Ducati DUCATI620Sport Motorcycle User Manual
Contents
1. a Gasoline is extremely flammable and is explosive under certain conditions Refuell in a well ventilated area with the engine stopped Do not smoke or allow open flames or sparks when refuelling or servicing the fuel system Always close the fuel petcock when the engine is not running to prevent flooding of the throttle body Do not overfill fuel tank see instructions page 38 Motorcycle exhaust contains poisonous carbon monoxide gas Do not inhale exhaust gases and never run the engine in a closed garage or confined area Use only Ducati approved parts and accessories This motorcycle was not intended to be equipped with a sidecar or to be used to tow any trailer or other vehicle Ducati does not manufacture sidecars or trailers and cannot predict the effects of such accessories on handling or stability but can only warn that the effects will be adverse and any damage to motorcycle components caused by the use of such accessories will not be remedied under warranty Warning Do not ride the motorcycle with helmets attached to the hook the helmets could cause an accident by distracting the operator or interfering with normal vehicle operation Protective apparel Always wear a helmet Most motorcycle accident fatalities are due to head injuries For safety eye protection gloves and high top sturdy boots should also be worn 78 The exhaust system becomes very hot during operation never touch the exhaust system Wear cl2. FOR UNITED STATES OF AMERICA VERSION ONLY Reporting of safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Ducati North America If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Ducati North America To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline Safety warnings Traffic Rules vary from jurisdiction to jurisdiction Know the regulations in your jurisdiction before riding this motorcycle Warning This motorcycle is designed and intended for use on streets and other smooth paved areas only Do not use this motorcycle on unpaved surfaces Such use could lead to upset or other accident Noise emission warranty Ducati Motor S p A warrants that this exhaust system at the time of sale meets all applicable U S EPA Federal noise standards This warranty extends to the first person who buys this exhaust
3. 3 EOBD pilot light will flash Count a number of flashes corresponding to the first figure of the code open full throttle and keep the position for 2 seconds then release In this way the input of one figure is acknowledged EOBD pilot light comes on and stays on for 4 seconds Carry out the same procedure for the following figures of the code Failure to do so will cause the EOBD pilot light to flash 20 times then it will stay on This means that the procedure has been aborted It will be necessary to turn the key to OFF and restart from point 1 4 Repeat operations described in point 3 up to the last figure of the code 5 Release the throttle twistgrip if the code is correct the EOBD warning light shall flash signalling that engine block has been disabled The warning light turns off after 4 seconds If the code is NOT correct the EOBD warning light stays on and it is then possible to turn the key to OFF and repeat the procedure starting from point 1 as many times as necessary infinite Note Should the throttle twistgrip be released before the set time the warning light turns on again It is then necessary to bring the key to OFF and restart the procedure from point 1 Operation When the ignition key is turned to OFF the immobilizer inhibits engine operation When the ignition key is turned back to ON to start the engine the following happens 1 if the CPU recognised the code the CODE light on the instr
4. Cleaning the motorcycle with water cleaners may lead to seizure or severe failure of front fork wheel hub assembly electric system front fork seals air inlets or exhaust silencers and adversely affect the operation of motorcycle safety features If needed clean off stubborn dirt or exceeding grease from engine parts using a degreasing agent Be sure to avoid contact with drive parts chain sprockets etc Rinse with warm water and ary all surfaces with chamois leather 62 Warning Loss of braking may occur immediately after washing the motorcycle Never grease or lubricate the brake discs Loss of braking and further accidents may occur Clean the discs with an oil free solvent Storing the bike away If the motorcycle is to be left unridden over long periods it is advisable to carry out the following operations before storing it away clean the motorcycle drain all fuel from tank pour a few drops of engine oil into the cylinders through the spark plug seats then crank the engine by hand a few times so a protective film of oil will spread on cylinder inner walls place the motorcycle on the service stand disconnect and remove the battery Battery should be checked and charged whenever the motorcycle has been left unridden for over a month protect the motorcycle with a suitable canvas available from Ducati Performance This will protect paintwork and let condensate breathe out Important notes Some countries
