SRV-TSB-20-004

CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
Date:
To:
From:
April 28, 2020
Dealer Principal, General Manager, Service Manager, North American Dealer
Network
Richard Kenton, Technical Director
Eric Bradley, Technical Training and Publications Manager
Dear Dealers,
Ongoing product quality testing and field reports have identified a potential for the rear brake
application to soften over time as a consequence of use. To correct in cases of this occurrence,
new rear brake hoses (ABS control unit to rear brake master cylinder – yellow, and ABS control
unit to rear brake caliper - blue) are now available for the above listed model.
OLD
NEW
NOTE
All Monster 821 model versions currently produced and being shipped by DMH to all
destinations have already been equipped with these new brake hoses.
1/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
Application
You can find the precise list of VIN numbers involved in CR191 on the DCS, in sections:
VIN
HISTORY
CAMPAIGNS
It is possible to search by individual frame number.
It is possible to search for all the frame numbers that you received
from Ducati Motor Holding.
Customer Impact
All motorcycles in your inventory (to be registered or already registered) and to be delivered to
final Customers must be updated during pre-delivery operations and always before delivery to
the final Customer. All motorcycles already delivered to final Customers must undergo this
inspection as soon as they come to your workshop. Note: this is NOT a safety recall.
Parts Distribution
If required, the following components required to carry out the upgrade under this Workshop
Campaign must be ordered for each affected frame number.

61911301A: ABS control unit / rear brake master cylinder hose

61911281A: ABS control unit / rear brake caliper hose

85250241A: Copper washers (8pcs)
The required self-locking ties (small (14 pcs) and large (14 pcs)) are easy to find consumables
and should be sourced locally.
2/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
Warranty Reimbursement Rules
Reimbursement for work associated with this Service Campaign will be made through the
regular warranty claim procedure using the “Vehicle History” section of the DCS. The warranty
claim is pre-filled and is identified as CR191. Two operation types are provided and described
below:
Operation TYPE 1:
Description
TYPE 1
Check rear brake pedal travel
Spare Parts
No Parts Required
Labor
12 min
(2 LU)
Operation TYPE 2:
Description
TYPE 2
Check rear brake pedal travel and
replace rear brake lines
Spare Parts
Rear brake hoses
and washers
Labor
3h:30min
(35 LU)
Operation Type 2 includes reimbursement for the parts listed for the operation; copper
washers (8) part no. 85250241A, ABS control unit / rear brake master cylinder hose Part no.
61911491A, ABS control unit / rear brake caliper hose Part no. 61911481A, the consumable ties
and DOT 4 brake fluid; and labor for 3h:30min (35 labor units) that includes the time necessary
for:

Vehicle reception

Check rear brake pedal travel

Rear brake hose removal (ABS control unit / brake master cylinder and ABS control unit
/ brake caliper)

Installation of new rear brake hose assembly (ABS control unit / brake master cylinder
and ABS control unit / brake caliper)

