting
Customizing the Riding Mode: DTC level setting
Customizing the Riding Mode: Engine setting
Customizing the Riding Mode: storing settings
Customizing the Riding Mode
Setting MENU
LAP time
Displayed errors description
Error warnings
Errors
OIL SERVICE or DESMO SERVICE indication
OIL SERVICE or DESMO SERVICE countdown indication
OIL SERVICE zero warning
Service warning (SERVICE)
External air temperature
Average fuel consumption
Menu 2 functions
Clock
Trip time
Partial fuel reserve counter (TRIP FUEL)
Trip meter 2 (TRIP B)
Trip meter 1 (TRIP A)
Odometer (TOT)
Menu 1 functions
Engine coolant temperature
DTC
ABS
Riding Mode
Engine rpm indication (RPM)
Motorcycle speed
Main functions
Parameter setting/displaying
Function push-buttons
Technological Dictionary
Acronyms and abbreviations used in the Manual
Display settings and functions
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System components
Accelerator position system (APS)
CAN line
Ducati traction control (DTC)
Electronic throttle valve (ETV)
Black Box System (BBS)
Map Sensor
Timing/rpm sensor
Throttle Position Potentiometer
Lambda sensor
Electronic Control Unit (ECU)
Handlebar controls: controls
Right-hand switch
Left-hand switch
Safety and protection sensors: controls
Horn
Checking the fuses
Side stand switch
Air temperature sensor
Engine temperature sensor
Clutch switch
Oil pressure sensor
Gear/neutral sensor
Rear stop switch
Front stop switch
M.07 - Chassis
Front wheel
Refitting the front wheel
Overhauling the front wheel
Removing the front wheel
Rear wheel
Refitting the rear wheel
Overhauling the rear wheel
Removing the rear wheel
Front brake control
Refitting the front brake system
Refitting the brake discs
Overhauling the front brake components
Removing the brake discs
Removing the front brake system
Maintenance operations
Refitting the front brake master cylinder
Removing the front brake master cylinder
Rear brake
Refitting the rear brake calliper
Removing the rear brake disc
Removing the rear brake calliper
Refitting the rear brake control
Disassembling the rear brake control
Removing the rear brake control
ABS information
Disabling the ABS
ABS operating information
Operating principle
ABS components
Wiring/hose routing
Refitting the ABS control unit
Removing the ABS control unit
Changing the rear phonic wheel sensor
Changing the front phonic wheel sensor
ABS component maintenance
Bleeding the ABS hydraulic system
Adjusting the phonic wheel sensor AIR-GAP
Handlebar unit: Throttle twistgrip
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Refitting the throttle twistgrip
Removal of the throttle twistgrip
Refitting the handlebar
Removing the handlebar
Handlebar unit: clutch control
Refitting the clutch unit
Disassembling the clutch unit
Gearchange mechanism
Refitting the gearchange mechanism
Disassembling the gearchange control
Removing the gearchange mechanism
Fork - steering head: front fork
Refitting the front forks
Overhauling the front forks
Removal of the front forks
Fork - steering head: steering
Refitting the steering tube components
Removing the steering head components
Steering angle adjustment
Adjusting the steering head bearing clearance
Rear shock absorber unit
Refitting the rear suspension
Overhauling the rear shock absorber
Removing the rear shock absorber
Rear suspension system
Swinging arm
Refitting the rear swinging arm
Overhauling the rear swinging arm
Inspecting the swinging arm shaft
Removing the swinging arm
Final drive
Lubricating the chain
Washing the chain
Refitting the rear sprocket
Replacing the rear sprocket
Refitting the front sprocket
Removing the front sprocket
Inspecting the final drive
Footpeg brackets
Rimontaggio piastra porta pedane
Smontaggio piastra porta pedane
Refitting the footpegs
Removing the footpegs
Stands
Refitting the side stand
Removing the side stand
Frame inspection
Refitting the headlight assembly
Refitting the rear subframe
Reassembling structural components and frame
Checking the frame
Removal of the rear subframe
Removing of the headlight assembly
Disassembling structural components and frame
Tail light - number plate holder
Rimontaggio fanale posteriore
Smontaggio fanale posteriore
Refitting the number plate holder
Removing the number plate holder
Electrical component tray
Refitting the electrical component tray
Removing the electrical component tray
M.08 - Fuel system / Exhaust system
Fuel tank
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Refitting the fuel tank
Refitting the fuel tank flange
Removing the tank flange
Refitting the filler cap
