DUCATI MONSTER 696/796 CARTRIDGE KIT

DUCATI MONSTER 696/796 CARTRIDGE KIT

INSTALLATION OF THE KYB CARTRIDGE KIT Available for models Ducati Monster 696 and 796 from 2011 to 2014 This manual concerns the installation of the aftermarket KYB suspension Cartridge Kit for the Ducati Monster models 696 and 796 with the KYB stock forks. It describes the replacement of the cartridge in the left and right fork. Product code: MONSTER-CARTRIDGE-1 Duration: ± 60 minutes An additional instructional video can be found on this kit s webshop page. For additional information about the installation or adjustment of this KYB Cartridge Kit, please contact the nearest authorized KYB dealer. SAFETY Always use the correct tools. Follow every step as described in the manual. KYB, Technical Touch and/or their affiliated companies cannot be held liable for improper installation and/or use of this KYB cartridge kit. 2

CONTENTS OF THIS CARTRIDGE KIT Before installation, check the completeness of the kit. 8 RIGHT LEG 6 7 9 5 1 3 4 LEFT LEG 2 1. Cartridge 2. Spring 3. Preload push rod 4. Stroke limiter shaft 5. Top out spring 6. Inner tube cap 7. Bump stop 8. Counter nut 9. Top cap 3

SPECIAL TOOLS Top Cap Socket 000.0560.0 T-bar Standard Inner Cap 000.0609.0 T-bar Aftermarket Inner Cap 000.0610.0 Consumables 700 ml W10 fork oil 270 strength Loctite or similar thread locker 4

INSTRUCTIONS Removal of the cartridge from the right fork leg Note: Make sure you don t damage the outer tube with the vise, use a soft material to clamp it in. 1. Clamp the outer tube in a vise where the lower triple clamp clamps on the tube. 2. Unscrew the top cap. 3. Drain the oil from the fork leg. 5

Removal of the cartridge from the right fork leg 4. Clamp the fork leg with the axle bracket in the vise. 5. Push in the cartridge on the top cap side. 6. Remove the cartridge bolt in the axle bracket. Note: the cartridge may rotate with the bolt. An impact wrench may be needed to loosen the bolt. 7. Take out the cartridge. 6

Installation of the KYB cartridge in the right fork leg 1. Place the KYB cartridge in the fork leg. 2. Tighten the bolt fixing the cartridge to the axle bracket. Tighten to 35Nm. 3. Fill the fork leg with 400ml W10 fork oil. 4. Tighten the top cap using the Top Cap Socket. Tighten to 35Nm. 7

Installation of the KYB cartridge in the right fork leg Caution: Make sure you don t overtighten the rebound adjuster screw. When the resistance of the screw increases, you need to return it to the last click. 5. Turn the rebound adjuster screw fully in (direction H). 6. Push in the fork leg several times to bleed the air from the cartridge. An equal hydraulic resistance (damping) over the full stroke can be felt when the cartridge is completey filled with oil. 7. Unscrew the rebound adjuster 15 clicks (direction S ). 8

Removal of the stock stroke limiter from the left fork leg Note: Make sure you don t damage the outer tube with the vise, use a soft material to clamp it in. 1. Clamp the outer tube in a vise where the lower triple clamp clamps on the tube. 2. Unscrew the top cap. 3. Drain the oil from the fork leg. 9

Removal of the stock stroke limiter from the left fork leg Caution! If you hold the fork leg by the outer tube, the inner tube will slide out much further with the bump stop removed. 4. Clamp in the fork leg on the axle bracket. 5. Loosen the bump stop. 6. Remove the top cap. 7. Remove the bump stop. 8. Heat up the inner tube cap to break the thread locker glue. 9. Unscrew the inner tube cap using the T-bar Standard Inner Cap. 10

Removal of the stock stroke limiter from the left fork leg 10. Remove the stroke limiter. 11. Remove the stock spring. 11

Installation of the KYB stroke limiter and spring in the left fork leg Caution: The preload push rod is not fixed to the stroke limiter and can slide out while unpacking. 1. Remove the top cap from the KYB stroke limiter using the Top Cap Socket. 2. Remove the lock nut and rubber bump stop from the stroke limiter. 3. Place the KYB spring into the fork leg. 4. Place the KYB stroke limiter with the preload push rod into the fork leg. 5. Put Loctite 270 strength onto the KYB inner tube cap. 6. Screw the inner tube cap into the inner tube using the T-bar Aftermarket Inner Cap. 12

Installation of the KYB stroke limiter and spring in the left fork leg 7. Slide the KYB bump stop onto the stroke limiter shaft. 8. Screw the lock nut onto the stroke limiter. 9. Install the KYB top cap using the Top Cap Socket. 10. Screw the lock nut to the top cap, tighten to 30Nm. 10. Fill the fork leg with 300ml W10 fork oil. 11. Install the top cap using the Top Cap Socket. Tighten to 35Nm. 12. Screw out (counter clockwise) the preload adjuster until max out, screw in (clockwise) the preload adjuster 5 full revolutions to set it halfway. 13

ADJUSTMENT GUIDELINES Adjustment options Preload The spring preload adjuster has an adjustment range of 10mm. Every full revolution increases/decreases 1mm of preload. The spring preload adjuster is located on the top cap of the left fork leg. Rebound The rebound adjuster (tension) completely turned in (clockwise), is position 0 (maximum damping/ slowest movement). The rebound adjuster has a range of 30-35 clicks, the adjusted position is always counted from the fully turned in position. It is recommended to make steps of 2 or 3 clicks in case you want to change the rebound damping, fine-tuning the rebound can be done per 1 click. The rebound adjuster is located on the top cap of the right fork. Caution: Make sure you don t overtighten the rebound adjuster screw. When the resistance of the screw increases, you need to return it to the last click. Oil level The size of the air chamber can be adjusted by increasing or decreasing the oil level in the fork legs. Adding oil will make the suspension more progressive. Changes in the oil level should be done in steps of 10ml. 14

ADJUSTMENT GUIDELINES Adjustment guide Note that for suspension setup, there is no setup that will work for everybody and for every condition. Damping characteristics will always be a compromise of different settings. Preload: Preload affects the ride height and available suspension travel under braking and accelerating. A floating feeling on the front wheel indicates too much preload. In case the front end feels low, the preload can be increased. Generally a more sporty riding style requires an increased preload. Rebound: The rebound damping controls how fast your fork extends after being compressed. Too much rebound will keep the suspension compressed after absorbing a bump, not enough rebound will make the front feel loose. A correct rebound setting will provide more feedback and traction. Oil level The air chamber size can be adjusted with the oil level. When the suspension bottoms out, the oil level has to be increased. A too hard suspension can be adjusted by lowering the oil level. Changes in the oil level should be done in steps of 10ml. 15

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