Filling and bleeding procedure of the rear brake system

Soft cleaning of the vehicle
3/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
Table of contents
Introduction
Page
1
Application
2
Customer Impact
2
Parts Distribution
2
Warranty Reimbursement Rules
3
Spare Parts
4
Service Solution
Operation 1: Check rear brake pedal travel
Operation 2: Rear Brake Line Replacement
Part 1: Vehicle Preparation
Part 2: Rear Brake Hose Removal
Part 3: Rear Brake Hose Installation – Master Cyl. to Rear Caliper
Part 4: Rear Brake Hose Installation – ABS Control to ABS control
Part 5: Rear Brake System Filling and Bleeding
Part 6: Vehicle Refitting
5
5
7
7
17
19
22
27
28
Spare Parts
Part No.
Description
61911301A
ABS control unit /
rear brake master cylinder hose
61911281A
ABS control unit /
rear brake caliper hose
85250241A
Copper washers (8pcs)
Picture
4/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
Service Solution
WARNING
To ensure the correct execution of the operation within the provided labor time to
carry out the updates, it is necessary to follow the sequence indicated in the
following instructions
Operation 1: Check rear brake pedal travel
WARNING
Before measuring the heights (A) and (B) in following steps, always check that the free
play travel of the rear brake lever is correct (between 2 mm to 5 mm)
Remember that the idle stroke refers to the stroke performed by the brake cylinder
control rod before operating the pump. If the idle stroke is outside the specified
values, it must be adjusted again using the adjustment screw on the control rod
5/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
1. Measure height (A) between rear brake lever lower end and load-bearing surface; brake
lever must be in rest position (upper limit stop)
2. Slowly position the 8 kg weight onto rear brake lever; then measure height (B) between
rear brake lever lower end and load-bearing surface
3. The difference between the measured heights (A) and (B) must fall within the range:
A - B = between 15 mm to 23 mm
a) If the difference between the measured heights (A) and (B) falls within the above range, no
further action is required
b) If the difference between the measured heights (A) and (B) is greater than 23 mm, proceed
to the Operation 2: Rear Brake Line Replacement
6/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
Operation 2: Rear Brake Line Replacement
Part 1: Vehicle preparation
1. Position the bike on the rear paddock stand.
2. Drain all the oil contained inside the rear brake system.
3. Remove the seat.
4. Remove the fuel tank (See Sec.8: “Supply/exhaust system – Fuel tank” of the Workshop
Manual).
5. Working on the LH side, remove screw M5x10 (1) retaining cover (2) and pull it up to
remove it.
6. Working on the RH side, remove 2 screws M5x9 (3) and screw M6x22 (4) with relevant
spacer (5) retaining coolant reservoir cover (6) and pull it out.
7/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
7. Loosen clamp (7) and pull out crank case breather (8) from the Airbox.
8. Disconnect injector-wiring connector (9), vertical lambda sensor connector (10),
potentiometer wiring connector (11) and pull out starter relay (12), injection relay (13) and
fuel pump relay (14).
9. Remove the 2 large self-locking ties (15).
8/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
10. Working on vehicle RH side:
10 A. Remove the 2 click clamps (16) and pull out the horizontal head secondary air hose
(17) and the vertical head secondary air hose (18).
10 B. Disconnect secondary air (AIS) connector (19).
11. Working on vehicle LH side:
11 A. Disconnect the 2 connectors (20) of the engine ECU.
11 B. Remove the 4 large self-locking ties (21).
9/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
11 C. Remove the 3 small self-locking ties (22).
11 D. Disconnect the air temperature sensor connector (23).
11 E. Pull out ignition switch connector (24) from the relevant tab present on the Airbox.
11 F. Remove click clamp (25) and pull out Airbox drain hose (26).
11 G. Remove 3 screws M5x20 (27) with relevant spacers (28) retaining coil support
bracket to access the map sensor connector.
11 H. Pull out the horizontal head pressure sensor hose (29) and the vertical head
pressure sensor hose (30) by removing the 2 ties (31).
10/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
11 I.
Disconnect the map sensor connector (32).
12. Working on vehicle RH side, loosen clamp (33) positioned on the vertical cylinder head,
while on the LH side, loosen clamp (34) positioned on the horizontal cylinder head.
13. Remove the Airbox from the vehicle.
14. Protect the engine with a cloth near the ABS control unit, and cover the intake manifolds
as shown in the figure to avoid the possible penetration of brake fluid or impurities inside
the manifolds.
WARNING
11/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
Remember that the brake fluid could damage the paint or parts of the motorcycle.
Wash the affected area with plenty of water in case of accidental contact. Damage
to finish and components due to brake fluid contact is not covered by warranty and
is the responsibility of the dealer to repair
15. Remove the silencer (See Sec.8: “Fuel/exhaust system – Exhaust system” of the Workshop
Manual 2.0).
16. Remove the vertical head exhaust manifold (See Sec.8: “Fuel/exhaust system – Exhaust
system” of the Workshop Manual 2.0).
BEFORE
AFTER
17. Remove the special screw (35) with the 2 copper washers (36) securing brake hose (37) to
rear brake master cylinder
12/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
18. To pull out the RH front footpeg holder plate (38) assembly remove:
 the special screw (39) while holding nut M8 (40)
 the nut (41) while holding it on the opposite side
 the special screw (42)
 the screw M10x50 (43)
19. Pull out the RH front footpeg holder plate (38) by removing self-locking tie (44) and
disconnect rear stop light connector (45).
13/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
20. Release clutch cable (46) by removing:
 1 small self-locking tie (47)
 2 large self-locking ties (48)
 1 screw M6x25 (49) with relevant spacer (50) and cable guide (51)
21. Slide out nipple and release clutch cable (46) from cable guide (52).
22. Remove the 2 self-tapping screws (53) and slide out the cover (54).
14/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
NOTE
To make cover (54) removal easier, follow the sequence below:
 move the cover towards motorcycle front end
 turn cover downwards to release its end from the exhaust manifold
 slide out the cover towards motorcycle front end
1
2
3
15/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
23. Remove the 3 screws M5x12 (55) securing cable guide (56) to swinging arm, then slide it
out.
24. To remove the ABS control unit - brake master cylinder and ABS control unit - rear brake
caliper hoses, proceed as follows:
1. Remove the 6 large self-locking ties (57) and the small self-locking tie (58).
16/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
2. The 4 small self-locking ties (59) and the hose grommet (60) by removing the relevant
retaining screw.
Part 2: Rear brake hose removal
1. Working on ABS control unit, remove the special screw (61) with the 2 copper washers (62).
WARNING
Remember that the brake fluid could damage the paint or parts of the motorcycle.
Wash the affected area with plenty of water in case of accidental contact. Damage to
finish and components due to brake fluid contact are not covered by warranty and are
the responsibility of the dealer to repair
17/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
2. Pull out the brake hose (37) towards the front end following the sequence of operations
indicated below:

