Instruction/ maintenance manual of the product Monster 620 Ducati
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1 E Owner’ s manual DUCA TI MON ST E R MONSTER620 MONSTER800 MONSTER1000.
2 E.
3 E Hearty welcome among Ducati fans! Please accept our best compliments for choosing a Ducati motorcycle. We think you will ride your Ducati motorcycle for long journeys as well as short daily trips. Ducati Motor Holding S.p.A. wishes you smooth and enjoyable riding.
4 E T ABLE OF CONTENTS General 6 Warranty 6 Symbols 6 Useful information for safe riding 7 Carrying the maximum load allowed 8 Identification data 9 Controls 10 Position of motorcycle controls 10 Inst.
5 E Charging the battery 50 Chain tensioning 51 Chain lubrication 52 Replacing bulbs 53 Headlamp alignment 56 T yres 57 Checking engine oil level 59 Cleaning and replacing the spark plugs 60 Cleaning .
6 E GENERAL W arranty In your own interest, and in order to guarantee product reliability , you are strongly advised to refer to our authorized Dealers and workshops for any servicing requiring particular technical expertise.
7 E Useful information for safe riding W ar ning Read this section before riding your motorcycle. Accidents are frequently due to inexperience. Always make sure you have your licence with you when riding; you need a valid licence to be entitled to ride your motorcycle.
8 E Carrying the maximum load allowed Y our motorcycle is designed for long-distance riding, carrying the maximum load allowed in full safety . Even weight distribution is critical to preserving these safety features and avoiding trouble when performing sudden manoeuvres or riding on bumpy roads.
9 E Identification data All Ducati motorcycles have two identification numbers, for frame (fig. 1) and engine (fig. 2.1 - 2.2). Frame number Engine number Note These numbers identify the motorcycle model and should always be indicated when ordering spare parts.
10 E CONTROLS W ar ning This section details the position and function of all the controls you need to drive your motorcycle. Be sure to read this information carefully before you use the controls. P osition of motorcycle controls (fig. 3) 1) Instrument panel.
Instrument panel (fig. 4) 1) High beam light (blue) . Comes on when high beam is on. 2) T urn indicator light (green) . Comes on and flashes when a turn indicator is on. 3) Fuel warning light (yellow) . Comes on when there are about 3.5 liters fuel left in the tank (3 liters in the plastic tank).
12 E LCD unit functions When the ignition key is turned to ON , the instrument panel carries out a Check of all instruments (pointers, display , lights) (see fig. 5 and 6). LCD (1) T urn the key to ON and press (B) (fig. 6) to display trip meter and odometer alternatively .
13 E Oil temperature When the oil temperature goes below 50 °C (122 °F), " LO " will be displayed. " HI " will be displayed when the temperature exceeds 170 °C (338 °F). Fuel light " FUEL" will be displayed when the fuel warning light comes on.
14 E The key A performs the same functions as the keys B, and is also used to wipe off and re-program other black keys, if needed. Note The three keys have a small plate (1) attached that reports their identification number . W ar ning Keep the keys in different places.
15 E Code card The keys come with a CODE CARD (fig. 8) that reports: A) (fig. 9) the electronic code to be used in case of engine block, i.e. bike did not start after key-ON .
16 E Procedur e to disable immobilizer engine block through thr ottle twistgrip 1) T urn the key to ON and fully open throttle. Keep it open. The EOBD warning light turns off after 8 seconds. 2) Release the throttle as soon as the EOBD warning light turns off.
17 E Operation When the ignition key is turned to OFF , the immobilizer inhibits engine operation. When the ignition key is turned back to ON to start the engine, the following happens: 1) if the CPU recognised the code, the CODE light on the instrument panel will flash briefly .
18 E Ignition switch and steering lock (fig. 10) It is located in front of the fuel tank and has four positions: A) ON : lights and engine on; B) OFF : lights and engine off; C) LOCK : steering locked; D) P : parking light and steering lock. Note T o move the key to the last two positions, press it down before turning it.
Left switch (fig. 11.1 - 11.2) 1) Dip switch, light dip switch, two positions: position = low beam on; position = high beam on. Note This device is not fitted on the Australia and Japan versions. 2) Switch = 3-position turn indicator: centre position = OFF; position = left turn; position = right turn.
