Ducati Monster 695 User Manual
How to use the manual
1 - How to use the manual
This manual has been prepared for Ducati Authorized Service Centers and workshop personnel
involved in the maintenance and repair of Ducati motorcycles. It gives fundamental information on how
to work in perfect harmony with the concepts of “good technique” and “safety on work sites” for
servicing or replacing of original spare parts both for chassis and engine concerning this motorcycle.
All operations described in this manual must be carried out by senior skilled technicians, who are
requested to strictly follow the Manufacturer’s instructions.
Some information has been intentionally omitted, as, at our advice, a specialized technician must have
this technical background. Additional information on how to install the different components is provided
in the spare parts catalogue.
Caution
This manual also describes pre-delivery checks.
Ducati Motor Holding S.p.A. declines all responsibility for any technical errors or omissions in this
manual and reserves the right to make changes without prior notice.
The information given in this manual was correct at the time of going to print.
Caution
Reproduction and disclosure of all or part of the contents of this manual are strictly forbidden without
prior written authorization of Ducati Motor Holding S.p.A. All rights on this manual are reserved for
Ducati Motor Holding S.p.A. Applications for authorization must be submitted in writing and must
specify the reasons for reproduction or disclosure.
Ducati Motor Holding S.p.A.
Manual layout
This manual is divided in sections (1), each identified by a letter.
Each section (1) includes several chapters (2), which are numbered consecutively.
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How to use the manual
Each chapter (2) may include several paragraphs (3).
The repair procedures described in this manual include the necessary disassembly and reassembly
instructions,
i.e. the full procedure is detailed starting with the motorcycle fully assembled until bringing it back to
the original condition.
Caution
Some of the sections of this manual are not present, being the relevant parts not installed on the
vehicle.
Caution
The manual structure has been designed to be applied to all the different models manufactured by
DUCATI MOTOR HOLDING.
To make reading easier, the sub-sections table of contents is kept unchanged for all models.
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Symbols - abbreviations - references
2 - Symbols - abbreviations - references
For easy and rational reading, this manual uses graphic symbols for highlighting situations in which maximum
care is required, practical advice or simple information. Please pay maximum attention to these symbols as
they are meant to avoid repeating technical concepts or safety rules throughout the text. These symbols must
be considered as “hints” to important information. Please refer to this page whenever in doubt as to their
meaning.
Left-hand and right-hand in the descriptions refer to motorcycle direction of travel.
Warning
Failure to follow the instructions given in text marked with this symbol can lead to serious personal injury or
death.
Caution
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)
The bold reference indicates a part that is not illustrated in the figures next to the text, but can be found in the
exploded view at the beginning of each section.
(X)
The non-bold reference indicates a part that is illustrated in the figures next to the text.
Product specifications
Symbols inside the diagram show the type of threadlocker, sealant or lubricant to be used at the points
indicated. The table below shows the symbols together with the product specifications.
Symbol Specifications Recommended product
Engine oil (for specifications, see sect. C 2,
Fuels and lubricants).
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
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Symbols - abbreviations - references
Anti-freeze (nitride, amine and phosphate
free) 30-40% water solution.
SHELL
Advance coolant or Glycoshell
GREASE A Multipurpose, medium fiber, 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. Corrosion protectant,
waterproof.
SHELL
Retinax HD2
GREASE E PANKL grease PLB 05.
GREASE F OPTIMOL - PASTE WHITE T. Grease
LOCK 1 Low-strength threadlocker. Loctite 222
LOCK 2 Medium-strength threadlocker, compatible
with oil.
Loctite 243
LOCK 3 High-strength sealant for threaded parts. Loctite 270
LOCK 4 Flange sealant. Resistant to high
mechanical stress, solvents and high
temperatures (up to 200°C). For pressures
up to 350 atm. 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 gaps up to 0.40 mm.
Loctite 577
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Symbols - abbreviations - references
LOCK 7 Speed bonder for rubber and plastics.
Elastomer loaded 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 401
LOCK 10 Product for metal parts to seal and lock
freely sliding parallel or threaded
couplings. Resistant to high mechanical
stress and high temperature, solvent-proof
and chemical-proof.
Loctite 128443
LOCK 11 Instantaneous jelly sealant featuring
tensile / cut strength.