5. However always adjust your speed to the visibility road and traffic conditions you are riding in Always signal your intention to turn or pull to the next lane in good time using the suitable turn indicators Be sure you are clearly visible and do not ride within the blind spot of vehicles ahead Be very careful when tackling road junctions or when riding in the areas near exits from private grounds car parks or on slip roads to access motorways Always turn off the engine when refuelling Be extremely careful not to spill fuel on the engine or on the exhaust pipe when refuelling Do not smoke when refuelling While refuelling you may inhale noxious fuel vapours Should any fuel drops be spilled on your skin or clothing immediately wash with soap and water and change your clothing Always remove the key when you leave your motorcycle unattended The engine exhaust pipes and mufflers stay hot for a long time Warning The exhaust system might be hot even after engine is switched off pay particular attention not to touch exhaust system with any body part and do not park the vehicle next to inflammable material wood leaves etc Park your motorcycle where no one is likely to hit it and use the side stand Never park on uneven or soft ground or your motorcycle may fall over Carrying the maximum load allowed Your motorcycle is designed for long distance riding carrying the maximum load allowed in full safety Eve
6. when turning the key to ON It reminds you of the routine maintenance servicing to be done Instrument panel lighting Turn the key to ON and press B fig 6 within 5 seconds to change instrument panel lighting power 13 The immobilizer system For improved anti theft protection the motorcycle is equipped with an IMMOBILIZER an electronic system that inhibits engine operation whenever the ignition switch is turned off Accommodated in the handgrip of each ignition key is an electronic device that modulates an output signal This signal is generated by a special antenna incorporated in the switch when the ignition is turned on and changes every time The modulated signal acts as a password and tells the CPU that an authorised ignition key is being used to start up the engine When the CPU recognises the signal it enables engine start up Keys fig 7 The Owner receives a set of keys comprising 1 RED key A 2 BLACK keys B N Warning Red key A has a rubber cover for preserving it in perfect conditions and avoiding contact with other keys Never remove this protection unless really needed The keys B are regular ignition keys and are used to start up the engine open the lock of the fuel tank filler plug open the seat lock 14 The key A performs the same functions as the keys B and is also used to wipe off and re program other black keys if needed Note The three keys have
7. 1 Instrument panel Key operated ignition switch and steering lock Left switch Clutch lever 5 Cold start lever Right switch Throttle twistgrip Front brake lever 9 Gear change pedal 10 Rear brake pedal AUN MND fig 3 Instrument panel fig 4 Blue light D omes on when high beam is on Green light omes on and flashes when a turn indicator is on Yellow light P omes on when there are about 4 liters fuel left in the ank Green light N omes on when in neutral position Red light So Comes on when engine oil pressure is too low It briefly comes on when the ignition is switched to ON and normally goes out a few seconds after engine starts It may shortly come on when the engine is hot however it should go out as the engine revs up ADS FOWONOS Important If this light stays on stop the engine or it may suffer severe damage 6 Orange light Comes on and flashes when the motorcycle is parked Immobilizer on it is also used for immobilizer diagnosis Note When the Immobilizer is on this light flashes for 24 hours and then goes out The Immobilizer is still operating 7 Orange EOBD light amp When on engine operation is inhibited It goes out after a few seconds usually 1 8 2 sec 8 Speedometer km h Gives road speed a LCD 1 Odometer km Gives total distance covered Trip meter km Gives distance covered since last resetting 9
8. Important Using the clutch properly will avoid damage to transmission parts and spare the engine Note It is possible to start the engine with side stand down and the gearbox in neutral When starting the bike with a gear engaged pull the clutch lever in this case the side stand must be up 20 Cold start lever fig 13 Use this device to start the engine from cold It will increase the engine idling speed after starting Lever positions A closed B fully open The lever can be opened and closed gradually to adjust speed until engine is fully warm see pages 34 35 Important Never use the cold start device when the engine is warm or leave it open when riding 21 Right switch fig 14 1 Switch light switch three positions right position light off centre position 3002 front and rear parking lights number plate and instrument panel lights on left position headlight front and rear parking lights number plate and instrument panel lights on Note This device is not fitted on the Australia and Japan versions 2 Switch for ENGINE STOP two positions position RUN run position w OFF stop yn Warning This switch is mainly intended for use in emergency cases when you need to stop the engine quickly After stopping the engine return the switch to the position to enable starting Important Riding with the lights on stopping the eng
9. Nut 2 has a left hand thread Fit an open end wrench to the hexagon portion of linkage 1 Rotate linkage until setting pedal in the desired position Tighten both check nuts onto linkage To set the rear brake pedal loosen check nut 4 Turn pedal travel adjusting screw 5 until pedal is in the desired position Tighten check nut 4 Work pedal by hand to make sure it has 1 5 2mm free play before brake begins to bite If not so set the length of cylinder linkage as follows Loosen the check nut 6 on cylinder linkage Tighten linkage into fork 7 to increase play or unscrew linkage to reduce it Tighten check nut 6 and check pedal free play again MAIN COMPONENTS AND DEVICES Location fig 20 1 Tank filler plug 2 Seat catch and helmet hooks 3 Side stand 4 Rear view mirrors 5 Rear shock absorber adjusters 6 Cataliser 26 Tank filler plug fig 21 Opening Lift the protection lid 1 and fit the ignition key into the lock Turn the key clockwise 1 4 turn to unlock Lift the plug Closing Refit the plug with the key in it and push it down into its seat Turn the key anticlockwise to its initial position and take it out Close the lock protection lid 1 Note The plug can only be closed with the key in Warning Always make sure you have properly refitted see page 38 and closed the plug after each refuelling 27 Seat catch and hel