20 E Clutch lever (fig. 12.1 - 12.2) Lever (1) (fig. 12.2) disengages the clutch. It features a dial adjuster (2) (fig. 12.2) for lever distance from the twistgrip on handlebar . T o set lever distance from twistgrip, push lever (1) (fig. 12.2) fully forward and turn the dial adjuster (2) (fig.
A B 21 E Cold start lever (fig. 13) Use this device to start the engine from cold. It will increase the engine idling speed after starting. Lever positions: A) = closed B) = fully open. The lever can be opened and closed gradually to adjust speed until engine is fully warm (see page 37).
Right switch (fig. 14.1) 1) Switch, light switch, three positions: right position = light off; centre position = front and rear parking lights, number plate and instrument panel lights on; left position = headlight, front and rear parking lights, number plate and instrument panel lights on.
23 E Throttle twistgrip (fig. 14.2) The twistgrip (1) on the right handlebar opens the throttles. When released, it will spring back to the initial position (idling speed). Front brake lever (fig. 14.2) Pull in the lever (2) towards the twistgrip to operate the front brake.
24 E Rear brake pedal (fig. 15) Push down on the pedal (1) to apply the rear brake. The system is hydraulically operated. Gear change pedal (fig. 16) The gear change pedal is at rest when in the central position N , is moved up and down to change gears and then returns to the central position.
25 E 5 4 6 7 fig. 18 Setting the gear change and rear brake pedals The gear change and rear brake pedals can be adjusted to suit the preferred riding position of each rider . T o set the gear change pedal, lock linkage (1) and loosen the check nuts (2) and (3).
26 E MAIN COMPONENTS AND DEVICES 1 10 13 7 8 2 9 3 5 4 9 6 11 12 13 fig. 19 Location (fig. 19) 1) T ank filler plug. 2) Seat catch. 3) Hook for helmet fastening cable. 4) Passenger grab handle. 5) Side stand. 6) Rear view mirrors. 7) Rear shock absorber adjusters.
27 E T ank filler plug (fig. 20) Opening Lift the protection lid (1) and fit the ignition key into the lock. T urn the key clockwise 1/4 turn to unlock. Lift the plug. Closing Refit the plug with the key in it and push it down into its seat. T urn the key anticlockwise to its initial position and take it out.
28 E 0 1 Seat catch and helmet hook Opening Fit the ignition key into the lock. T urn the key clockwise to detach seat from frame. Pull the seat backwards to slide it off its front holders. On the rear end of the compartment underneath the seat, there is the helmet fastening cable (1) (see page 43).
29 E Side stand (fig. 23) Important Before lowering the side stand, make sure that the bearing surface is hard and flat. Do not park on soft or pebbled ground or on asphalt melt by the sun heat and similar or the motorcycle may fall over . When parking in downhill road tracts, always park the motorcycle with its rear wheel facing downhill.
30 E Shock absorber adjusters The rear shock absorber has outer adjusters that enable you to adjust your motorcycle to the load. The adjuster (1) located on the right side, on the connection holding the shock absorber to the swingarm, controls rebound damping.
31 E W ar ning The shock absorber is filled with gas under pressure and may cause severe damage if taken apart by unskilled persons. When carrying a passenger and luggage, set the rear shock absorber spring to maximum preload to improve motorcycle handling and keep safe clearance from the ground.
32 E T o change the preload of the spring inside each fork leg, turn the adjusting nut (2) with a 22-mm hexagon wrench. Preload setting range (A) is from 25 to 10 mm Factory setting is 18 mm.
33 E Changing motorcycle track alignment (fig. 27-28- 29) Motorcycle track alignment is the result of tests carried out under different riding conditions by our technical staff. Modifying factory setting is a very delicate operation, which may lead to serious damages if carried out by unskilled people.
34 E UNIBALL articulated head (A) maximum extension is 5 threadings, i.e. 7.5 mm (B). B A fig. 29.
35 E DIRECTIONS FOR USE Running-in recommendations Max. rotation speed (fig. 30) Rotation speed for running-in period and during standard use (rpm): 1) up to 1000 km; 2) from 1000 to 2500 km; 3) after 2500 km. Up to 1000 km During the first 1000 km, keep the revolution meter under control.
36 E Important During the whole running-in period, the maintenance and service rules recommended in the Warranty Card should be observed carefully . Failure to comply with these rules will release Ducati Motor Holding S.p.A. from any liability whatsoever for any engine damage or shorter engine life.