Loctite 454 gel
DUCATI liquid gasket 942470014
Exhaust pipe paste. Self-curing sealant,
hardens when heated. For temperatures
over 1,000°C.
Fire gum holts
Spray used in treating electrical systems
to eliminate moisture and condensation.
Provides high resistance to corrosion.
Waterproof.
SHELL
Advance Contact Cleaner
Dry lubricant that polymerizes in the air Molycote D321R
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Dangerous products – warnings
3 - Dangerous products – warnings
General safety rules
Carbon oxide
When a maintenance operation must be performed with the engine running, position the motorcycle
out of doors or in a well-ventilated area. Never operate the engine in an enclosed place.
Warning
Exhaust emissions contain carbon oxide, which is a poisonous gas and may lead to loss of conscience
or even death.
Operate the engine out of doors or, if working indoors, use an exhaust emission extraction plant.
Fuel
Always make sure the area is well ventilated. Do not smoke near the motorcycle or the area where fuel
is stored and keep any sources of ignition, such as flames or sparks, well away from motorcycle and
fuel storage area.
Warning
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions. Keep away from children.
Hot component parts
Warning
The engine and exhaust component parts become hot when the engine is running and will stay hot for
some time after the engine has been stopped. Wear heat gloves before handling these components or
allow for the engine and exhaust system to cool down before proceeding.
Warning
The exhaust system will stay hot for some time after the engine has been stopped. Do not touch these
components with your body and do not park the vehicle near flammable materials (including wood,
leaves...).
Used engine oil
Warning
Prolonged or repeated contact with engine oil may cause skin cancer. If exposed to engine oil on a
daily basis, make it a rule to wash your hands thoroughly with soap right after handling engine oil.
Keep away from children.
Brake lining debris
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Dangerous products – warnings
Never attempt to clean the brake assembly using compressed air or a dry brush.
Brake fluid
Warning
Avoid spilling brake fluid onto plastic, rubber or paint-finished parts or they will 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. Keep away from sources of ignition, such as sparks and flames.
Do not smoke near the battery. Make sure the area is well ventilated when charging a battery.
General maintenance indications
A word of advice
Ducati would like to suggest that you follow the instructions below so to ensure an efficient, fault-free
motorcycle operation.
-
When diagnosing breakdowns, primary consideration should always be given to what the customer
reports. Your questions to the customer should aim at clarifying the problem.
-
Diagnose the problem systematically and accurately before proceeding further. This manual provides
the theoretical background for troubleshooting that should be combined with personal experience and
attendance at Ducati training courses.
-
Repair work should be planned carefully in advance to prevent any unnecessary downtime, for
example picking-up of required spare parts or arrangement of required tools, etc.
-
Time and money can be saved by limiting the number of operations needed to reach the part to be
repaired. The disassembly procedure in this manual describes the most efficient way to reach a part
to be repaired.
General advice on repair work
-
Always use top quality tools. Lift the motorcycle only with devices in full compliance with relevant
European directives.
-
During repair work always keep the tools within reach, possibly in the right order. Never put them on
the vehicle or in hardly reachable places or somehow hidden.
- Work place must be neat and clean.
- During repair work always change gaskets, seals and split pins.
-
When loosening or tightening nuts and bolts, always start with the largest and always start from the
center. Tighten nuts and bolts working crossways; tighten to the specified torque.
- At disassembly, mark any parts and positions which might easily be confused at reassembly.
- Use Ducati original spare parts only. Use the recommended lubricants only.
- 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.
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Description
0Description
1 - How to use the manual 3
Manual layout 4
2 - Symbols - abbreviations - references 5
Product specifications 6
3 - Dangerous products – warnings 8
General safety rules 8
General maintenance indications 9
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Identification data
1 - Identification data
Identification data for Monster 695 i.e.
Each Ducati motorcycle has two identification numbers - frame number and engine number, and an EC
nameplate (A) (not used in the USA version).
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Identification data
Note
The frame and engine numbers identify the motorcycle model; please state these numbers when
ordering spare parts.
