Description

0Model-specific information

0Specifications

0Use and maintenance operations

0Fairing

0Controls - Devices

0Wheels - Suspensions - Brakes

0Frame

0Fuel system / Exhaust system

0Injection - ignition system

0Engine

0Electric system

0GENERAL SUMMARY

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

0Model-specific information

1 - Identification data 3

Identification data for Monster 695 i.e. 3

0Specifications

1.1 - Technical specifications 3

Transmission assembly 4

Timing/valves 4

Cylinder / piston 5

Cooling system 5

Front suspension 6

Rear suspension 6

Hydraulic brakes 7

Charging system / generator 7

Ignition system 7

Injection system 8

Lights / instrument panel 8

1.2 - Dimensions 9

2 - Fuels and lubricants 10

3 - Torque settings 11

Frame torque settings 11

Engine torque settings 15

4 - Service Tools 18

Engine special tools 18

Frame special tools 23

0Use and maintenance operations

1 - Preliminary checks 3

Running-in precautions 3

Pre-ride checks 4

2 - Starting – engine warm-up 5

Starting the engine 5

3 - Routine maintenance table 7

Scheduled maintenance chart: operations to be performed by the dealer 7

Scheduled maintenance chart: operations to be performed by the customer 8

4 - Maintenance operations 9

Checking the engine oil level 9

Changing the engine oil and filter cartridge 9

Checking valve clearances 12

Adjusting valve clearances 13

Changing and cleaning the air filters 14

Changing the brake fluid 15

Draining the braking circuit 18

Filling the brake circuit 20

Changing the clutch fluid 23

Draining the clutch circuit 25

Filling the clutch circuit 27

Adjusting steering bearings play 29

Adjusting chain tension 31

Checking brake pad wear. Changing brake pads 32

Adjusting the throttle and choke cables 35

Adjusting the position of the gear change and rear brake pedals 37

Adjusting the rear shock absorber 38

Tester description 40

Instrument power supply 42

DDS diagnosis instrument 45

Checking and adjusting timing belt tension 45

Zero setting the throttle position sensor (TPS) 50

Adjusting idling condition 54

Checking engine oil pressure 56

Checking cylinder compression 61

Checking fuel pressure 64

Procedure to override the immobilizer system 67

Guided diagnosis 71

Checking the charging system 74

0Fairing

1 - Rear-view mirrors 3

Disassembling the rear-view mirrors 4

Refitting the rear-view mirrors 4

Removing the seat 6

Refitting the seat 8

Removing the splash guard 9

Refitting the splash guard 10

Removing the side body panels 11

Refitting the side body panels 12

4 - Front and rear mudguard 13

Removing the front mudguard 14

Refitting the front mudguard 15

Removing the rear mudguard 16

Refitting the rear mudguard 16

0Controls - Devices

1 - Throttle control – choke 3

Adjusting the throttle and choke cables 4

Disassembling the throttle control 4

Reassembling the throttle control 6

Removing the choke control 7

Refitting the choke control 8

2 - Clutch hydraulic control 10

Removing the clutch master cylinder assembly 11

Refitting the clutch master cylinder assembly 12

Removing the clutch transmission unit 13

Refitting the clutch transmission assembly 14

3 - Front brake control 17

Removing the front brake master cylinder 18

Refitting the front brake master cylinder 19

4 - Rear brake control 20

Removing the rear brake master cylinder 21

Disassembling the rear brake control 23

Refitting the rear brake master cylinder 24

5 - Gear change control 26

Removing the gear change control 27

Disassembling the gear change control 28

Refitting the gear change control 29

6 - Seat lock and releasing mechanisms 30

Removing the seat releasing mechanism 31

Refitting the seat releasing mechanism 32

0Wheels - Suspensions - Brakes

1 - Front wheel 3

Removing the front wheel 4

Overhauling the front wheel 6

Refitting the front wheel 8

2 - Front fork 10

Removing the front fork 11

Overhauling the front fork 12

Refitting the front fork 20

3 - Front brake 22

Braking system maintenance 23

Removing the front brake system 23

Removing the brake discs 25

Overhauling the front brake components 25

Refitting the front brake system 26

4 - Rear wheel 29

Removing the rear wheel 30

Overhauling the rear wheel 31

Refitting the rear wheel 32

5 - Rear swingarm 33

Removing the swingarm 34

Swingarm shaft inspection 36

Checking swingarm end float 37

Refitting the rear swingarm 38

6 - Rear brake 40

Removing the rear brake system 41

Refitting the rear brake system 43

7 - Rear suspensions 45

Rear suspension 46

Removing the monoshock absorber 46

Overhauling the rear shock absorber 47

Removing the rear suspension rocker arm 49

Overhauling the rear suspension rocker arm 50

Refitting the rear suspension 52

8 - Final drive 53

Final drive inspection 54

Removing the chain sprocket 55

Refitting the chain sprocket 56

Removing the rear sprocket 57

Refitting the rear sprocket 58

0Frame

1 - Handlebar 3

Removing the handlebar 4

Refitting the handlebar 5

Adjusting steering bearing play 8

Adjusting the steering angle 9

Disassembling the steering tube components 10

Refitting the steering tube components 12

4 - Footpeg supports 15

Removing the footpegs 16

Refitting the footpegs 18

Removing the side stand 21

Refitting the side stand 23

6 - Frame inspection 24

Removing the frame and related components 25

Checking the frame 28

Refitting frame and related components 28

7 - Tail light and number plate holder 29

Removing the tail light and number plate holder 30

