Ducati Monster '02 User Manual

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Owner’s manual

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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.
We are steadily doing our best to improve our “Technical
Assistance” service. For this reason, we recommend you
to strictly follow the indications given in this manual,
especially for motorcycle running-in. In this way, your
Ducati motorbike will surely give you unforgettable
emotions.

Enjoy your ride!

Ducati Motor Holding S.p.A. declines any liability
whatsoever for any mistakes incurred in drawing up this
manual. The information contained herein is valid at the
time of going to print. Ducati Motor Holding S.p.A.
reserves the right to make any changes required by the
future development of the above-mentioned products.

For your safety, as well as to preserve the warranty,
reliability and worth of your motorcycle, use original
Ducati spare parts only.

Warning

This manual forms an integral part of the
motorcycle and - if the motorcycle is resold - must
always be handed over to the new owner.

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Setting the gear change and rear brake pedals 23

Main components and devices 24

Location 24
Tank filler plug 25
Seat catch and helmet pin 26
Side stand 27
Shock absorber adjusters 28
Front fork adjusters 29

Directions for use 31

Running-in recommendations 31
Pre-ride checks 33
Starting the engine 34
Moving off 36
Braking 36
Stopping the motorcycle 37
Refueling 37
Parking 38
Tool kit and accessories 39

Main maintenance operations 40

Lifting the fuel tank 40
Changing air filter 41
Checking brake and clutch fluid level 42
Checking brake pads for wear 43
Lubricating cables and joints 44
Throttle cable adjustment 45
Charging the battery 46
Chain tensioning 47
Chain lubrication 48

TABLE OF CONTENTS

General 6

Warranty 6
Symbols 6
Useful information for safe riding 7
Carrying the max load allowed 8
Identification data 9

Controls 10

Position of motorcycle controls 10
Instrument panel 11
The Immobilizer system 14
Keys 14
Code Card 15
Duplicate keys 16
Ignition switch and steering lock 17
Left switch 18
Clutch lever 19
Cold start lever 20
Right switch 20
Throttle twistgrip 21
Front brake lever 21
Rear brake pedal 22
Gear change pedal 22

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Replacing bulbs 48
Headlamp alignment 51
Tyres 52
Checking engine oil level 54
Cleaning and replacing the spark plugs 55
Cleaning the motorcycle 56
Storing the bike away 57
Important notes 57

Technical data 58

Overall dimensions 58
Weights 58
Top-ups 59
Engine 60
Timing system 60
Performance data 61
Spark plugs 61
Brakes 62
Transmission 63
Frame 64
Wheels 64
Tyres 64
Suspensions 65
Electric system 65

Monster versions 71

620/750 71
620S/750S (USA only) 71
Dark 620/750/900 i.e. 71

For United States of America version only 72

Routine maintenance record 81

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GENERAL

Warranty

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. Our highly skilled
staff have access to the implements required to perform
any servicing job at best, and use Ducati original spare
parts only as the best guarantee for full
interchangeability, smooth running and long life.

All Ducati motorcycles come with a “Warranty Card”.
However, warranty does not apply to the motorcycles
used in competitions or competitive trials. No motorcycle
part may be tampered with, altered, or replaced with
parts other than original Ducati spare parts during the
warranty period, or the warranty right will be
automatically invalidated.

Symbols

Ducati Motor Holding S.p.A. advises you to read this
booklet carefully so as to become familiar with your
motorcycle. In case of any doubts, please call a Ducati
Dealer or Authorized Workshop. The information
contained herein will prove useful on your trips - and
Ducati Motor Holding S.p.A. wishes you smooth,
enjoyable riding - and will help you keep the performance
of your motorcycle unchanged for a long time. This
manual contains some special remarks:

Warning

Failure to comply with these instructions may put

you at risk and lead to severe injury or death.

Important

Possibility of damaging the motorcycle and/or its

components.

Note

Additional information concerning the job being

carried out.

The terms right and left are referred to the motorcycle

viewed from the riding position.