37 E Starting the engine Note Follow the “High ambient temperature” procedure to start the engine when it is warm. W ar ning Before starting the engine, become familiar with the controls you will need to use when riding. Regular ambient temperature (10 °C/50 °F to 35 °C/95 °F): 1) Move the ignition key to ON (fig.
38 E This model is equipped with a servoignition system. T o achieve assisted engine starting, press the button (2) and release it immediately . Pressing the button (2) operates automatic engine starting for a maximum period of time that varies depending on engine temperature.
39 E Moving off 1) Disengage the clutch squeezing the control lever . 2) Push down on gear change lever sharply with the tip of your foot to engage the first gear . 3) Speed up engine, by turning the throttle twistgrip and slightly releasing the clutch lever at the same time.
40 E Braking Slow down in time, shift down to engine-brake first and then brake applying both brakes. Pull the clutch lever before stopping the motorcycle, to avoid sudden engine stop. W ar ning Use both brake lever and pedal for effective braking. Using only one of the brakes will give you less braking power .
41 E Stopping the motorcycle Slow down gradually , then shift down and release the throttle twistgrip. Finally change from first to neutral. Apply brakes and you will bring the motorcycle to a complete stop. T o switch the engine off, simply turn the key to OFF (page 18).
42 E Parking Stop the motorcycle, then put it on the side stand to park it (see page 29). T o avoid theft, turn the handlebar fully left and turn the key to LOCK position. If you park in a garage or other facilities, make sure that there is proper ventilation and that the motorcycle is not near a source of heat.
43 E T ool kit and accessories (fig. 37) The compartment under the seat holds: an Owner’ s manual; a helmet fastening cable; a tool bag for usual maintenance and checks. T o reach this compartment, remove the seat first (page 28) then the protective cover (1).
44 E MAIN MAINTENANCE OPERA TIONS Lifting the fuel tank (fig. 39) W ar ning Make sure the fuel in the tank is less than 5 litres or fuel may leak out through the filler plug breather . Remove the seat (page 28) and lift the hook (1). Lift the tank and unhook the service rod (2, fig.
45 E Changing air filter (fig. 41) Replace the air filter at the required intervals shown in the routine maintenance chart (see Warranty Card). The air box is accessible after lifting the fuel tank as described on page 44. T o remove the filter , release the cover clips (1) on both sides of the air box and take off the cover (2).
46 E Checking brake and clutch fluid level (fig. 43.1 - 43.2) Fluid level should never fall below the MIN mark on each reservoir . If level drops below the limit, air might get into the circuit and affect the operation of the system involved.
47 E Brake system If you find exceeding play on brake lever or pedal and brake pads are still in good condition, contact a Ducati Dealer or Authorized Workshop to have the system inspected and any air drained out of the circuit. W ar ning Brake and clutch fluid will damage paintwork and plastic parts if accidentally spilled.
48 E 1 fig. 45 Lubricating cables and joints The condition of the outer sheaths of the throttle and fast-idle cables should be checked at regular intervals.
49 E Throttle cable adjustment The throttle twistgrip must have a free play of 2 - 4 mm, measured at the edge of the twistgrip and at all positions of the handlebars. If it needs adjusting, use the suitable adjuster (1, fig. 46) provided on the throttle control.
50 E Charging the battery (fig. 47) Before charging the battery , it is best to remove it from the motorcycle. Always disconnect the black negative terminal ( - ) first, and then the red positive terminal ( + ). Undo the straps (1) and remove the battery .
51 E 1 2 Chain tensioning T urn the rear wheel slowly until you find the position where chain is tightest. With the motorcycle on the side stand, push the chain up pressing with a finger at the mid-length of swingarm. The lower portion of the chain should have a slack of 25÷27 mm (620), 25 mm (800/1000) (fig.
52 E Chain lubrication The chain fitted on your motorcycle has O-rings that keep dirt out of and lubricant inside the sliding parts. The seals might be irreparably damaged if the chain is cleaned using non-specific solvents or washed using steam or water jets.
53 E 1 Replacing bulbs Before replacing a burnt-out bulb, make sure that the new one complies with voltage and wattage as specified on page 70 - “Electric System”. Headlamp (fig. 50 and 51) T o gain access to headlamp bulbs, slacken the lower screw (1) holding the rim-reflector assembly to the body and disconnect the connector (2, fig.