Data punched on frame
European version
1 Manufacturer’s name: Ducati Motor Holding
2 Type – same on all Monsters
3 Variant
4 Version
5 Year of manufacture (7=2007)
6 Plant of manufacture
7 Progressive serial No.
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Identification data
Data punched on frame
USA version
1 Ducati
2 Type of motorcycle
3 Variant – Code number or Check digit (X)
4 Model year (7=2007)
5 Plant of manufacture
6 Progressive serial No.
Data punched on engine
European version
1 Manufacturer’s name: Ducati Motor Holding
2 Engine type
3 Progressive production No.
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Identification data
Data punched on engine
USA version
1 Engine type
2 Model year
3 Progressive production No.
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Model-specific information
0Model-specific information
1 - Identification data 3
Identification data for Monster 695 i.e. 3
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Technical specifications
1.1 - Technical specifications
Description
Reference Technical specifications
Vehicle dimensions
Total length 2100 mm
Total width 794 mm
Total height 1058 mm
Wheelbase 1440 mm
Handlebar height - from grip to the
ground
980 mm.
Seat height 770 mm
Front footpeg height 360 mm
Rear footpeg height 490 mm
Min. ground clearance 120 mm
Dry weight in running order with no
fuel
168 kg
Weight in running order Not over 390 Kg
Frame
Type Chromium-molybdenum steel tube trellis
frame
Steering head angle 24°
Steering angle 27°
Trail 96 mm
Front rim Light alloy, three spokes
Front rim size MT 3.50x17"
Front tyre size 120/60 - ZR 17
Rear rim Light alloy, three spokes with cush drive
damper pads
Rear rim size MT 4.50x17"
Rear tyre size 160/60 - ZR 17
Type of tyre Radial tubeless tyre
Front brake Hydraulic with 2 calipers
Rear brake Hydraulic with 1 caliper
Engine
Type Twin-cylinder 4-stroke Otto-cycle engine
Bore 88 mm
Stroke 57.2 mm
Displacement 695 cu. cm
Compression ratio 10.5 ± 0.5:1
Max. power at crankshaft (95/1/EC)
derated
52 kW (70 HP) at 8500 rpm
22 kW at 8250 rpm
Max. power at crankshaft, measured
on test bench
53.7 kW (73 HP) at 8500 rpm
Max. crankshaft torque
derated
61 Nm (6.2 kgm) at 6750 rpm
46 kW at 3000 rpm
Max. torque at crankshaft, measured
on test bench
61 Kw (6.2 Kgm) at
6750 rpm
Max. engine speed 9200 rpm
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Technical specifications
Timing system Toothed belt, overhead camshaft, 2 valves
per cylinder, 4 rocker arms
Lubrication system Forced lubrication by pump
Oil pump Gear pump with by-pass valves
Cooling system Air cooling
Air filter One filtering element in the airbox
Crankshaft type Enbloc
Cylinders "L" at 90°
Colors
Description Code
Ducati anniversary red, red frame
and black wheel rims
F_473.101 (PPG)
Shining black, black frame and
wheel rims
248.514 (PPG)
Matte black, black frame and
wheel rims
291.501 (PPG)
Transmission assembly
Reference Technical specifications
Clutch Multi-plate wet clutch
Clutch control Hydraulic
Gearbox Six gears
Primary drive 33/61
Transmission ratio 1.85
Final drive 15/48
Gearbox type Constant mesh spur gears, controlled by gear change
lever on vehicle left side
Gear ratios
1
st
2
nd
3
rd
4
th
5
th
6
th
13/32
18/30
21/28
23/26
22/22
26/24
Timing/valves
Reference Standard value Max. allowed value
Timing diagram
With 1 mm valve clearance
Intake Opening 19° B.T.D.C.
Closing 60° A.B.D.C.
Exhaust Opening 56° B.B.D.C.
Closing 24° A.T.D.C.
Intake valve diameter 43 mm
Exhaust valve diameter 38 mm
Valve lift
With 0 mm valve clearance Intake 10.80 mm
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Technical specifications
Exhaust 10.30 mm
Opening rocker arm - intake 0.10-0.15 mm 0.05-0.15 mm
Opening rocker arm -
exhaust
0.10-0.15 mm 0.05-0.15 mm
Closing rocker arm - intake 0-0.05 mm 0-0.20 mm
Closing rocker arm -
exhaust
0-0.05 mm 0-0.20 mm
Adjusting timing
belt tension
DDS
Minimum value
145 Hz (horizontal)
160 Hz (vertical)
70 Hz
145 Hz (horizontal)
160 Hz (vertical)
70 Hz
Idle speed adjustment
1200 ± 50 rpm
Cylinder / piston
Reference Standard value Service limit
Cylinder
Max. oval 0.03 mm.