Route the ABS control unit fitting below the wiring support

Release brake hose (37) from cable guide (63)
Slide out the brake
hose towards
motorcycle front end
3. Working on the ABS control unit, remove the special screw (64) with the 2 copper washers
(65) securing brake hose (66) to ABS control unit.
4. Working on the rear brake caliper, remove the special screw (67) with the 2 copper
washers (68) securing brake hose (66) to rear brake master cylinder.
18/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
5. Pull out the brake hose (66) towards the front end following the sequence of operations
indicated below:

Route the ABS control unit fitting below the wiring support

Release brake hose (66) from cable guide (63)
Slide out the brake
hose towards
motorcycle front end
Part 3: New rear brake hose installation
Brake hose connecting the ABS control unit to the rear brake caliper
1. Take the new brake hose (A) connecting the ABS control unit to the rear brake caliper.
19/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
NOTE
The new brake hose can be recognized by the different chamfering that characterizes
the end part of the fittings.
OLD
NEW
2. Install the new brake hose (A) connecting the ABS control unit to the rear brake caliper, as
shown below:

Route the ABS control unit fitting below the wiring support

Position brake hose (A) inside cable guide (63)

Position brake hose (A) inside cable guide (69), in the position shown in the figure

Route brake hose (A) between swinging arm and generator cover
20/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
3. Fasten the ABS control unit fitting to the control unit as shown in the figure, using 2 new
copper washers (B) and tighten the special screw (64) to 25 Nm ± 5% with certification.
4. Fasten the rear brake caliper fitting, aiming it as shown in the figure, using 2 new copper
washers (C) and tighten the special screw (67) to 25 Nm ± 5% with certification.
21/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
Part 4: Brake hose connecting the ABS control unit to the rear brake master cylinder
1. Take the new brake hose (D) connecting the ABS control unit to the rear brake master
cylinder.
NOTE
The new brake hose can be recognized by the different chamfering that characterizes
the end part of the fittings.
OLD
NEW
2. Install the new brake hose (D) connecting the ABS control unit to the rear brake master
cylinder, as shown below:

Route the ABS control unit fitting below the wiring support.

Position brake hose (D) inside cable guide (63), close to brake hose (A).

Position brake hose (D) inside cable guide (69), in the position shown in the figure.
22/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
3. Before fastening the fittings of brake hose (D):

Tie the brake hoses (A) and (D) to the vertical head cover using the 2 large self-locking
ties (72), aiming these latter as shown in the figure

Tie the brake hoses (A) and (D) to the hose grommet (69) using the 2 large selflocking ties (73), aiming these latter as shown in the figure

Tie the brake hoses (A) and (D) close to the vertical head-rear subframe connector
using the small self-locking tie (74), aiming this latter as shown in the figure.