Removing the filler cap
Removing the fuel tank
Airbox - Throttle Body
Refitting airbox and throttle body
Removing the airbox and throttle body
Air intake
Refitting the secondary air system
Removing the secondary air system
Refitting the air filters
Removing the air filters
Exhaust system
Refitting the silencer
Refitting the exhaust system
Removing the exhaust system
Removing the silencer
Canister filter
Refitting the Canister filter
Removing the Canister filter
Canister filter system
M.09 - Engine
Removing-refitting the engine assembly
Refitting the engine
Removing the engine
Lubrication system: oil pump
Refitting the oil pump
Reassembling the oil pump
Disassembling the oil pump
Removing the oil pump
Cooling system: water tank
Refitting the water tank
Removing the water tank
Cooling system: water radiator
Refitting the cooling system hoses and unions
Removing the cooling system hoses and unions
Refitting the water radiator
Replacing the cooling fan
Removing the water radiator
Cooling system: water pump
Refitting the water pump
Removing the water pump
Cylinder head assembly: checks and adjustments
Checking the engine timing
Checking valve lift
Checking and adjusting the valve clearance
Cylinder head assembly: timing system
Refitting the timing outer covers
Refitting the timing belts
Refitting the cylinder heads pulleys/idler pulleys
Reassembling the timing pulleys
Refitting the idler and tensioner pulley mounting pins
Refitting the timing layshaft pulley
Removing the timing layshaft pulleys
Disassembling the camshaft pulleys
Removing the tensioner pins
Removing the cylinder head pulley/idler pulley
Removing the tensioner pulley/timing belt
Removing the timing belt covers
Cylinder head assembly: camshafts
Refitting the intake manifold and water union
Removing the intake manifold and water union
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Refitting the camshafts
Checking the camshafts and supports
Removing the camshafts
Cylinder head assemblies: valves - rocker arms
Refitting the cylinder head assemblies
Reassembling the cylinder head
Overhauling the cylinder head components
Removing the valve rocker arms
Removing the valves
Removing the cylinder heads
Cylinder/piston assembly
Refitting the cylinder/piston assembly
Overhauling the cylinder/piston components
Removing the cylinder/piston assembly
Clutch assembly: clutch
Reassembling the clutch
Checking and overhauling the components
Removing the clutch
Description of the clutch assembly
Clutch assembly: clutch cover
Refitting the clutch cover
Reassembling the clutch cover
Disassembling the clutch cover
Removing the clutch cover
Clutch assembly: primary drive gears
Refitting the primary drive gears and checking backlash
Removing the primary drive gears
Gearbox assembly: gearchange mechanism
Refitting the gearchange mechanism
Refitting the gear interlock plunger and ratchet
Disassembling gear interlock plunger and ratchet
Removing the gearchange mechanism
Gearbox assembly: gearbox shafts
Reassembling the gearbox assembly
Reassembling the gearbox shafts
Inspecting the fork selector drum
Inspecting the gear selector forks
Overhauling the gearbox
Disassembling the gearbox shafts
Removing the gearbox assembly
Flywheel - generator
Refitting the generator cover
Refitting the flywheel-generator assembly
Overhauling the flywheel-generator assembly
Removing the flywheel - generator assembly
Disassembling the generator cover
Removing the generator cover
Crankcase assembly: outer components
Refitting the starter motor
Removing the starter motor
Refitting the starter motor gear
Removing the starter motor idler gear
Refitting the timing gears
Removing the timing gears
Refitting the external components
Removing outer components
Crankcase assembly: crankcase halves
Reassembling the crankcase halves
Reassembling the crankcase halves
Main bearing shells
Overhauling the crankcase halves
Separating the crankcase halves
Crankcase assembly: connecting rods
Refitting the connecting rod assembly
Reassembling the connecting rod assembly
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Symbols - Abbreviations - References
To allow quick and easy consultation, this manual uses graphic symbols to highlight situations in which
maximum care is required, as well as practical advice or information. Pay attention to the meaning of the
symbols since they serve to avoid repeating technical concepts or safety warnings throughout the text. The
symbols should therefore be seen as real "reminders". Please refer to this page whenever in doubt as to
their meaning.