Max. taper with smaller
diameter up
0.03 mm.
Diameter
class A
class B
class C
88.000 mm
88.010 mm
88.020 mm
0- 0.010 mm
0-0.010 mm
0-0.010 mm
Piston
Diameter
class A
class B
class C
87.970 mm
87.980 mm
87.990 mm
± 0.005 mm
± 0.005 mm
± 0.005 mm
Gudgeon pin-piston clearance
0.004 - 0.012 mm 0.025 mm
Piston-cylinder coupling clearance
0.025-0.045 mm 0.12 mm
Gudgeon pin-connecting rod
clearance
0.006-0.028 mm 0.005 mm
Con-rod bearings-crankpin coupling
diameter clearance
0.015-0.058 mm
Cylinder compression
Standard
Minimum
Max. allowed difference
9 - 11 bar
8 bar (min.)
2 bar (max.)
Gearbox
Reference Standard value Service limit
Gearbox shafts
Axial play 0.05 – 0.20 mm
Gearbox drum
Axial play 0.10 - 0.40 mm
Gear selector fork
Fork sliding shoe thickness 3.90-4.00 mm
Fork – gear clearance 0.070- 0.285 mm 0.4 mm
Cooling system
Reference Technical specifications
Type
Air: heat is discharged through the
large fins of both cylinder-head
assemblies
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Technical specifications
Front wheel
Reference Standard value Service limit
Tread min. thickness
In the most worn position 2 mm
Tyre pressure
Cold 2.1 bar - 2.3 bar
Wheel shaft eccentricity
On 100 mm 0.2 mm
Wheel rim eccentricity
Radial 0.8 mm 2 mm
Axial 0.5 mm 2 mm
Front suspension
Reference Technical specifications
Type
Upside-down hydraulic fork
ø 43
non adjustable
Travel along leg axis 130 mm
Clevis pin
Non adjustable
Oil quantity per leg 0.400 cu dm
Rear wheel
Reference Standard value Service limit
Tread min. thickness
In the most worn position 2 mm
Tyre pressure
Cold 2.2 bar - 2.4 bar
Swingarm shaft eccentricity
On 100 mm 0.2 mm
Wheel rim eccentricity
Radial 0.8 mm 2 mm
Axial 0.5 mm 2 mm
Chain
Make
Type
D.I.D.
520 V L 4
Dimensions 5/8" x 1/4"
No. of links 106
Rear suspension
Reference Technical specifications
Type
Progressive monoshock featuring
adjustable rebound and spring
preload
Shock absorber
Stroke 65 mm
Standard damping force setting.
Turn out the adjusters from
fully closed position (clockwise)
8 clicks
Spring standard length 157 mm
Wheel travel 148 mm
Hydraulic brakes
Reference Standard value Service limit
FRONT
Brake disc
Type Drilled twin disc
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Technical specifications
Thickness 4 ± 0.1 mm 3.6 mm (min.)
Flange material Steel
Braking ring material Steel
Diameter 300 mm
Braking surface
44 cm
2
per disc
Brake caliper
Make Brembo
Type PF 2x28 - 2 pistons
Caliper cylinder diameter 30 mm - 34 mm
Pads friction material FERIT I/D 450-FF
Brake master cylinder
Type PS 15
Master cylinder diameter 15 mm
REAR
Brake disc
Type Drilled disc
Thickness 4 ± 0.1 mm 3.6 mm (min.)
