CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
Date:
To:
From:

May 22, 2020
All required parties in descending order, 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 1200 model versions currently produced and being shipped by DMH to all
destinations have already been equipped with these new brake hoses.
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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
Application
You can find the precise list of VIN numbers involved in CR193 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



61911291A: ABS control unit / rear brake caliper hose



85250241A: Copper washers (8pcs)

The required self-locking ties (small (6 pcs) and large (13 pcs)) are easy to find consumables
and should be sourced locally.

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
Warranty Reimbursement Rules
Reimbursement for work associated with this Service Campaign will be made through the
regular warranty claim procedure using the “VIN History” section of the DCS. The warranty
claim is pre-filled and is identified as CR193. 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:36min
(36 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.
61911301A, ABS control unit / rear brake caliper hose Part no. 61911291A, the consumable ties
and DOT 4 brake fluid; and labor for 3h:36min (36 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

Table of contents
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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
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 – ABS unit to Rear Caliper
Part 4: Rear Brake Hose Installation – Master Cylinder to ABS unit
Part 5: Rear Brake System Filling and Bleeding
Part 6: Vehicle Refitting

5
5
7
7
16
19
21
26
27

Spare Parts
Part No.

Description

61911301A

ABS control unit /
rear brake master cylinder hose

61911291A

ABS control unit /
rear brake caliper hose

85250241A

Copper washers (8pcs)

Picture

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
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 using the adjustment screw on the control rod.

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
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

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
Operation 2 Part 1: Vehicle preparation
1. Position the bike on the rear paddock stand
2. Remove the rear wheel (See Sec. 7: "Chassis – Rear wheel" of the Workshop Manual)
3. Drain all the oil contained inside the rear brake system

4. Remove the seat
5. Remove the fuel tank (See Sec.8: “Fuel/exhaust system – Fuel tank” of the Workshop
Manual)
6. Working on the LH side, remove screw M5x10 (1) retaining cover (2) and pull it up to
remove it
7. 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

8. Loosen clamp (7) and pull out Crankcase ventilation hose (8) from the Airbox

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
9. 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)
10. Remove the 2 large self-locking ties (15)

11. Working on vehicle RH side:
11 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)
11 B. Disconnect secondary air (AIS) connector (19)

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
12. Working on vehicle LH side:
12 A. Disconnect the 2 connectors (20) of engine ECU
12 B. Remove the 4 large self-locking ties (21)

12 C. Remove the 3 small self-locking ties (22)
12 D. Disconnect the air temperature sensor connector (23)
12 E. Pull out ignition switch connector (24) from the relevant tab present on the Airbox.

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
12 F. Remove click clamp (25) and pull out Airbox drain hose (26)
12 G. Remove 3 screws M5x20 (27) with relevant spacers (28) retaining coil support
bracket to access the map sensor connector

12 H. Pull out horizontal head pressure sensor hose (29) and vertical head pressure sensor
hose (30) by removing the 2 clamps (31)
12 I.

Disconnect the map sensor connector (32)

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
13. 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.
14. Remove the Airbox from the vehicle

15. 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
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 motorcycle finishes and components due to brake fluid contact during repairs is
not warrantable and is the responsibility of the dealer to remedy

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
16. Remove the silencer (See Sec.8: “Fuel/exhaust system – Exhaust system” of the Workshop
Manual).
17. Remove the vertical head exhaust midpipe (See Sec.8: “Fuel/exhaust system – Exhaust
system” of the Workshop Manual)
BEFORE

AFTER

18. Remove the special screw (35) with the 2 copper washers (36) securing brake hose (37) to
rear brake master cylinder

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
19. 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)

20. Pull out the RH front footpeg holder plate (38) by removing self-locking tie (44) and
disconnect rear stop light connector (45)

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CR193 - Rear Brake Hoses Check and Replace if
required
Monster 1200 Model Year 2017-2020 (all versions)
Monster 1200S Model Year 2017-2020 (all versions)
Technical Service Bulletin SRV-TSB-20-006
21. Remove the 2 self-tapping screws (46) and slide out the cover (47)

NOTE
To make cover (47) 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

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CR193 - Rear Brake Hoses Check and Replace if