The terms right-hand and left-hand refer to the motorcycle viewed from the riding position.
Warning
Failure to comply with these instructions may put you at risk, and could lead to severe injury or even death.
Important
Failure to follow the instructions in text marked with this symbol can lead to serious damage to the
motorcycle and its components.
Note
This symbol indicates additional useful information for the current operation.
Product specifications
Symbols in the diagram show the type of threadlocker, sealant or lubricant to be used at the points
indicated. The table below shows the symbols used and the specifications of the various products.
Symbol Specifications Recommended
product
Engine oil (for characteristics see Fuel, lubricants and other fluids). SHELL Advance
4T Ultra
DOT 4 special hydraulic brake fluid. SHELL Advance
Brake DOT 4
SAE 80-90 gear oil or special products for chains with O rings. SHELL Advance
Chain or
Advance Teflon
Chain
Anti-freeze (nitride, amine and phosphate free) 30 to 40% + water. SHELL Advance
coolant or
Glycoshell
GREASE
AMultipurpose, medium fibre, lithium grease. SHELL Alvania
R3
GREASE
BMolybdenum disulphide grease, high mechanical stress and high
temperature resistant. SHELL Retinax
HDX2
GREASE
CBearing/joint grease for parts subject to prolonged mechanical stress.
Temperature range: -10 to 110 °C. SHELL Retinax
LX2
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GREASE
D
Protective grease, with anti-corrosive and waterproofing properties. SHELL Retinax
HD2
GREASE
E
Grease
PANKL - PLB 05
GREASE
F
Grease
OPTIMOL -
PASTE WHITE T
GREASE
G
Grease
PANKL - PLB07
GREASE
H
Grease
KLÜBER
STABURAGS
NBU 30 PTM
GREASE
I
Copper grease
CUPRUM 320
LOCK 1
Low-strength threadlocker.
Loctite 222
LOCK 2
Medium-strength threadlocker, compatible with oil.
Loctite 243
LOCK 3
High-strength threadlocker for threaded parts.
Loctite 270
LOCK 4
Surface sealant resistant to high mechanical stress and solvents. Resists
high temperatures (up to 200 °C) and pressures up to 350 bar; fills gaps
up to 0.4 mm.
Loctite 510
LOCK 5
Permanent adhesive for freely sliding cylindrical couplings or threaded
couplings on mechanical parts. High resistance to mechanical stress and
solvents. Temperature range: 55 to 175 °C.
Loctite 648
LOCK 6
Pipe sealant for pipes and medium to large fittings. For water and gases
(except oxygen). Maximum filling capacity: 0.40 mm (diameter
clearance).
Loctite 577
LOCK 7
Instant adhesive for rubber and plastics with elastomer charged ethylic
base.
Loctite 480
LOCK 8
High-strength retaining compound for threaded parts, bearings, bushes,
splines and keys. Operating temperature range: 55 to 150 °C.
Loctite 601
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LOCK 9
Medium-strength threadlocker.
Loctite 406
LOCK
10
Product for metal parts to seal and lock freely sliding cylindrical couplings
or threaded couplings. Resistant to high mechanical stress and high
temperature, excellent resistance to solvents and chemical attack.
Loctite 128443
LOCK
11
Medium-strength threadlocker.
Loctite 401
LOCK
12
Instant adhesive gel offering tensile/shear strength.
Loctite 454 gel
DUCATI sealing compound.
Three bond
1215 - Sealing
compound
Exhaust pipe sealing paste. Self-sealing paste hardens when heated and
resists temperatures exceeding 1000 °C.
Holts Firegum
Clear universal silicone.
BOSTIK clear
universal
silicone.