Material Steel
Diameter 245 mm
Braking surface 25 sq cm
Brake caliper
Make Brembo
Type P 32 F - 2 pistons
Caliper cylinder diameter 32 mm
Pads friction material FERIT I/D 450 FF
Brake master cylinder
Type PS11
Master cylinder diameter 11 mm
Charging system / generator
Reference Technical specifications
Battery
Voltage 12V
Charge 16 Ah
Type Sealed, maintenance free
Generator
Capacity 12V - 520 W
Ignition system
Reference Technical specifications
Ignition
Type Electronic type with inductive
discharge system
Starting
Type Electric starter motor 12V - 520 W
Spark plugs
Make and type Champion RA 4 HC - NGK DCPR8E
Electrode gap 0.6 ÷ 0.7 mm
Fuel system
Make Type
Unleaded fuel 95 - 98 RON
THROTTLE BODY Ø 45 mm
Injectors per cylinder 1
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Technical specifications
Firing points per injector 1
Injection system
Make Type
Control unit
Marelli CPU 5AM2
Lights / instrument panel
Reference Technical specifications
Bulbs
Front headlamp (low beam / high
beam)
12V - 55/60W
Number plate light 12V - 5W
Parking / stop light 12V - 5/21W
Turn indicator light 12V - 10W
Instrument panel light 12V - 2W
Turn indicator warning light 12V - 1.2W
High beam warning light 12V - 1.2W
Neutral light 12V - 1.2W
Oil pressure warning light 12V - 1.2W
Injection system warning light 12V - 1.2W
Fuses
Regulator 30 A
Instrument panel 5A
Injection 20A
Key sense 10 A
Ecu 5A
Loads 15 A
High and low beam, parking lights 15 A
Spare 20A
Spare 5A
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Dimensions
1.2 - Dimensions
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Dimensions
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Fuels and lubricants
2 - Fuels and lubricants
Fuels Type cu. dm (liters)
Fuel tank, including a 3 cu. dm (litres)
reserve
Lead-free fuel with at least 95 - 98 RON
at origin
14
Engine sump and oil filter SHELL Advance Ultra 4 3.1
Clutch and front/rear brake circuits SHELL Advance Brake Dot 4
Protection for electrical contacts SHELL Advance Contact Cleaner
Front fork SHELL Advance Fork 7.5 or DONAX TA 0.400 (each leg)
Caution
Do not use fuel or lubricant additives.
Engine oil
A good engine oil has special properties. Use only a highly detergent engine oil with certified SE, SF or SG, or even
higher, service ratings.
Oil viscosity
SAE 10W-40
The other viscosity grades specified in the table can be used where the average ambient temperatures are within
the limits shown.
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Torque settings
3 - Torque settings
Frame torque settings
Part Thread (mm) Nm tolerance ±10% Note
Chain, front sprocket
Front sprocket retaining screw M 5x0.8
6
*
LOCK 1
Front sprocket guard screw M 6x1 6
Light units
Headlight retaining screw M 8x1.25 12
Tail light nuts M 6x1 6
Screw securing headlight holder to
subframe on silent block
4
Number plate light nuts M 5x0.8 2.5
Cat's eye mounting nut M 4x0.7 2
Cable guide to headlight bracket screw M 6x1 9
Turn indicators retaining screw M 6x1 6
Headlight holder retaining screw M 6x1 10
Headlight reflector retaining screw M 4x0.7 2.3
Warning lights and indicators
Instrument panel silentblock fasteners 4
Screw retaining instrument panel to
silentblock
M 5x0.8 5
Temperature/air pressure sensor retaining screw
M 5x0.8 3
Front fork
Steering head retaining screw, center
position
M 8x1.25 23 * GREASE B
Steering head retaining screws M 8x1.25 24 * GREASE B
Bottom yoke screw M 8x1.25 20 * GREASE B -
sequence 1-2-1
Fork bottom end bolt M 8x1.25 20 * GREASE B -
sequence 1-2-1
Steering lock nut M 8x1.25 18 LOCK 2 (apply Loctite
to nut thread only)
Steering bearings ring nut M 35x1 30 * GREASE B
Front fork splashguard retaining screw M 5x0.8 5.5 LOCK 2