Tie the brake hose (A) to the rear speed sensor cable using the small self-locking tie
(75), aiming this latter as shown in the figure.
23/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
4. Take the footpeg holder plate assembly (38) and tie the brake hose (D) to the rear stop
light sensor wiring using the small self-locking tie (70), aiming this latter as shown in the
figure
5. Connect the rear stop light connector (45)
NOTE
When fitting the RH front footpeg holder plate assembly, make sure that bushing (71) is
present on swingarm shaft and take care not to damage the brake hose and wiring.
6. Fasten the RH front footpeg holder plate (38) assembly following the sequence below:

Tighten special screw (42) to 72 Nm ±5% with grease GADUS S2 V220 AD 2 (or
equivalent) + certification

Tighten nut (41) to 60 Nm ± 5% with grease GADUS S2 V220 AD 2 (or equivalent) +
certification while holding it from the opposite side

Tighten screw M10x50 (43) to 45 Nm ± 5% with grease GADUS S2 V220 AD 2 (or
equivalent) + certification

Tighten special screw (39) to 25 Nm ± 5% while holding nut M8 (40) and certify
24/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
NOTE
Check the correct alignment between the footpeg holder plate and the swinging
arm.
7. Fasten the fitting to the ABS control unit as shown in the figure, using 2 new copper
washers (E) and tighten the special screw (61) to 25 Nm ± 5% with certification.
8. Fasten the rear brake master cylinder fitting as shown in the figure using 2 new copper
washers (F) and tighten the special screw (63) to 25 Nm ± 5% with certification.
25/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
WARNING
Make sure that brake hose (A) and brake hose (D) fittings are aimed on the ABS
control unit as shown in the figure and check also that there are no interferences.
WARNING
Make sure that brake hose (A) and brake hose (D) fittings are respectively aimed on
the brake caliper and brake master cylinder as shown in the figure.
26/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
Part 5: Rear brake system filling and bleeding
Proceed with the DOT4 fluid filling inside the rear brake system and bleed the system
following the procedure indicated in the bulletin SRV-TTB-17-003 valid for the Monster 821
model.
WARNING
Remember that the brake fluid could damage the paint or parts of the motorcycle.
Wash the affected area with plenty of water in case of accidental contact.
Damage due to brake fluid contact with vehicle component is NOT covered by
warranty and is the responsibility of the dealer to repair.
1. Fasten brake hose (A) to the swinging arm through hose grommet (60) and tighten the
relevant retaining screw to 8 Nm ± 10%.
2. Tie the brake hose (A) to the rear speed sensor cable using the 4 small self-locking ties
(76), aiming these latter as shown in the figure.
27/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
Part 6: Vehicle Refitting
1. Install cable guide (56) on swinging arm by tightening the 3 screws M5x12 (55) to 5 Nm ±
10% applying LOCTITE 243 on threads.
2. Position the crank case breather hose on vertical cylinder head and secure it to head cover
using the 2 large self-locking ties (77), aiming these latter as shown in the figure.
3. Install the cover (54) following the procedure below:

Fit the cover and position it as shown in figure

Turn cover upwards to insert it between exhaust manifold and vertical head belt cover
guard

Position cover inside its seat
1
2
3
28/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
4. Tighten the 2 self-tapping screws (53) securing cover (54) to 1.6 Nm ± 10%.
NOTE
Before carrying on with the tightening, start the 2 self-tapping screws (53) taking care
to start them in the original thread already present.
5. Fit clutch nipple and position clutch cable (46) as shown below:

Route clutch cable (46) inside cable guide (52)

Position clutch cable (46) inside cable guide (51)

Install cable guide (51) with spacer (50) and tighten screw M6x25 (49) to = 10 Nm ±
10% applying LOCTITE 243 on threads

Secure clutch cable (46) to wiring protection on vertical head using the 2 large selflocking ties (78), aiming these latter as shown in the figure