Spray used to protect electric systems. Eliminates moisture and
condensation and provides excellent corrosion resistance. Water repellent.
SHELL Advance
Contact Cleaner
Dry lubricant, polymerising on contact with air.
Molykote M55
Plus
Emulsion for lubrication of rubber.
P 80
Protection lubricant emulsion.
KLUBERPLUS S
06/100
Lubricant for mechanical elements
Castor oil
Degreasing agent
Deta Blu
Acronyms and abbreviations used in the manual
ABS
Antilock Braking System
BBS
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Black Box System
CAN
Controller Area Network
DDA
DUCATI Data Acquisition
DSS
DUCATI Skyhook Suspension
DSB
Dashboard
DTC
DUCATI Traction Control
HF
Hands Free
ECU
Engine Control Unit
Technological Dictionary
Riding Mode
The rider can choose from three different preset bike configurations (Riding Modes) and pick the one that
best suits his/her riding style or ground conditions. The Riding Modes allow the user to instantly change the
engine power delivery (ENGINE), the ABS settings, the DTC settings.
Available Riding Modes: Sport, Touring and Urban.
Within every Riding Mode, the rider can customise any settings.
Ducati Traction Control (DTC)
The Ducati Traction Control system (DTC) supervises the rear wheel slipping control and settings vary
through eight different levels that are programmed to offer a different tolerance level to rear wheel slipping.
Each Riding Mode features a pre-set intervention level. Level eight indicates system intervention whenever
a slight slipping is detected, while level one is for very expert riders because it is less sensitive to slipping
and intervention is hence softer.
Anti-lock Braking System (ABS)
The ABS system fitted on Monster 1200 and Monster 1200 S is a system that actuates combined braking
with anti lift-up function for the rear wheel so as to guarantee not only a reduced stopping distance, but
also a higher stability under braking. The ABS features 3 levels, one associated to each Riding Mode.
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General safety rules
Carbon monoxide
When a maintenance operation must be performed with the engine running, make sure that the working
area is well-ventilated. Never run the engine indoors.
Warning
Exhaust gases contain carbon monoxide, which is a poisonous gas that can cause unconsciousness or even
death if inhaled.
Run the engine outdoors or, if working indoors, use an exhaust gas extraction system.
Fuel
Always make sure the working area is well ventilated. Keep any sources of ignition, such as cigarettes, open
flames or sparks, well away from working area and fuel storage area.
Warning
Fuel is highly flammable and can explode under certain conditions. Keep away from children.
Hot parts
Warning
The engine and exhaust parts become hot when the motorcycle engine is running and will stay hot for some
time after the engine has been stopped. Wear heat-resistant gloves before handling these components or
allow the engine and exhaust system to cool down before proceeding.
Warning
The exhaust system might be hot, even after engine is switched OFF; pay particular attention not to touch
exhaust system with any body part and do not park the motorcycle next to inflammable material (wood,
leaves etc.).
Used engine oil
Warning
Prolonged or repeated contact with used engine oil may cause skin cancer. If working with engine oil on a
daily basis, we recommend washing your hands thoroughly with soap immediately afterwards. Keep away
from children.
Brake dust
Never clean the brake assembly using compressed air or a dry brush.
Warning
Inhalation of asbestos fibres is a proven cause of respiratory illness and cancer.
Brake fluid
Warning
Spilling brake fluid onto plastic, rubber or painted parts of the motorcycle may cause damages. Protect
these parts with a clean shop cloth before proceeding to service the system. Keep away from children.
Coolant
Engine coolant contains ethylene glycol, which may ignite under particular conditions, producing invisible
flames. Although the flames from burning ethylene glycol are not visible, they are still capable of causing
severe burns.
Warning
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Take care not to spill engine coolant on the exhaust system or engine parts. These parts may be hot and
ignite the coolant, which will subsequently burn with invisible flames. Coolant (ethylene glycol) is irritant
and poisonous when ingested. Keep away from children. Never remove the radiator cap when the engine is
hot. The coolant is under pressure and will cause severe burns.
The cooling fan operates automatically: keep hands well clear and make sure your clothing does not snag
on the fan.