Electric system
Coil-to-frame retaining screw M 5x0.8 1.5
Coil-to-airbox nut M 5x0.8 3
LH and RH switch screw M 5x0.8 2.1
Key cover blind nut M 6x1 7
Key-operated switch bolt M 6x1 ** ** Shear bolt head
LOCK 2
Battery cable screw M 6x1 6
Starter motor nut M 6x1 5
Nut securing cable to contactor M 6x1 4
Speed sensor retaining screw M 6x1 10
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Torque settings
Screw retaining voltage regulator to oil
breather tank and frame
M 6x1 6
Screw retaining regulator to oil breather
tank
M 6x1 6
Screw retaining battery mount to
silentblocks
M 6x1 6
Nut retaining battery mount to cylinder
head
M 8x1.25 13
Control unit retaining screw M 6x1 10
Screw retaining ground cable to engine M 8x1.25 12
TPRT sensor retaining screws M 4x0.7 2
Horn mount screw M 8x1.25 15 LOCK 2
Warning horn retaining screw M 8x1.25 25 LOCK 2
Immobilizer antenna Assemble in production
line, apply Lock 11
between Antenna and
Switch cover
Nut securing temperature sensor support
to subframe
5
Relay mount retaining screw M 5x0.8 1
Front brake
Front brake caliper retaining screw M 10x1.25 43 * GREASE B
Front brake master cylinder retaining screw M 6x1 10 sequence 1 (UP) -2-1
Front/rear brake bleed coupling M 10x1 23
Brake lever pin M 8x1.25 24 LOCK 2
Rear brake
Rear brake caliper retaining screw M 8x1.25 24 * GREASE B
Brake bleeding fitting M 10x1 23
Rear brake master cylinder retaining screw M 6x1 10
Screw retaining rear brake hose clip to
swingarm
M 5x0.8 6
Rear brake fluid reservoir retaining screw M 6x1 2
Rear swingarm
Chain adjuster safety screw M 3x0.5 1.8
Chain adjuster screw M 8x1.25 8 GREASE B
Swingarm shaft screw M 10x1.5 43 * GREASE C
Aluminium swingarm shaft retaining screw M 8x1.25
18
*
GREASE C
Chain sliding shoe retaining screw M 6x1 6 LOCK 1
Rear brake caliper plate retaining pin M 8x1.25
25
*
LOCK 1
Handlebar
Handlebar clamp screw M 8x1.25 20 * GREASE B -
sequence 1-2-1
Clutch master cylinder retaining screw M 6x1 10 sequence 1 (UP) -2-1
Clutch hose fitting M 10x1 23
Clutch bleed nipple M 6x1 4
Clutch transmission unit screw M 6x1 10
Throttle control securing screw M 6x1 10
Throttle control cover securing screw M 4x0.7 1.8
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Torque settings
Counterweight retaining screw M 6x1 9
Rear shock absorber
Rear shock absorber upper screw M 10x1.25 42 * GREASE B
Rear shock absorber lower screw M 10x1.25 42 * GREASE B
Suspension linkage upper screw M 10x1.25 42 * GREASE B
Suspension rocker arm to frame fixing
screw
M 12x1.5 75 * GREASE B
Ball joints to actuating rod nut M 12x1.5 36
Front and rear mudguard
Front mudguard retaining screw M 6x1 3 LOCK 2
Rear mudguard retaining screw M 6x1 3 LOCK 2
Number plate holder protection screw M 6x1 5.5
Splashguard to underseat retaining screw M 6x1 1.8
Number plate holder to splashguard nut M 6x1 1.9
Footpegs and Levers
Lever and gearbox pin M 8x1.25 24 LOCK 2
Gear change lever fixing screw M 6x1 10 LOCK 1
Actuating rod ball joints screw on gear
change lever
M 6x1 10
Footpeg holders to engine retaining screws M 10x1.5 36
Footpeg holders to frame retaining screws M 8x1.25 24
Heat guard to footpeg holder retaining
screw
M 6x1 3
Front and Rear wheel
Front wheel nut M 25x1.25 63 * GREASE B
Rear wheel shaft nut M 25x1.25 83 * GREASE B
Brake disc mounting screw M 8x1.25 24 * DRILOC 218 as OE at
BREMBO, Lock 2 for
spare parts
Rear chain sprocket nut M 10x1.25 46 * LOCK 2
Fuel Tank
Retaining screw of plastic fuel tank flange M 6x1 10
Fuel hose clamp 1.5
Fuel filler plug fixing screw M 5x0.8 6
Fuel tank hinge bracket retaining screw M 6x1 10
Fuel tank pads retaining screw M 6x1 10
Exhaust
Nut securing exhaust pipe clamp to
silencers
M 10x1.25 42.4 Screwdriver max.