10. Revolution counter rpm Shows the engine rotation speed minute b LCD 2 Clock Oil temperature 11 11 LCD unit functions When the ignition key is turned to ON the instrument panel carries out a Check of all instruments pointers display lights see fig 5 and 6 LCD 1 Turn the key to ON and press B fig 6 to display trip meter and odometer alternatively Resetting the trip meter Keep B pressed fig 6 for more than 2 seconds When the TRIP function is enabled trip meter display LCD 1 will reset LCD 2 Turn the key to ON and press A fig 6 to display clock and oil temperature Setting the clock Press A for at least 2 seconds Press B to set AM PM Press A to set hours press B repeatedly to set correct hour Press A to set minutes Press B to increase the value Keep the button pressed for more than 5 seconds to proceed faster Press A to quit this function fig 5 Oil temperature When the oil temperature goes below 50 C 122 F 71 gt E ri oF LO will be displayed HI will be displayed when the Lu ok LLI E temperature exceeds 170 C 338 F c Li 1 Li F ma of mi E Fuel light FUEL will be displayed when the fuel warning light comes on CHEE Maintenance indicator After the first 1 000 Km 621 m and then every 10 000 Km 6210 m MAlnt will be displayed for 5 seconds
11. actions should be smooth under these conditions Sudden acceleration braking or turning may cause loss of control When the roadway is wet rely more on the throttle to control vehicle speed and less on the front and rear brakes The throttle should also be used judiciously to avoid skidding the rear wheel from too rapid acceleration or deceleration On rough roads exercise caution slow down and grip the fuel tank with your knees for better stability When quick acceleration is necessary as in passing shift to a lower gear to obtain the necessary power Do not down shift at too high an r p m to avoid damage to the engine from overreving Avoiding unnecessary weaving is important to the safety of both the rider and other motorists Do not exceed the legal speed limit or drive too fast for existing conditions High speed increases the influence of any condition affecting stability and the loss of control Operate motorcycle only at moderate speed and out of traffic until you have become thoroughly familiar with its operation and handling characteristics under all conditions This is a very high performance motorcycle designed and intended for use by experienced careful riders only A new motorcycle must be operated according to a special break in procedure see Running in recommendations Warning Before starting engine check for proper operation of brake clutch shifter throttle controls correct fuel and oil supply 77
12. from it then draw a horizontal line dictated by headlamp centre and a vertical one in line with the longitudinal axis of motorcycle If possible perform this check in dim light Switch on the low beam The height of the light spot measured at the upper limit between dark and lighted up area should not exceed 9 10 of the height from ground of headlamp centre Note The procedure described here is in compliance with the Italian Standard establishing the maximum height of the light beam Owners in other countries will adapt said procedure to the provisions in force in their countries fig 64 57 The height of the light beam can be corrected using the screw 1 fig 65 on the left side of the headlamp Turn the screw clockwise to lower the beam anticlockwise to raise it The side position of the headlamp is adjusted using the adjusting screw 2 fig 65 on the right side of headlamp Turn the screw clockwise to move the beam E to the right anticlockwise to move it to the left FEE ZO LEFT 2 RIGHT l LEFT S RIGHT Tyre pressures Front tyre 2 1 2 2 bar Rear tyre 2 1 2 3 bar As tyre pressure is affected by temperature and altitude variations you are advised to check and adjust it whenever you are riding in areas where ample variations in temperature or altitude occur Important Check and set tyre pressure when tyres are cold To avoid front wheel rim distortion wh
13. have the cable replaced by your Ducati Dealer or Authorised Workshop To prevent these failures smear the ends of the Bowden cables with SHELL Advance Grease or Retinax LX2 at regular intervals For the throttle cable it is best to remove the cover 1 fig 51 by unscrewing the two fastening screws 2 and then grease the cable end and the pulley Warning When refitting the cover be sure to slide the cable properly onto the suitable pulley and inside the guide in the cover 3 fig 52 Refit the cover and tighten the screws 2 To ensure smooth operation of side stand joint clean off any dirt and apply SHELL Alvania R3 at all points exposed to friction 48 Throttle cable adjustment The throttle twistgrip must have a free play of 1 5 2 mm measured at the edge of the twistgrip at all positions of the handlebars If it needs adjusting use the suitable adjuster 1 fig 53 provided on the throttle control 49 Charging the battery fig 54 Before charging the battery it is best to remove it from the motorcycle Always disconnect the black negative terminal first and then the red positive terminal Undo the straps 1 and remove the battery Warning Batteries develop explosive gases keep battery away from heat sources and flames Charge the battery in a well ventilated room Connect the battery charger leads to the battery terminals red to positive terminal b
