Ducati Monster 796 Instruction manual

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

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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

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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

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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

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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

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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

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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

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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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9.1 - Crankcase assembly: external components 174
Removing outer components 176
Refitting the external components 180
Removal of the timing gears 185
Refitting the timing gears 186
Removal of the starter motor idler gear 187
Refitting the starter motor gear 188
9.2 - Crankcase assembly: crankcase halves 189
Separation of the crankcase halves 190
Overhaul of the crankcase halves 193
Overhauling the main bearings 196
Reassembly of the crankcase halves 197
Shimming the shafts 198
Reassembly of the crankcase halves 201
9.3 - Crankcase assembly: crankshaft/connecting rods assembly 208
Removal of the crankshaft/connecting rods assembly 209
Disassembly of the crankshaft/connecting rods assembly 210
Overhaul of the connecting rods 210
Reassembly of the connecting rods 215
Refitting the crankshaft/connecting rod assembly 217

1 - General
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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

How to use this manual
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1 -How to use this manual
This manual has been prepared for technical personnel at Ducati Authorized Service Centres with the aim of providing
fundamental information on how to work in accordance with the modern concepts of “best practice” and “safety in the
workplace” during the maintenance, repair or replacement of original components of the cycle parts and engine of this
motorcycle.
All operations described in this manual must be carried out by experienced, skilled technicians, who are required to follow
the Manufacturer's instructions in full.
Some information has been intentionally omitted, as we believe that all specialised technicians should have a basic
technical background. Additional information on how to install various components is provided in the spare parts
catalogue.
Important
This manual also describes the essential checks to be carried out prior to delivery of the motorcycle.
Ducati Motor Holding S.p.A. declines all liability for any technical errors or omissions in this manual and reserves the right
to make changes made necessary by the technical evolution of its products without prior notice.
The information contained herein was correct at the time of going to press.
Important
Reproduction or disclosure of all or part of the contents of this manual is strictly forbidden. All rights on this manual are
reserved for Ducati Motor Holding S.p.A. Applications for authorisation for reproduction must be submitted in writing and
must specify the reasons for such reproduction.
Ducati Motor Holding S.p.A.
Layout of the manual
This manual is divided into sections (1), each identified by a number.
Each section (1) is made up of several chapters (2), which are numbered consecutively.
The chapters (2) may be further subdivided into paragraphs (3).
The manual describes all repair operations starting from the fully assembled motorcycle.
The full procedure is described up to the point in which the motorcycle is restored to its fully assembled starting condition.
Important
Some of the sections of this manual are not present, since the motorcycle in question is not equipped with the relevant
parts.

How to use this manual
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Important
The layout of the manual is designed in such a way as to be applicable to all the different models manufactured by Ducati
Motor Holding.
To facilitate consultation of the manual, the table of contents is identical for all motorcycle models.

Symbols - Abbreviations - References
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2 -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 an aid to
memory. 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.
Text references
(X)
References in bold type indicate a part that is not illustrated in the figures next to the text, but which can be found in the
exploded views at the beginning of each chapter.
(X)
References in non-bold type indicate a part that is illustrated in the figures alongside the text.
Product specifications
Symbols in the diagram show the type of thread locker, 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 Sect. 3 - 2,
Fuel, lubricants and other fluids)SHELL Advance Ultra 4
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% solution in water. SHELL Advance coolant or Glycoshell
GREASE A Multipurpose, medium fibre, lithium grease. SHELL Alvania R3
GREASE B Molybdenum disulphide grease, high mechanical
stress and high temperature resistant. SHELL Retinax HDX2
GREASE C Bearing/joint grease for parts subject to
prolonged mechanical stress. Temperature range:
-10 to 110 °C.
SHELL
Retinax LX2
GREASE D Protective grease, with anti-corrosive and
waterproofing properties. SHELL Retinax HD2

Symbols - Abbreviations - References
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GREASE E PANKL grease - PLB 05.
GREASE F OPTIMOL grease - PASTE WHITE T.
LOCK 1 Low-strength thread locker. Loctite 222
LOCK 2 Medium-strength threadlocker, compatible with
oil. Loctite 243
LOCK 3 High-strength thread locker for threaded parts. Loctite 270
LOCK 4 Flange 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 smooth or threaded
cylindrical fasteners on mechanical parts. High
resistance to mechanical stress and solvents.
Temperature range: -55 to 175 °C.
Loctite 128455
LOCK 6 Pipe sealant for pipes and medium to large
fasteners. For water and gases (except oxygen).
Maximum filling capacity: diameter clearances up
to 0.40 mm.
Loctite 577
LOCK 7 Speed bonder 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.
Temperature range: -55 to 150 °C.
Loctite 601
LOCK 9 Medium-strength threadlocker. Loctite 406
LOCK 10 Product for metal parts to seal and lock cylindrical
freely sliding 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 liquid gasket. 942470014
Exhaust pipe paste. Self-sealing paste, hardens
when heated; resists temperatures exceeding
1000 °C.
Holts Firegum
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 D321R

Symbols - Abbreviations - References
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Emulsion for lubrication of rubber P 80

Hazardous Products - Warnings
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3 -Hazardous Products - Warnings
General safety rules
Carbon monoxide
When a maintenance operation must be performed with the engine running, maker sure that the working area is well-
ventilated. Never run the engine in an enclosed space.
Warning
Exhaust fumes 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 fume 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
Petrol 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; take special care not to touch the exhaust system
with any part of your body 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,
make it a rule to wash your hands thoroughly with soap immediately afterwards. Keep away from children.
Brake pad dust
Never clean the brake assemblies using compressed air or a dry brush.
Brake fluid
Warning
Avoid spilling brake fluid onto plastic, rubber or painted parts of the motorcycle to avoid the risk of damage. Protect these
parts with a clean shop cloth before proceeding to service the motorcycle. Keep away from children.
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.
General maintenance indications
Useful tips
Ducati recommends that you follow the instructions below in order to prevent problems and obtain the best end result:
-when diagnosing faults, primary consideration should always be given to what the customer reports about motorcycle
operation since this information can highlight anomalies; your questions to the customer concerning symptoms of the

Hazardous Products - Warnings
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fault should be aimed at clarifying the problem;
-diagnose the problem systematically and accurately before proceeding further. This manual provides the theoretical
background for troubleshooting; this basis must be combined with personal experience and attendance at periodic
training courses held by Ducati;
-repair work should be planned carefully in advance to prevent any unnecessary downtime, for example obtaining the
required spare parts or preparing the necessary tools, etc.;
-limit the number of operations needed to access the part to be repaired. Note that the disassembly procedures in this
manual describe the most efficient way to reach the part to be repaired.
General advice on repair work
-Always use top quality tools. When lifting the motorcycle, only use devices that comply fully with the relevant European
directives.
-When working on the motorcycle, always keep the tools within reach, ideally in the order required, and never put them
on the motorcycle or in hard-to-reach or inaccessible places.
-The workplace must be kept clean and tidy at all times.
-Always replace gaskets, sealing rings and split pins with new parts.
-When loosening or tightening nuts or screws, always start with the largest or start from the centre; tighten nuts and
screws to the specified tightening torque working in a crosswise sequence.
-Always mark any parts and positions which might easily be confused at the time of reassembly.
-Use exclusively Ducati original replacement parts and the recommended brands of lubricants.
-Use special service tools where specified.
-Ducati Technical Bulletins often contain updated versions of the service procedures described in this manual. Check the
latest Bulletins for details.

2 - Information about the model
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02 - Information about the model
1 - Identification data 3
Monster 796 / 796 ABS identification data 3