number of revolutions
400rpm
Special screw securing exhaust manifolds
to crankcase
M 12x1.5 25 LOCK 1
Exhaust pipe to casing retaining screw M 6x1 9
1/8” gas stainless steel plugs fastener for
exhaust pipes
M 10x1.25 25
Exhaust silencer to footpeg holder
retaining screw
M 6x1 10
Exhaust pipe to head nut M 8x1.25 24
Lambda sensor fastener M 18x1.5 45
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Torque settings
Seat
Seat lock ring nut M 22x1.5 1 LOCK 3
Seat lock holder retaining screw M 5x0.8 6
Seat cover holder retaining screw M 5x0.8 3
Seat pulley screw Self-tapping LOCK 2
Screw retaining seat cover and tool box
compartment cover to seat
M 6x1 2
Seat lock retaining screw M 5x0.8 6
Oil inlet/breather
Airbox hose clip 2
Airbox stud to airbox fixing M 6x1 6
Peg to airbox stud fixing M 6x1 4
Oil breather valve hose clip M 6x1 1.2
Oil breather tank hose clip 2
Oil breather tank to frame retaining screw M 6x1 6
Fuel system, Canister
Throttle body mounting clip 2
Pressure regulator to throttle body
retaining screw
M 6x1 5
Canister mount plate nut 8
Fairing
Side body panel retaining screw M 5x0.8 0.8
Headlight fairing to bracket retaining
screw
M 6x1 8
Side stand
Side stand plate retaining screw M 10x1.5 36 LOCK 5
Side stand sensor wire retainer screw M 6x1 10
Side stand pivot nut M 8x1.25 24
Side stand sensor retaining screw M 6x1 10
Frame
Engine to frame mounting bolt nut M 12x1.5 60 * GREASE B
Oil pipe fitting on casing M 9/16"UNF" 19
Fitting for oil delivery pipe to heads M 8x1.25 15
* critical point for dynamic safety. Tightening torque tolerance must be: ± 5% Nm.
Note
For product specifications and symbols, refer to "Product specifications" (A 2).
Engine torque settings
Part Thread (mm) Nm Min. Max. Note
Blow-by valve M 40x1.5 40 36 44
Mesh filter duct plug M 32x1.5 42 38 46
Oil temperature sensor ring nut M 30x1.5 38 34 42 LOCK 4
Wet clutch drum nut M 25x1.5 190 180 200 GREASE B
Generator rotor nut M 24x1 270 256 284 LOCK 5
Crankshaft gear fixing nut M 22x1 190 171 209 GREASE B
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Torque settings
Oil drain plug M 22x1.5 42 38 46
Oil mesh filter M 22x1.5 42 38 46
Oil filler plug M 22x1.5 5 5 6
Steel/alum. crankshaft blanking plug M 20x1 15 13.5 16.5 THREE BOND 1375B
Gearbox drum locating screw M 16x1.5 30 27 33
Oil filter nipple M 16x1.5 42 38 46 LOCK 2 or
THREE BOND 1324
Oil cartridge filter M 16x1.5 11 10 12 Engine oil on seal
Mesh filter duct plug M 15x1 20 18 22 LOCK 5 or
THREE BOND 1375B
By-pass pump plug M 15x1 25 22 28 LOCK 5 or
THREE BOND 1375B
Ring nut for belt rollers on lay shaft M 15x1 71 64 78 GREASE A
Ring nuts for belt rollers on heads M 15x1 71 64 78 GREASE A
Generator cover inspection plug M 15x1 20 18 22 THREE BOND 1215
Nut for timing lay shaft gear M 14x1 55 50 60 GREASE A
Radiator preset blanking plug M 14x1.5 27 24 30 LOCK 5 or
THREE BOND 1375B
Pick-up inspection screw M 12x1 15 13 17 LOCK 2 or
THREE BOND 1324
Earth screw M 12x1 15 13 17 LOCK 2 or
THREE BOND 1324
Oil temperature sensor M 12x1.5 18 16 19 LOCK 4
Spark plugs M 12x1.25 20 18 22
Head nuts:
1st snug torque
2nd snug torque
final torque
M 10x1.5
15
25
40
23
38
27
42
Smear GREASE C on