14. or has a vitrified appearance change the spark plug Check electrode gap it should be 0 6 0 7 mm Important If the gap needs adjusting be very careful when bending the side electrode If gap is too wide or too close engine performance will be affected This could also cause misfiring or irregular idling Clean the electrode and the insulating material accurately using a small metal brush and check seal condition Clean the seat in the cylinder head Be careful not to let any foreign matters fall into the combustion chamber Refit spark plug into cylinder head Tighten until thread is fully into the head Tighten the spark plug to 20 Nm If you do not have a torque wrench you can use the wrench supplied with the tool kit to tighten the spark plug an additional 1 2 turn Important Never use spark plugs with a heat rating other than recommended or a thread length other than standard Spark plugs should be tightened properly Cleaning the motorcycle To preserve the finish of metal parts and paintwork wash and clean your motorcycle at regular intervals anyway according to the road conditions you ride in Use specific products only Prefer biodegradable products Avoid aggressive detergents or solvents Important Do not wash your motorcycle right after use When the motorcycle is still hot water drops will evaporate faster and spot hot surfaces Never clean the motorcycle using hot or high pressure water jets
15. such as France Germany Great Britain Switzerland etc have compulsory emission and noise standards that include mandatory inspections at regular intervals It is the Owner s responsibility to have any parts not in compliance with the standards in force in his her country replaced with spare parts complying with local law 63 TECHNICAL DATA Overall dimensions mm fig 69 Weights Dry weight 182 Kg Carrying full load 385 Kg Warning Failure to observe weight limits could result in poor handling and impair the performance of your motorcycle and you may lose control of the motorcycle 64 fig 69 Top ups Type of fluid cu dm litres Fuel tank including a reserve Unleaded fuel 16 of 4 cu dm liters 95 fuel octane rating at least Oil sump and oil filter SHELL Advance Ultra 4 33 Front Rear brake and clutch circuits Special fluid for hydraulic systems SHELL Advance Brake DOT 4 Protectant for electric contacts Spray for electric systems _ SHELL Advance Contact Cleaner Front fork SHELL Advance Fork 7 5 or Donax TA each leg 0 410 Important Do not use any additives in fuel or lubricants 65 Engine Twin cylinder four stroke 90 L type longitudinal Bore 80 mm Stroke 67 5 mm Total displacement 618 c c Compression ratio 0 5 1 10 5 Max power at crankshaft 95 1 CE 45 kW 61 HP at 8750 rpm Max torque at crankshaft
16. system for purposes other than resale and to all subsequent buyers Warranty claims should be directed to Ducati North America Inc 237 West Parkway Pompton Plains New Jersey 07444 1028 Tel 001 973 839 2600 Fax 001 973 839 2331 Noise and exhaust emission control system information Source of Emissions The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but is toxic Ducati utilizes lean carburetor settings and other systems to reduce carbon monoxide and hydrocarbons Exhaust Emission Control System The Exhaust Emission Control System is composed of lean carburetor settings and no adjustments should be 75 a made except idle speed adjustments with the throttle stop screw The Exhaust Emission Control System is separate from the crankcase emission control system Crankcase Emission Control System The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner and the throttle body Evaporative Emission Control System California motorcycles are equipped with an evaporative emission control system which consists of a charcoal canister and associated piping This system prevents the escape of
17. the date the motorcycle is delivered to an ultimate purchaser Ducati North America Inc 237 West Parkway Pompton Plains New Jersey 07444 1028 001 973 839 2600 83 vsa ROUTINE MAINTENANCE RECORD km Ducati Mileage Date Service Name 1000 10000 20000 30000 40000 50000 84
18. the engine with side stand down and the gearbox in neutral When starting the bike with a gear engaged pull the clutch lever in this case the side stand must be up 34 2 Move the cold start lever to the B position fig 32 3 Check that the stop switch 1 fig 31 is positioned to O RUN then press the starter button 2 Let the engine start without using the throttle control Important Never operate the electric start button more than 5 seconds at a time If needed allow 10 seconds before attempting to restart the engine 4 Move the cold start lever to the vertical position A to let engine idle at about 1400 1500 rpm Important Do not rev up the engine when it is cold Allow some time for oil to reach all points that need lubricating 5 As the engine warms up move the cold start lever gradually towards the vertical position A Once fully warm the engine should hold idling rom with the cold start shut down High ambient temperature over 35 C 95 F Follow the same procedure for Regular ambient temperature however do not use the cold start device Cold ambient temperature below 10 C 50 F Follow the procedure for Regular ambient temperature however allow 5 minutes for the engine to warm up see step 5 Moving off 1 Disengage the clutch squeezing the control lever 2 Push down on gear change lever sharply with the tip of your foot