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Useful information for safe riding

Warning

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.
Do not lend your motorcycle to inexperienced riders or
who do not hold a valid licence.
Both rider and pillion passenger must always wear a
safety helmet.
Wear proper clothing, with no loose items or accessories
that may become tangled in the controls or limit your
zone of vision.
Never start or run the engine indoors. Exhaust gases are
poisonous and may lead to loss of consciousness or even
death within a short time.
Both rider and pillion passenger should keep their feet on
the footpegs when the motorcycle is in motion.
Always hold the handlebar firmly with both hands so you
will be ready for sudden changes of direction or in the
road surface. The pillion passenger should always hold
on to the suitable handles under the seat with both
hands.
Ride within the law and observe national and local rules.
Always respect speed limits where these are posted.
However, always adjust your speed to the visibility, road
and traffic conditions you are riding in.
Always signal your intention to turn or pull to the next

lane in good time using the suitable turn indicators.
Be sure you are clearly visible and do not ride within the
blind spot of vehicles ahead.
Be very careful when tackling road junctions, or when
riding in the areas near exits from private grounds, car
parks or on slip roads to access motorways.
Always turn off the engine when refueling.
Be extremely careful not to spill gasoline on the engine
or on the exhaust pipe when refueling.
Do not smoke when refueling.
While refueling, you may inhale noxious gasoline
vapours. Should any gasoline drops be spilled on your
skin or clothing, immediately wash with soap and water
and change your clothing.
Always remove the key when you leave your motorcycle
unattended.
The engine, exhaust pipes, and mufflers stay hot for a
long time.
Park your motorcycle where no one is likely to hit it and
use the side stand.
Never park on uneven or soft ground or your motorcycle
may fall over.

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Carrying the maximum load allowed

Your 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.

Information about carrying capacity

The total weight of the motorcycle in running order
including rider, pillion passenger, luggage and additional
accessories should not exceed 370 Kg.

Try to arrange your luggage or heavy accessories in the
lowest possible position and close to motorcycle centre.
Be sure to secure the luggage to the supports provided
on the motorcycle as firmly as possible. Improperly
secured luggage may affect stability.
Never fix bulky or heavy objects to the handlebar or to
the front mudguard as this would affect stability and
cause danger.
Do not insert any objects you may need to carry into the
gaps of the frame as these may foul moving parts.
Make sure the tyres are inflated to the proper pressure
(see page 52) and that they are in good condition.

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Identification data

All Ducati motorcycles have two identification numbers,
for frame (fig. 1.1) and engine (fig. 1.2).

Frame number

Engine number

Note

These numbers identify the motorcycle model and

should always be indicated when ordering spare parts.

fig. 1.1 fig. 1.2

fig. 1.2

900

620/750

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CONTROLS

Warning

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.

Position of motorcycle controls (fig. 2)

1) Instrument panel.

2) Key-operated ignition switch and steering lock.

3) Left switch.

4) Clutch lever.

5) Fast-idle lever.

6) Right switch.

7) Throttle twistgrip.

8) Front brake lever.

9) Gear change pedal.

10) Rear brake pedal.

fig. 2

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Instrument panel (fig. 3)

1) Blue light .

Comes on when high beam is on.

2) Green light .
Comes on and flashes when a turn indicator is on.

3) Yellow light .
Comes on when there are about 3.5 liters fuel left in the
tank (3 liters in the plastic tank).

4) Green light N.
Comes on when in neutral position.

5) Red light .
Comes on when engine oil pressure is too low. It briefly
comes on when the ignition is switched to ON and
normally goes out a few seconds after engine starts.
It may shortly come on when the engine is hot, however,
it should go out as the engine revs up.

Important

If this light stays on, stop the engine or it may suffer

severe damage.

6) Orange light
Comes on and flashes when the motorcycle is parked
(Immobilizer on).

Note

When the Immobilizer is on, this light flashes for 48
hours and then goes out. The Immobilizer is still
operating.

7) Orange light
When on, engine operation is inhibited. It goes out after a
few seconds (usually 1.8 - 2 sec.).

8) Speedometer (km/h).
Gives road speed.
a) LCD (1):

- Odometer (km).
Gives total distance covered.

- Trip meter (km).
Gives distance covered since last resetting.

9) Revolution counter (rpm).
Shows the engine rotation speed/minute.
b) LCD (2):

- Clock

- Oil temperature

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5

1

4

2

7

6

8

a

b

fig. 3

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fig. 3.1

1

A

B

2

fig. 3.2

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. 3.1 and 3.2).

LCD (1)

Turn the key to ON and press (A) (fig. 3.2) to display trip
meter and odometer alternatively.

Resetting the trip meter

Keep (A) pressed (fig. 3.2) for more than 2 seconds.
When the TRIP function is enabled (trip meter), display
(LCD 1) will reset.