54 E Replace the bulb (4, fig. 52). Note Never touch the transparent body of the new bulb with your fingers or it will blacken resulting in reduced bulb brilliancy . Insert the locating pegs of the bulb base into their seats to obtain correct alignment; hook the clip (3) to the headlamp holders.
55 E T urn indicators (fig. 54) Remove the screw (1) and detach the glass (2) from the body . The bulb is of the bayonet-type: press and rotate anti- clockwise to remove. Fit the spare bulb by pressing and turning clockwise until it clicks. Refit the glass sliding the small tab (A) into the suitable slot in the indicator body .
56 E Headlamp alignment (fig. 56) When checking headlamp alignment, put the motorcycle upright. T yres should be inflated at the correct pressure and one person should be sitting astride the motorcycle, keeping it at right angles to its longitudinal axis and opposite a wall or a screen, 10 meters apart from it.
57 E Ty r e s Front pressure 2.1 bar - 2.3 Kg/sq cm Rear pressure: 2.2 bar - 2.4 Kg/sq cm As tyre pressure is affected by temperature and altitude variations, you are advised to check and adjust it whenever you are riding in areas where ample variations in temperature or altitude occur .
58 E Minimum tread depth Measure tread depth (S, fig. 58) at the point where tread is most worn down. It should not be less than 2 mm and anyway not below the legal limit.
59 E –10 Unigrade Multigrade 01 0 2 0 3 0 4 0 ° C 40 20W–40 20W–50 15W–40 15W–50 10W–40 10W–30 10W 20W 20 30 1 2 fig. 59 Checking engine oil level (fig. 59) Engine oil level can be checked through the sight glass (1) provided on the clutch cover .
60 E 0,6 ÷ 0,7 mm Cleaning and replacing the spark plugs (fig. 60) Spark plugs are essential to smooth engine running and should be checked at regular intervals.
61 E Cleaning the motorcycle T o preserve the finish of metal parts and paintwork, wash and clean your motorcycle at regular intervals, anyway according to the road conditions you ride in. Use specific products only . Prefer biodegradable products. A void aggressive detergents or solvents.
62 E Storing the bike away If the motorcycle is to be left unridden over long periods, it is advisable to carry out the following operations before storing it away: clean the motorcycle; remove the dr.
63 E 120 (620/800) 1440 2100 (620/800) - 2105 (1000) 803 (1000) 770 (620/800) 590 (620/800) 490 (620/800) 500 (1000) 500 (1000) 794 1140 (1000) 1060 (1000) 1138 (620/800) 1058 (620/800) 130 (1000) 360 (620/800) 360 (620/800) 370 (1000) 370 (1000) TECHNICAL DA T A Overall dimensions (mm) (fig.
64 E T op-ups T ype of fluid cu. dm. (liters) Fuel tank, including a reserve Unleaded fuel 14 (620/800) of 3.5 cu dm (liters) - 3 cu dm 95 fuel octane rating (at least) 15 (1000) in the plastic tank Oil sump and oil filter SHELL Advance Ultra 4 3,1 (620) 3.
65 E Engine T win cylinder , four -stroke, 90° “L” type, longitudinal. Bore: 80 mm (620) 88 mm (800) 94 mm (1000) Stroke: 61.5 mm (620) 66 mm (800) 71.5 mm (1000) T otal displacement: 618 cu.cm (620) 803 cu.cm (800) 992 cu.cm (1000) Compression ratio: 10.
66 E P erformance data Maximum speed in any gear should be reached only after a correct running-in period with the motorcycle properly serviced at the recommended intervals. Max. speed (rider alone): 198 Km/h (620) 210 Km/h (800) 220 Km/h (1000) Speed limits Above is the maximum speed limit that can be reached after the running-in period.
67 E Rear brake T ype: fixed drilled steel disc Disc diameter: 245 mm Hydraulically operated by a pedal on R.H. side Braking surface: 25 sq cm Brake caliper: cylinder Ø 32 mm Make and type: BREMBO P 2.I05N. Friction material: FERIT I/D 450 FF . Master cylinder type: PS 11.
68 E T ransmission Multiple-plate clutch: wet clutch (620/800); dry clutch (1000) ; operated by a control lever on left handlebar . Drive is transmitted from engine to gearbox main shaft via spur gears.
69 E W ar ning If the rear sprocket needs replacing, contact a Ducati Dealer or Authorized Workshop. If improperly replaced, this component could seriously endanger your safety and that of your passenger , and cause irreparable damage to your motorcycle.