Secure clutch cable (46) to frame using the small self-locking tie (79), aiming this
latter as shown in the figure
29/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
6. Fit the vertical head exhaust manifold (See Sec.8: “Fuel/exhaust system – Exhaust system”
of the Workshop Manual 2.0).
7. Fit the silencer (See Sec.8: “Fuel/exhaust system – Exhaust system” of the Workshop
Manual 2.0).
BEFORE
AFTER
8. Remove the adhesive tape from the intake manifolds.
9. Install the Airbox on the vehicle making sure that the two intake manifolds are perfectly
fitted inside it.
10. Working on vehicle RH side, fasten the Airbox using clamp (34) positioned on the
horizontal cylinder head and clamp (33) positioned on the vertical cylinder head and
tighten them to 2.5 Nm ± 10%.
30/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
11. Working on vehicle LH side:
11 A. Connect map sensor connector (32)
11 B. Install horizontal head pressure sensor hose (29) and vertical head pressure sensor
hose (30) by applying the 2 ties (31)
NOTE
Position ties with cut parts side facing downwards, as shown in the figure.
11 C. Install Airbox drain hose (26) and secure it with click clamp (25).
11 D. Install the coil support bracket by tightening the 3 screws M5x20 (27) with the
relevant spacers (28) to a torque of 6 Nm ± 10%.
31/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
11 E. Insert ignition switch connector (24) in the relevant tab present on the Airbox.
11 F. Connect the air temperature sensor connector (23)
11 G. Using the small self-locking tie (78) join the main wiring front central branch to the
airbox clip (close to the red taping and aiming it as shown in the figure).
11 H. Using the small self-locking tie (79) join the main wiring front branch to the air
temperature sensor wiring branch (aim it as shown in the figure).
11 I. Using the small self-locking tie (80) join the main wiring front branch to the air filter
cover (aim it as shown in the figure).
11 J. Using the large self-locking tie (81) join the ground wiring branch, the ECU wiring
branch and the air main wiring front central branch to the main wiring front branch
(aim it as shown in the figure).
32/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
11 K. Connect 2 connectors (20) of engine ECU.
11 L. Using the small self-locking tie (82) join the main wiring primary front branch to the
ECU support (aim it as shown in the figure).
NOTE
The main wiring primary front branch must not interfere with poppet (83) of ECU.
11 M. Using the 2 large self-locking ties (84) join the front branch and the ground jointing
braided wiring branch to the control unit-relay support (aim them as shown in the
figure).
11 N. Using the large self-locking tie (85) join the main branch to the control unit-relay
support (aim it as shown in the figure).
12. Working on vehicle RH side:
12 A. Connect secondary air (AIS) connector (19).
12 B. Install horizontal head secondary air hose (17) and vertical head secondary air hose
(18) by fastening them with the 2 click clamps (16).
33/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
NOTE
Make sure that secondary air hose (18) is correctly positioned on the Airbox.
13. Connect injector wiring connector (9), vertical lambda sensor connector (10),
potentiometer wiring connector (11) and insert starter relay (12), injection relay (13) and
fuel pump relay (14) in the relevant support as shown in the figure.
14. Using the large self-locking tie (86) join the main wiring primary central branch to the
airbox lower cover (aim it as shown in the figure).
15. Using the large self-locking tie (87) join the main wiring secondary central branch to the
airbox lower cover (aim it as shown in the figure).
34/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
16. Fit the crank case breather hose (8) on the Airbox and tighten clamp (7) to 1.5 Nm ± 10%.
17. Working on the LH side, install cover (2) tightening screw M5x10 (1) to 3 Nm ±10%.
18. Working on the RH side, install the coolant reservoir cover (6) and tighten the 2 screws
M5x9 (3) to 3 Nm ± 10% and screw M6x22 (4) with relevant spacer (5) to 10 Nm ± 10%.
19. Fit the fuel tank (See Sec.8: “Fuel/exhaust system – Fuel tank” of the Workshop Manual
2.0).
20. Start the engine and keep it at idle until reaching the fan activation condition.
21. Connect the DDS 2.0 diagnosis instrument and run a Global Scan.
22. Mount the seat.
35/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
23. Measure height (A1) between rear brake lever lower end and load-bearing surface; brake
lever must be in rest position (upper limit stop).
24. Slowly position the 8 kg weight onto rear brake lever; then measure height (B1) between
rear brake lever lower end and load-bearing surface
25. Note the difference between the measured heights (A1) and (B1)
Rear brake lever stroke 1 = (A1) – (B1)
26. Road test the vehicle on the road at a speed of about 30 mph (50 Km/h) and, by operating
only the rear brake, brake until the ABS is engaged at least 10 times
27. Measure again the rear brake lever stroke as referred to in steps 23 and 24
WARNING
The measurement of the rear brake lever stroke required must be taken with the same
temperature conditions as the previous measurement. Therefore, if the measurement
was taken with cold engine it will be necessary to wait for 2 hours before proceeding.
28. Note the difference between the measured heights (A2) and (B2)
Rear brake lever stroke 2 = (A2) – (B2)
29. Compare the 2 stroke values of the rear brake lever
30. If a stroke increase of the rear brake lever is detected, repeat the complete bleed
procedure
36/37
CR191 – Rear Brake Hoses Check and Replace if
Required
Monster 821 Model Year 2018-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-004
31. Once the new bleeding procedure is completed, check that the stroke of the rear brake
lever has not increased
32. Perform a soft cleaning of the bike before delivering it to the Customer
For questions on this Workshop Campaign,
please contact your Service Area Manager.
37/37