LCD (2)

Turn the key to ON and press (B) (fig. 3.2) to display clock
and oil temperature.

Setting the clock

Press (A) for at least 2 seconds.
Press (B) to set AM/PM.
Press (A) to set hours; press (B) repeatedly to set correct
hour.
Press (A) to set minutes.
Press (B) to increase the value. Keep the button pressed
for more than 5 seconds to proceed faster.
Press (A) to quit this function.

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Oil temperature

When the oil temperature goes below 50°, "LO" will be
displayed. "HI" will be displayed when the temperature
exceeds 170°.

Fuel light

"FUEL" will be displayed when the fuel warning light
comes on.

Maintenance indicator

After the first 1,000 Km/621 m and then every 10,000
Km/ 6210 m, "MAInt" will be displayed for 5 seconds
when turning the key to ON. It reminds you of the
routine maintenance servicing to be done.

Instrument panel lighting

Turn the key to ON and press (B) (fig. 3.2) within 5
seconds to change instrument panel lighting power.

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The immobilizer system

For improved anti-theft protection, the motorcycle is
equipped with an IMMOBILIZER, an electronic system
that inhibits engine operation whenever the ignition
switch is turned off.
Accommodated in the handgrip of each ignition key is an
electronic device that modulates an output signal. This
signal is generated by a special antenna incorporated in
the switch when the ignition is turned on and changes
every time. The modulated signal acts as a “password”
and tells the CPU that an "authorised" ignition key is
being used to start up the engine. When the CPU
recognises the signal, it enables engine start-up.

Keys (fig. 4.1)
The Owner receives a set of keys comprising:

- 1 RED key A

- 2 BLACK keys B

The keys B are regular ignition keys and are used to:

- start up the engine

- open the lock of the fuel tank filler plug

- open the seat lock.

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.

Important

Keep the keys in different places. Store the plate (1)

and the key A in a safe place.

1

B

A

fig. 4.1

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Code card

The keys come with a CODE CARD that reports:

A) (fig. 4.3) the electronic code to be used to start the
engine in the event of an emergency;

B) (fig. 4.3) the part no. code for the keys to be reported
to the DUCATI Service network when you are ordering
any duplicate keys.

Important

Keep the CODE CARD in a safe place. However, it
is advisable to keep the electronic code printed on the
CODE CARD handy when you ride your motorcycle, so
you will be able to start the engine in the event of an
emergency.

fig. 4.2

B

A

fig. 4.3

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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. This means that the
immobilizer system has recognised the key code and
enabled engine ignition. When you press the START
button, the engine will start up.

2) If the CODE light stays on, it means that the code has
not been recognised. When this is the case, turn the
ignition key back to OFF and then to ON again. If the
engine still does not start, try with another black key.
If the other key does not work out either, contact the
DUCATI Service network.

Warning

The keys accommodate electronic components

inside. If dropped or hit, they might damage.

Duplicate keys

If you need any duplicate keys, contact the DUCATI
Service network with all the keys you have left and your
CODE CARD.
DUCATI Service will program up to 8 new keys and re­program your original keys.
You may be asked to identify yourself as the legitimate
owner of the motorcycle. Be sure have any documents
you might need to this end ready.
The codes of any keys not submitted will be wiped off
from the memory to make those keys unserviceable in
case they have been lost.

Note

If you sell your motorcycle, do not forget to give all

keys and the CODE CARD to the new owner.

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fig. 5

Ignition switch and steering lock (fig. 5)
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.

Warning

This vehicle is equipped with an energy-saving
CPU. If the key stays ON for a long period but the ignition
button is not pressed within 15 seconds, the CPU will
stop operating to avoid current absorption. Move the key
to OFF and then to ON again.

Note

To move the key to the last two positions, press it
down before turning it. Switching to (B), (C) and (D), you
will be able to take the key out.

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Left switch (fig. 6.1- 6.2)

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.
To cancel turn indicators, return switch to central position
and push in.

3) Button = warning horn.

4) Button = high-beam flasher.

fig. 6.1

fig. 6.2

900

620/750

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Clutch lever

Lever (1) (fig. 7.2) disengages the clutch. It features a dial
adjuster (2) (fig. 7.2) for lever distance from the twistgrip
on handlebar.
To set lever distance from twistgrip, push lever (1) (fig.