19. to engage the first gear 3 Speed up engine by turning the throttle twistgrip and slightly releasing the clutch lever at the same time The motorcycle will start moving off 4 Let go of clutch lever and speed up 5 To shift up close the throttle to slow down engine disengage the clutch lift the gear change lever and let go of clutch lever To shift down release the twistgrip pull the clutch control lever shortly speed up to help gears synchronise shift down and release the clutch The controls should be used correctly and timely when riding uphill do not hesitate to shift down as soon as the motorcycle tends to slow down so you will avoid stressing the engine and the motorcycle abnormally 36 Important Avoid harsh accelerations as this may lead to misfiring and transmission snatching The clutch lever should not be pulled longer than necessary after gear is engaged or friction parts may overheat and wear out Braking Slow down in time shift down to engine brake first and then brake applying both brakes Pull the clutch lever before stopping the motorcycle to avoid sudden engine stop Warning Use both brake lever and pedal for effective braking Using only one of the brakes will give you less braking power Never use brake controls harshly or violently or you may lock the wheels and lose contro of the motorcycle When riding in the rain or on slippery surfaces braking will become less effective Always use th
20. 95 1 CE 54 Nm 5 5 Kgm at 6500 rpm Derated version Max power at crankshaft 95 1 CE 24 kW 32 6 HP at 9500 rpm Max torque at crankshaft 95 1 CE 42 Nm 4 3 Kgm at 3500 rpm Important Do not exceed specified rotation speed limits under any running condition 66 Timing system Desmodromic type with two valves per cylinder operated by four rockers 2 opening rockers and 2 closing rockers and an overhead camshaft It is operated by the crankshaft through spur gears belt rollers and toothed belts Desmodromic timing system fig 70 1 Opening or upper rocker arm 2 Opening rocker arm shim 3 Split rings 4 Closing or lower rocker arm shim 5 Return spring for lower rocker arm 6 Closing or lower rocker arm 7 Camshaft 8 Valve fig 70 Performance data Maximum speed in any gear should be reached only after a correct running in period with the motorcycle properly serviced at the recommended intervals Max speed rider alone 195 Kph Brakes Front brake Double drilled disc Braking surface material stainless steel Disc diameter 320 mm Hydraulically operated by a control lever on right handlebar Braking surface 88 sq cm Brake calipers with separate pistons Make BREMBO Type 30 34 4 pistons Friction material FERIT I D 450 FF Master cylinder type PS 16 Rear brake With fixed drilled disc Braking surface material stainless stee
21. E DUCATIGZ0Sport Hearty welcome among Ducati fans Please accept our best compliments for choosing a Ducati motorcycle We think you will ride your Ducati motorcycle for long journeys as well as short daily trips Ducati Motor Holding S p A wishes you smooth and enjoyable riding We are steadily doing our best to improve our Technical Assistance service For this reason we recommend you to strictly follow the indications given in this manual especially for motorcycle running in In this way your Ducati motorbike will surely give you unforgettable emotions Please contact our authorised service centres to have your motorcycle repaired or if you simply need advice Enjoy your ride Note Ducati Motor Holding S p A declines any liability whatsoever for any mistakes incurred in drawing up this manual The information contained herein is valid at the time of going to print Ducati Motor Holding S p A reserves the right to make any changes required by the future development of the above mentioned products For your safety as well as to preserve the warranty reliability and worth of your motorcycle use original Ducati spare parts only Warning This manual forms an integral part of the motorcycle and in the event the motorcycle is resold must always be handed over to the new owner TABLE OF CONTENTS General 6 Warranty 6 Symbols 6 Useful information for safe riding 7 Carrying the maximum load allowed 8 Ide
22. a small plate 1 attached that reports their identification number Warning Keep the keys in different places Store the plate 1 and the key A in a safe place It is also recommended to use always the same black key to start the bike Code card The keys come with a CODE CARD fig 8 that reports A fig 9 the electronic code to be used to be used in case of engine block i e bike did not start after key ON B fig 9 the part no code for the keys to be reported to the DUCATI Service network when you are ordering any duplicate keys Important Keep the CODE CARD in a safe place However it is advisable to keep the electronic code printed on the CODE CARD handy when you ride your motorcycle in case it is necessary to remove engine block through the procedure that uses the throttle twistgrip In case of faulty immobilizer system the following procedure gives the chance to disable engine block function signalled by the orange EOBD warning light that comes on immediately 7 fig 4 But this operation can be carried out only if the electronic code indicated on the code card is known fig 8 post fig 9 15 Procedure to disable immobilizer engine block through throttle twistgrip 1 Turn the key to ON and fully open throttle Keep it open The EOBD warning light turns off after 8 seconds 2 Release the throttle as soon as the EOBD warning light turns off
23. and clutch fluid and will damage paintwork and plastic parts if accidentally spilled Hydraulic oil is corrosive it may cause damage and lead to severe injuries Never mix different quality oils Check seals for proper sealing Clutch system If the control lever has exceeding play and the transmission snatches or jams as you try to engage a gear it means that there is air in the circuit Contact your Ducati Dealer or Authorised Workshop to have the system inspected and air drained out Warning Brake fluid level will increase as clutch plate friction material wears down Do not exceed specified level 3 mm above minimum level 46 Checking brake pads for wear fig 50 Front brake To facilitate inspection without removing the pads from the calipers brake pads have a wear mark If the grooves in the friction material are still visible the pad is still in good condition Rear brake The friction material on each pad should be at least 1 mm thick Important Have the brake pads replaced at a Ducati Dealer or Authorised Workshop 47 Lubricating joints The condition of the outer sheaths of the throttle and cold start cables should be checked at regular intervals The sheaths should show no signs of squeezing or cracking Work the controls to make sure the cable slides smoothly inside the sheath if you feel any friction or hard spots