the underhead and
thread of the stud
bolt
Con-rod bolts:
1
st
tightening
Stop for 2 sec. and
loosen by 360°
1st snug torque
2
nd
snug torque
Tightening
Check angle: > 30°
M 10x1
35
20
35
70.5
66
73
Smear GREASE B on
thread
Oil pump duct plug M 10x1.5 Fully home with tool
15 13 17
LOCK 5 or
THREE BOND 1375B
Head stud bolts M 10x1.5 25 23 26 LOCK 2 or
THREE BOND 1324
Pressure switch M 10x1 19 17 21
Reduction bushing M 10x1 LOCK 5 or
THREE BOND 1375B
Spark plug M 10x1 15 13 17
Neutral light switch M 10x1.25 10 9 11
Clutch-side casing service plug M 10x1.5 15 13 17 LOCK 5 or
THREE BOND 1375B
Crankshaft dowels M 8x1.25 13 11 15 THREE BOND 1375B
Gearbox pawl screw M 8x1.25 25 22 28
Gear stopper screw M 8x1.25 18 16 20 LOCK 2 or
THREE BOND 1324
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Torque settings
Intake and exhaust flange stud bolts M 8x1.25 15 13 17 LOCK 2 or
THREE BOND 1324
Intake manifold nuts M 8x1.25 23 20 26
Oil pump screws M 8x1.25 26 23 29
Casing jointing screws:
1st snug torque
final torque
M 8x1.25
19
25
17
22
21
28
Casing drilled screw M 8x1.25 20 18 22
Fixed tensioner M 8x1 20 18 22 LOCK 2 or
THREE BOND 1324
Mobile tensioner M 8x1.25 26 23 29
Ground screw M 8x1.5 13 11 15
Clutch spring screw M 6x1 6 5 7
Stator cable guide screws M 6x1 10 9 11 LOCK 2 or
THREE BOND 1324
Starter motor screws M 6x1 10 9 11 LOCK 2 or
THREE BOND 1324
Starter idle gear pin screw M 6x1 10 9 11 LOCK 2 or
THREE BOND 1324
Generator stator retaining screws M 6x1 10 9 11 LOCK 2 or
THREE BOND 1324
Flywheel / rotor screws M 6x1 13 11 15 LOCK 2 or
THREE BOND 1324
Gearbox bearing stop plate screws M 6x1 10 9 11 LOCK 2 or
THREE BOND 1324
Head service screws (aluminium) M 6x1 3 2 3 LOCK 5 or
THREE BOND 1375B
Intake manifold fuel pump fitting M 6x1 2.5 2 3 LOCK 2 or
THREE BOND 1324
Bosch pick-up retaining screws M 6x1 10 9 11
Nut securing fluid recovery tank
bracket
M 6x1
9 8 10
Battery mount lower stud bolt M 6x1 10 9 11 LOCK 2 or
THREE BOND 1324
Gearbox pawl screw M 6x1 9 8.5 9.5 LOCK 2 or
THREE BOND 1324
Inspection cover screws M 6x1 4.5 4.5 6
Rocker arm shaft cover screws M 6x1 10 9 11
Intake / exhaust valve cover screws M 6x1 10 9 11
Casing jointing screws M 6x1 9 8.5 9.5
Clutch cover screws M 6x1 9 8.5 9.5
Generator cover screws M 6x1 10 9 11
Clutch spring screws M 5x0.8 5 5 7
Driven belt roller flange retaining
screws
M 5x0.8 5 5 7
Manifold nipple M 5x0.8 3 2 3 LOCK 2 or
THREE BOND 1324
Split belt roller flange retaining screws M 5x0.8 5 5 7
Head cover plug M 5x0.8 2.5 2.5 3
Screws M 10x1.5 45 40 50
Screws M 8x1.25 25 22 28
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Torque settings
Screws M 6x1 10 9 11
Screws M 5x1 5 5 7
Note
For product specifications and symbols, refer to "Product specifications" (A 2).
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Service Tools
4 - Service Tools
Spare parts catalogue
Workshop special tools
Engine special tools
Part No. Description
88700.5644 Tool to set belt roller ring nut for camshaft
88713.2107 Reaction tool to tighten timing belt rollers
88713.2676 Head nuts tightening tool
88713.2103 Support for head assembly
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