70 E Suspensions Front suspension Hydraulic upside-down fork. Stanchion diameter: 43 mm T ravel along leg axis: 130 mm Rear Of the progressive type, thanks to a rocker arm connecting frame and upper pivot point of the shock absorber and an arch connected at the bottom to swingarm.
71 E 2 3 1 4 4 IN GOOD CONDITION BLOWN fig. 63 fig. 64 Fuses The main fuse box is located on the left side of the battery (fig. 63). T o expose the fuses, take off the box protective cover (1). Mounting position and ampere capacity are marked on it. Only 6 of the fuses are connected.
72 E 30) Neutral light switch 31) Oil pressure switch 32) Rear STOP light switch 33) Front STOP light switch 34) Left switch 35) Air temperature/pressure sensor 36) Instruments (instrument panel) 37) .
73 E Wire color coding B Blue W White V Violet Bk Black Y Y ellow R Red Lb Light blue Gr Grey G Green Bn Brown O Orange P Pink Legend of fuse box (5) Pos. Description Rat. 1-9 Main switch 30 A 2-10 Fuel pump, injectors, coils 20 A 3-11 Key sense 10 A 4-12 Control unit power supply 3 A 5-13 Passing 7.
74 E MONSTER VERSIONS 620 - 800 - 1000 A vailable in the following colors: Ducati anniversary red 473.101 (PPG); Ducati yellow 473.201 (PPG); Polished black 248.514 (PPG); Metal-color frame and rims. 620Dark - 620Dark SINGLE DISC A vailable in the following colors: Silver grey *0022 (PPG); Black frame and rims.
75 E USA FOR UNITED ST A TES OF AMERICA VERSION ONL Y Reporting of safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway T raffic Safety Administration (NHTSA) in addition to notifying Ducati North America.
76 E USA made except idle speed adjustments with the throttle stop screw . The Exhaust Emission Control System is separate from the crankcase emission control system. Crankcase Emission Control System The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
77 E USA Riding safety The points given below are applicable for every day motorcycle use and shoud be carefully observed for safe and effective vehicle operation. A motorcycle does not provide the impact protection of an automobile, so defensive riding in addition to wearing protective apparel is extremely important.
78 E USA The exhaust system becomes very hot during operation, never touch the exhaust system. Wear clothing that fully covers your legs. Do not wear loose clothing which could catch on the control levers, footrests, wheels, or chain. Any amount of alcohol will significantly interfere with your ability to safely operate your motorcycle.
79 E USA Label location (fig. B) 12 6 5 4 11 3 2 10 1 7 9 8 fig. B.
80 E USA Cod. 433 1 166 1A OBJECT IN MIRROR ARE CLOSER THAN THEY APPEAR Cod. 432 1 234 1A Manufactured by DATE: 07 / 97 GVWR: 925.9 Lbs ( 420 kg) GAWR front: 319.7 Lbs ( 145 kg) with 0/70ZR17 tire, MT 3.50x17 RIM at 32.7 PSI cold. GAWR rear: 606.2 Lbs ( 275 kg) with 170/60ZR17 tire, MT 5.
81 E USA California evaporation emission system (fig. C): Important In the event of fuel system malfunction, contact Ducati ’ s authorized Service Centres. CANISTER fig. C Ducati limited warranty on emission control system Ducati North America, Inc.
82 E USA parts replaced and labor charges based on Ducati ’ s recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate. The owner may be required to keep receipts and failed parts in order to receive compensation.
83 E USA transportation of the motorcycle to or from the Ducati dealer . Ducati shall not be liable for any other expenses, loss or damage, whether direct, incidental, consequential or exemplary arising in connection with the sale or use of or inability to use the Ducati motorcycle for any purpose.
84 E USA km Ducati Mileage Date Service Name 1,000 10,000 20,000 30,000 40,000 50,000 ROUTINE MAINTENANCE RECORD.
An important point after buying a device Ducati Monster 620 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Ducati Monster 620 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Ducati Monster 620 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Ducati Monster 620 you will learn all the available features of the product, as well as information on its operation. The information that you get Ducati Monster 620 will certainly help you make a decision on the purchase.
If you already are a holder of Ducati Monster 620, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Ducati Monster 620.
However, one of the most important roles played by the user manual is to help in solving problems with Ducati Monster 620. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Ducati Monster 620 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