24. bs MMB kg with A irc AM at B cold GAWA rear WEE Lbs ko vith io AM A V ot A cold This vehicle conforms to all applicable Federal Motor Vehicle Safety standards in effect on the date of manufacture shown above Vehicle I D No ZDM1TB9PXWB000001 Type classification Motorcycle 5 6 VEHICLE EMISSION CONTROL INFORMATION VEHICLE EMISSION CONTROL INFORMATION THIS VEHICLE CONFORMS TO U S EPA REGULATIONS APPLICABLE TO Tat MODEL YEAR NEW MOTORCYCLES Engine displacement 904 cc Engine family Engine exhaust control systern aiiat Engine displacement 904 cc Engine family Maite Engine exhaust control system mil Evap family THIS VEHICLE CONFORMS TO U S EPA AND CALIFORNIA REGULATIONS APPLICABLE TO 19mm MODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED TO 1 4 HC G KM ENGINE FAMILY EXHAUST EMISSION STANDARD IN CALIFORNIA ENGINE TUNE UP SPECIFICATIONS ENGINE TUNE UP SPECIFICATIONS SPARK PLUG CHAMPION Pam SPARK PLUG GAP mm 0 5 0 6 OIL SAE 20W50 FUEL Unleaded gasoline ITEM SPECIFICATIONS INSTRUCTIONS ITEM IGNITION TIMING E bTDC at idle speed No adjustment IGNITION TIMING IDLE SPEED RPM mm 0 12 mm No adjustment IDLE SPEED RPM IDLE MIXTURE No adjustment IDLE MIXTURE Opening ame mn VALVE CLEARANCE in amp ex See Service Manual VALVE CLEARANCE in amp ex Closing aaammsase mm SPARK PLUG CHAMPION Fam SPARK PLUG GAP mm 0 5 0 6 SPECIFICATIONS INSTRUCTIONS mm bTOCat i
25. ction with the sale or use of or inability to use the Ducati motorcycle for any purpose Some states do not allow the exclusion or limitation of any incidental or consequential damages so the above limitations may not apply to you B No express emission control system warranty is given by Ducati except as specifically set forth herein Any emission control system warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control systems warranty terms stated in this warranty The foregoing statements of warranty are exclusive and in lieu of all other remedies Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you C No dealer is authorized to modify this Ducati Limited Emission Control Systems Warranty IV Legal rights This warranty gives you specific legal rights and you may also have other rights which vary from state to state V This warranty is in addition to the Ducati limited motorcycle warranty VI Additional information Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs However Ducati is not liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any individual The warranty period begins on
26. dle speed No adjustment mm 0 12 mm No adjustment No adjustment Opening ausm mm See Service Manual Closing aaam mm OL SAE 20W50 FUEL Unleaded gasoline DUCATIMOTOR spa BOLOGNA ITALY DUCATIMOTOR spa BOLOGNA ITALY ie WARM AIR INLET 80 7 VEHICLE EMISSION CONTROL LABEL WARNING ENGINE DISPLACEMENT 904 cc ENGINE FAMILY CONTAINS HIGHLY COM PRESSED THIS VEHICLE CONFORMS TO U S EPA AND CALIFORNIA REGULATIONS GAS USE ONLY PERFECTLY DRY APPLICABLE TOnmma MODEL YEAR NEW MOTORCYCLES VAP FAMILY ae NITROGEN GAS OTHER GASES MAY CAUSE EXPLOSION DO NOT TO HORIZONTAL MANIFOLD INCINERATE REFER TO OWNER S TOTEE sea MANUAL FOR REGULATING GAS 40132 BOLOGNA TO VERTICAL MANIFOLD ITALY CAUTION NEVER FILL TANK SO FUEL LEVEL RISES INTO FILLER NECK IF TANK IS OVERFILLED HEAT MAY CAUSE FUEL TO EXPAND AND FLOW INTO EVAPORATIVE EMISSION CONTROL SYSTEM RESULTING IN HARD STARTING AND ENGINE HESITATION 8 California evaporation emission system This system consists of fig C 1 Warn air inlet 2 Canister 3 Dell Orto jet 4 Intake manifolds 5 Breather pipe 6 Fuel tank Important In the event of fuel system malfunction contact Ducati s authorized Service Centres fig C Ducati limited warranty on emission control system Ducati North America Inc 237 West Parkway Pompton Plains New Jersey 07444 1028 warrants that each
27. e brakes very gently and carefully when riding under these conditions Any sudden manoeuvres may lead to loss of control When tackling long high gradient downhill road tracts shift down gears to use engine braking Apply one brake at a time and use brakes sparingly Keeping the brakes applied all the time would cause the friction material to overheat and dangerously reduce braking power Underinflated tyres reduce braking efficiency steering accuracy and road holding in a bend Stopping the motorcycle If you let go of the throttle twistgrip the motorcycle will slow down gradually and smoothly Then shift down releasing the clutch and finally change from first to neutral Apply brakes and you will bring the motorcycle to a complete stop To switch the engine off simply turn the key to OFF page 18 Important Never leave the key in the ON position when engine is stopped or this will damage the electric components 37 Parking Stop the motorcycle then put it on the side stand see page 29 Turn the handlebar fully left and block it by pushing in the ignition key and turning it to the LOCK position If you park in a garage or other facilities make sure that there is proper ventilation and that the motorcycle is not near a source of heat or sparks You may leave the parking lights on by turning the key to position P Important Do not leave the key turned to P for long periods or the battery will run down Never leave