Refitting the tail light and number plate holder 31

0Fuel system / Exhaust system

1 - Fuel system description 3

2 - Plastic fuel tank 5

Removing the fuel tank 6

Removing the filler plug unit - plastic tank 7

Refitting the filler plug unit - plastic tank 7

Replacing fuel tank flange 8

Refitting the plastic fuel tank 9

6 - Throttle body for plastic tank 12

Removing the throttle body 13

Refitting the throttle body 15

Removing the airbox 19

Refitting the airbox 21

8 - Exhaust system 24

Catalytic converter operating principle 25

Removing the exhaust system 26

Refitting the exhaust system 29

0Injection - ignition system

1 - Description of the fuel injection-ignition system 3

General information on the fuel injection-ignition system 3

Intake air circuit 7

Operating stages 9

2 - Injection - ignition system 10

3 - Fuel injection-ignition system components 11

Electronic control unit 11

Electric injector 15

Lambda sensor 16

Air temperature / pressure sensor 18

Throttle position sensor 22

Rpm/timing sensor 23

Main and injection relays 24

0Engine

1 - Removing - reassembling the complete engine 5

Removing the engine 6

Reassembling the engine 9

2.1 - Lubrication system: oil pump 10

Lubrication system 11

Removing the oil pump 13

Disassembling the oil pump gear 14

Reassembling the oil pump gear 15

Refitting the oil pump 16

2.3 - Lubrication system: oil breather reservoir 17

Removing the oil breather tank 18

Refitting the oil breather tank 19

4.1 - Head unit: checks and adjustments 20

Checking and adjusting valve clearance 21

Checking engine timing 25

4.2 - Cylinder heads: side covers / timing system 27

Removing the timing side covers 28

Disassembling the timing system 29

Reassembling the timing system 33

Refitting the timing side covers 40

4.3 - Head unit: camshafts 41

Removing the engine oil temperature sensor 42

Refitting the engine oil temperature sensor 43

Disassembling the intake manifold 44

Refitting the intake manifolds 45

Removing the cam covers 46

Removing the valve covers 49

Refitting the valve covers 49

Removing the camshafts 50

Checking the camshafts 52

Checking the oil seals 52

Checking the circlips 53

Checking the bearings 53

Refitting the camshaft 54

Refitting the cam covers 56

4.4 - Head unit: valves - rocker arms 58

Disassembling the engine heads 59

Overhauling the head parts 65

Reassembling the head 72

5 - Cylinder / piston assy 80

Removing cylinder / piston assy 81

Overhauling the cylinder / piston assy 84

Refitting cylinder / piston assy 90

6.1 - Clutch unit: APTC wet clutch 92

APTC clutch unit description 93

Disassembling the APTC system 94

Checking and overhauling the APTC unit 97

Reassembling the APTC unit 101

6.2 - Clutch unit: clutch cover 104

Removing the clutch cover 105

Disassembling the clutch cover 106

Reassembling the clutch cover 108

Refitting the clutch cover 109

6.3 - Clutch unit: primary gears 111

Disassembling the primary drive gears 112

Refitting the primary drive gears and checking meshing play 116

7.1 - Gearbox assembly: gear selector levers 119

Removing the gear selector levers 120

Disassembling the gear selector levers 121

Removing the gear stopper and ratchet 122

Reassembling gear stopper and ratchet 123

Reassembling the gear selector lever 124

Reassembling the gear selector lever 126

7.2 - Gearbox assembly: gearbox shafts 128

Removing the gearbox 129

Disassembling the gearbox shafts 131

Overhauling the gearbox 136

Inspecting the gear selector forks 137

Inspecting the fork selector drum 138

Reassembling the gearbox shafts 139

Reassembling the gearbox 142

8 - Flywheel - generator 143

Removing the generator cover 144

Disassembling the generator cover 146

Removing the flywheel - generator assembly 147

Checking the flywheel - generator assembly 149

Refitting flywheel / generator assembly 152

Reassembling generator cover 154

Checking the engine sensor air gap 157

9.1 - Casing unit: outer components 159

Removing the outer components 160

Reassembling the outer components 163

Removing the timing lay gear 165

Reassembling the timing lay gear 167

Removing the starter motor driven gear 168

Refitting the starter motor driven gear 169

9.2 - Casing unit: crankcases 170

Opening the casings 171

Overhauling the casings 174

Overhauling the main bearings 176

Reassembling the casings 177

Shimming the shafts 179

Closing the casings 189

9.3 - Casing unit: connecting rods 194

Removing the connecting rods 195

Disassembling the connecting rods 195

Overhauling the connecting rods 196

Reassembling the connecting rods 202

Refitting the connecting rod unit 203

0Electric system

1 - Wiring diagram 3

Wiring diagram key 4

Wire color coding - wiring diagram 4

Legend of fuse box 5

Arrangement of wiring on frame 6

2 - Charging system – battery 23

Checking the charging system 23

Recharging the battery 24

Adding electrolyte 25

Battery mount 29

Rectifier - regulator 31

3 - Electric starting 33

Electric starting system 33

Starter motor 34

Starter contactor 36

4 - Lighting devices 38

Changing light bulbs 38

High beam relay 43

Beam setting 44

5 - Indicators and lighting system 45

Checking the indicators and lighting system components 45

Changing light bulbs 50

6 - Protection and safety devices 52

Checking protection and safety devices components 52

Checking the fuses 54

7 - Warning lights and indicators 55

Instrument panel 55

8 - Immobilizer and Transponder 59

How to use the multimeter to check electric systems 66