Battery
Warning
The battery gives off explosive gases; never cause sparks or allow naked flames and cigarettes near the
battery. When charging the battery, ensure that the working area is properly ventilated.
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General safety rules
Carbon monoxide
When a maintenance operation must be performed with the engine running, make sure that the working
area is well-ventilated. Never run the engine indoors.
Warning
Exhaust gases contain carbon monoxide, which is a poisonous gas that can cause unconsciousness or even
death if inhaled.
Run the engine outdoors or, if working indoors, use an exhaust gas extraction system.
Fuel
Always make sure the working area is well ventilated. Keep any sources of ignition, such as cigarettes, open
flames or sparks, well away from working area and fuel storage area.
Warning
Fuel is highly flammable and can explode under certain conditions. Keep away from children.
Hot parts
Warning
The engine and exhaust parts become hot when the motorcycle engine is running and will stay hot for some
time after the engine has been stopped. Wear heat-resistant gloves before handling these components or
allow the engine and exhaust system to cool down before proceeding.
Warning
The exhaust system might be hot, even after engine is switched OFF; pay particular attention not to touch
exhaust system with any body part and do not park the motorcycle next to inflammable material (wood,
leaves etc.).
Used engine oil
Warning
Prolonged or repeated contact with used engine oil may cause skin cancer. If working with engine oil on a
daily basis, we recommend washing your hands thoroughly with soap immediately afterwards. Keep away
from children.
Brake dust
Never clean the brake assembly using compressed air or a dry brush.
Brake fluid
Warning
Spilling brake fluid onto plastic, rubber or painted parts of the motorcycle may cause damages. Protect
these parts with a clean shop cloth before proceeding to service the system. Keep away from children.
Coolant
Engine coolant contains ethylene glycol, which may ignite under particular conditions, producing invisible
flames. Although the flames from burning ethylene glycol are not visible, they are still capable of causing
severe burns.
Warning
Take care not to spill engine coolant on the exhaust system or engine parts. These parts may be hot and
ignite the coolant, which will subsequently burn with invisible flames. Coolant (ethylene glycol) is irritant
and poisonous when ingested. Keep away from children. Never remove the radiator cap when the engine is
hot. The coolant is under pressure and will cause severe burns.
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The cooling fan operates automatically: keep hands well clear and make sure your clothing does not snag
on the fan.
Battery
Warning
The battery gives off explosive gases; never cause sparks or allow naked flames and cigarettes near the
battery. When charging the battery, ensure that the working area is properly ventilated.
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Model identification
Identification data
Each Ducati motorcycle is identified by two numbers, one for the frame and one for the engine.
Note
Please quote these numbers, which identify the motorcycle model, when ordering spare parts.
DATA STAMPED ON THE FRAME
Europe and Australia versions
1Manufacturer: Ducati Motor Holding
2Type
3Variant
4Version
5Production year (E = 2014) (F= 2015)
6Manufacturing facility
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7Progressive serial no.
Data stamped on the frame, Europe (Monster 821) and Australia version
Data stamped on the frame, Europe (Monster 821 – 35 kW) version
Data stamped on the frame, France (Monster 821 — 25 kW) version
1Manufacturer: Ducati Motor Holding
2Type
3Variant
4Version
5Production year (E = 2014) (F= 2015)
6Manufacturing facility
7Progressive serial no.
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Data stamped on the frame, USA/Canada, California version
1Manufacturer: Ducati Motor Holding
2Type
3Variant
4Version (X= Check Digit)
5Model Year (F= 2015) (G=...)
6Manufacturing facility
7Progressive serial no.
DATA STAMPED ON ENGINE
Data stamped on the Europe/France/Japan version engine
1Manufacturer: Ducati Motor Holding
2Engine type
3Progressive production no.
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Data stamped on engine, Australia version
1Manufacturer: Ducati Motor Holding
2Engine type
3Progressive production no.
Data stamped on the USA/Canada version engine
1Engine type
2Model Year (F= Model Tear 2015) (G=...)
3Progressive serial no.
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Other manuals for MONSTER 821
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