28. ed parts when refitting them otherwise some of them might suddenly come off when riding and you may loose control of your motorcycle Important At reassembly always fit nylon washers when tightening fastening screws to avoid damage to painted parts and Plexiglas headlamp fairing Some fastening screws are of the self tapping type do not overtighten otherwise threading might damage thus avoiding further use Side body panels Unscrew the three screws 1 fig 36 and 37 that hold each body panel to the headlamp fairing Unscrew the screw 2 that holds each body panel to the frame 40 ar St u S ay TAY NY N Half faired version fig 38 Unscrew the screw 3 that holds each body panel to the lower support bracket Disconnect the indicator connectors and remove the body panels Fully faired version fig 39 Unscrew the screw 4 that holds the left body panel to the side stand fixing plate Unscrew the screw 5 that holds the right body panel to the rear brake pedal shaft Disconnect the indicator connectors Unscrew the four screws 6 that join the body panels together at the bottom end and remove the body panels Omit this latter step if you wish to remove both body panels together Simply slide them off from under the motorcycle Be sure not to force them apart to avoid damage Headlamp fairing Unscrew the two nuts 1 fig 40 that hold the rear vie
29. en riding on bumpy roads increase front tyre pressure by 0 2 0 3 bar Tyre repair or replacement In the event of a tiny puncture tubeless tyres will take a long time to deflate as they tend to keep air inside If you find low pressure on one tyre check the tyre for punctures yN Warning A tyre must be replaced when punctured Only fit tyres of the same type as original equipment tyres Be sure to tighten the valve caps securely to avoid leaks when riding Never use tube type tyres Failure to heed this warning may lead to sudden tyre bursting and to serious danger to rider and passenger After replacing a tyre the wheel must be balanced Important Do not remove or shift the wheel balancing weights Note If tyres need replacing contact a Ducati Dealer or Authorised Workshop to make sure wheels are removed and refitted correctly Minimum tread depth Measure tread depth S fig 66 at the point where tread is most worn It should not be less than 2mm and anyway not below the legal limit Important Visually inspect the tyres at regular intervals for cracks and cuts especially on the side walls bulges or large spots that are indicative of internal damage Replace them if badly damaged Remove any stones or other foreign bodies caught in the tread 59 Checking engine oil level fig 67 Engine oil level can be checked through the sight glass 1 provided on the clutch cover When checkin
30. essible after lifting the fuel tank Undo the clips 1 of the cover on both sides of the air box then remove cover 2 Remove the filter 3 fig 46 and fit a new one Important A clogged filter will reduce air intake increase fuel consumption reduce engine power and foul the spark plugs Do not use the motorcycle without filter or suspended matters could get into the engine and cause damage Install the filter properly into its seat in the air box as shown in figure 46 and refit all the parts you have removed Important If you are using the motorcycle on dusty or very wet roads replace filter more frequently than recommended intervals see Warranty Card 44 Checking brake and clutch fluid level Fluid level should never fall below the MIN mark on each reservoir fig 47 to 49 If level drops below the limit air might get into the circuit and affect the operation of the system involved Brake and clutch fluid must be topped up and changed at the intervals specified in the routine maintenance chart see Warranty Card by a Ducati Dealer or Authorised Workshop Important It is recommended all brake and clutch lines be changed every four years Brake system If you find exceeding play on brake lever or pedal and brake pads are still in good condition contact your Ducati Dealer or Authorised Workshop to have the system inspected and any air drained out of the circuit yn Warning Brake
31. fuel vapors from the throttle body and fuel tank Tampering warning Tampering with Noise Control System Prohibited Federal Law prohibits the following acts or causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person 76 Among those acts presumed to constitute tampering are the acts listed below 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use Otherwise the owner may become subject to penalties under state and local ordinances Problems that may affect motorcycle emissions If you are aware of any of the following symptoms have the vehicle inspected and repaired by your local Ducati dealer Symptoms Hard starting or stal
32. g oil level the motorcycle should be upright and the engine warm Allow a few minutes for oil to settle to a steady level after stopping the engine Oil level should be between the marks near the sight glass Top up oil level with SHELL Advance Ultra 4 if low Undo the filler plug 2 and top up to correct level Refit the plug Important Engine oil and oil filters must be changed by a Ducati dealer or authorized workshop at regular intervals as specified in the routine maintenance chart see Warranty Card Viscosity SAE 10W 40 The other viscosity degrees indicated in the table can be used if the local average temperature is within the limits specified for that oil viscosity 60 Multigrade Unigrade 40C Cleaning and replacing the spark plugs fig 68 Spark plugs are essential to smooth engine running and should be checked at regular intervals This is done quite easily and quickly and provides a good measure of engine condition Remove the LH fairing remove the spark plug caps from the cylinder head using the wrench supplied with the bike Check the colour of the insulating ceramic material of the central electrode a light brown even colour is a sign of good engine condition If colour has altered or you find any dark deposits change the spark plug and report this to your Dealer or authorised workshop Check wear on the central electrode If it looks worn out