7.2) fully forward and turn the dial adjuster (2) (fig. 7.2) to
one of its four positions. Remember that position no. 1
gives maximum distance between lever and twistgrip,
whereas lever and twistgrip are closest when adjuster is
set to position no. 4.
When you pull in the lever (1) (fig. 7.1 and 7.2) , you will
disengage the engine from the gearbox and therefore
from the driving wheel. Using the clutch properly is
essential to smooth riding, especially when moving off.

Warning

Set clutch lever when motorcycle is stopped.

Important

Using the clutch properly will avoid damage to
transmission parts and spare the engine.

fig. 7.1

fig. 7.2

900

620/750

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Right switch (fig. 9.1 and 9.2)

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.

2) Switch for ENGINE STOP, two positions:
position (RUN) = run.
position (OFF) = stop.

Warning

This switch is mainly intended for use in emergency
cases when you need to stop the engine quickly. After
stopping the engine, return the switch to the position
to enable starting.

Important

Riding with the lights on, stopping the engine using
switch (2) and leaving the ignition key in the ON
position, may run the battery flat as the lights will remain
on.

3) Button = engine start.

1

1

fig. 8

Cold start lever (fig. 8)
Use this device to start the engine from cold. It will
increase the engine idling speed after starting.
Lever positions:
A) (vertical) = closed
B) fully open.
The lever can be opened and closed gradually to adjust
speed until engine is fully warm (see page 34).

Important

Never use the cold start lever when the engine is

warm or leave it open when riding.

900620/750

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fig. 9.1

fig. 9.2

900

620/750

Throttle twistgrip (fig. 9.1 and 9.2)

The twistgrip (4) on the right handlebar opens the
throttles (900). When released, it will spring back to the
initial position (idling speed).

Front brake lever (fig. 9.1 and 9.2)
Pull in the lever (5) towards the twistgrip to operate the
front brake. The system is hydraulically operated and you
just need to pull the lever gently.
On 900 models, the control lever is provided with a dial
adjuster (6) for lever distance adjustment from twistgrip
on handlebar.

Warning

Please read the instructions on page 36 before

using these controls.

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1

fig. 11.1

Gear change pedal (fig. 11.1)
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.
down = push down on the pedal to engage 1stgear and
to shift down. The N light will go out.
up = lift the pedal to engage the 2ndgear and then the 3rd,
4th, 5thand 6thgear (6thgear: 900 only).
Each time you move the pedal you will engage the next
gear.

Rear brake pedal (fig. 10)
Push down on the pedal (1) to apply the rear brake.
The system is hydraulically operated.

fig. 10

6

(900)

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fig. 11.3

Setting the gear change and rear brake pedals

(fig. 11.2)
The gear change and rear brake pedals can be adjusted
to suit the preferred riding position of each rider.

To set the gear change pedal, lock linkage (1) and loosen
the check nuts (2) and (3).

Note

Nut (2) has a left-hand thread.

Rotate linkage (1) until setting pedal in the desired
position.
Tighten both check nuts onto linkage.
To set the rear brake pedal,
loosen check nut (4).
Turn pedal travel adjusting screw (5) until pedal is in the
desired position.
Tighten check nut (4).
Work pedal by hand to make sure it has 1.5 - 2 mm free
play before brake begins to bite.
If not so, set the length of cylinder linkage as follows.
Loosen the check nut (6) on cylinder linkage.
Tighten linkage into fork (7) to increase play, or unscrew
linkage to reduce it.
Tighten check nut (6) and check pedal free play again.

1

3

2

fig. 11.2

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MAIN COMPONENTS AND DEVICES

Location (fig. 12)

1) Tank filler plug.

2) Seat catch.

3) Hook for helmet fastening cable.

4) Passenger grab handle.

5) Side stand.

6) Rear view mirrors.

7) Shock absorber adjusters.

8) Front fork adjusters (900S).

9) Fuel tank lifting rod.

11) Seat cover (DARK excluded).

12) Fuel tank clip.

fig. 12

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Tank filler plug (fig. 13)

Opening

Lift the protection lid (1) and fit the ignition key into the
lock. Turn 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. Turn the key anticlockwise to its initial position and
take it out.
Close the lock protection lid (1).

Note

The plug can only be closed with the key in.

Warning

Always make sure you have properly refitted (see

page 37) and closed the plug after each refueling.

1/4

0

OPEN

1

fig. 13