33. handlebars with both hands and push down on the thrust arm 1 with your foot until it is fully extended Tilt the motorcycle until the side stand is resting on the ground Warning A Do not sit on the motorcycle when it is supported on the side stand To move the side stand to its rest position horizontal position tilt the motorcycle to the right and at the same time lift the thrust arm 1 with your foot Note Check for proper operation of the stand mechanism two springs one into the other and the safety sensor 2 at regular intervals Note It is possible to start the engine with side stand down and the gearbox in neutral When starting the bike with a gear engaged pull the clutch lever in this case the side stand must be up 29 Shock absorber adjusters Rear shock absorbers feature spring preload rebound and compression adjustment The adjuster 1 fig 26 on the shock absorber expansion reservoir LH side of the frame controls compression damping The adjuster 2 fig 25 on the left of the connection holding the shock absorber to the swingarm controls rebound damping Turn the adjusters 1 and 2 clockwise to increase damping Two ring nuts 3 fig 26 located on the top section of the shock absorber are used to adjust the outer spring preload To change spring preload slacken the upper ring nut Once preload has been set as required tighten the upper ring nut Then tighten or slac
34. improperly replaced this component could seriously endanger your safety and that or your passenger and cause irreparable damage to your motorcycle Frame Tubular trestle frame with upper section made of high strength steel Steering angle on each side 28 Headstock angle 24 Trail 96 mm Wheels Three spoke light alloy rims Front wheel Make BREMBO Dimensions 3 50x17 Rear wheel Make BREMBO Dimensions 4 50x17 Front wheel shaft can be removed Tyres Front tyre Tubeless radial tyre Size 120 70 ZR17 Rear tyre Tubeless radial tyre Size 160 60 ZR 17 Spark plugs Make CHAMPION Type RA 4 HC As an alternative Make NGK Type DCPR8E 69 Suspensions Available colors Front Ducati matt black 248 514 PPG Hydraulic upside down fork Metal color rims and frame Stanchion diameter Silver 0022 PPG 43 mm Black rims and frame Travel along leg axis 120 mm Rear The rear shock absorber enables the adjustment of rebound and compression damping and spring preload At the bottom pivot point it is connected to the swingarm Swingarm is made from steel and hinges on a pivot pin passing through the engine The whole system gives the bike excellent stability Shock absorber hydraulic damping varies with shock absorber travel Travel 71mm Rear wheel travel 136 mm 70 Electric system Basic electric items are Headlamp with double filame
35. ine using switch 2 and leaving the ignition key in the ON position may run the battery flat as the lights will remain on 3 Button engine start 22 Throttle twistgrip fig 15 The twistgrip 1 on the right handlebar opens the throttles When released it will spring back to the initial position idling speed Front brake lever fig 15 Pull in the lever 2 towards the twistgrip to operate the front brake The system is hydraulically operated and you just need to pull the lever gently Warning Please read the instructions on pages 36 37 before using these controls 23 Rear brake pedal fig 16 Push down on the pedal 1 to apply the rear brake The system is hydraulically operated Gear change pedal fig 17 The gear change pedal is at rest when in the central position N is moved up and down to change gears and then returns to the central position down push down on the pedal to engage 1st gear and to shift down The N light will go out up lift the pedal to engage the 2nd gear and then the 3rd 4th and 5th gear Each time you move the pedal you will engage the next gear 24 Setting the gear change and rear brake pedals The gear change and rear brake pedals can be adjusted to suit the preferred riding position of each rider To set the gear change pedal lock linkage 1 and loosen the check nuts 2 and 3 Note
36. ith these instructions may put you at risk and lead to severe injury or death Important Possibility of damaging the motorcycle and or its components Note Additional information on the job being carried out The terms right and left are referred to the motorcycle viewed with respect to the direction of travel Useful information for safe riding Warning Read this section before riding your motorcycle Accidents are frequently due to inexperience Always make sure you have your licence with you when riding you need a valid licence to be entitled to ride your motorcycle Do not lend your motorcycle to inexperienced riders or who do not hold a valid licence Both rider and pillion passenger must always wear a safety helmet Wear proper clothing with no loose items or accessories that may become tangled in the controls or limit your zone of vision Never start or run the engine indoors Exhaust gases are poisonous and may lead to loss of consciousness or even death within a short time Both rider and pillion passenger should keep their feet on the footpegs when the motorcycle is in motion Always hold the handlebars firmly with both hands so you will be ready for sudden changes of direction or in the road surface The pillion passenger should always hold on to the suitable grab handle at the rear seat with both hands Ride within the law and observe national and local rules Always respect speed limits where these are posted
37. ken the lower ring to increase or decrease spring preload Warning Use a specific pin wrench to turn the preload adjusting nut Be careful when turning the nut with the wrench as the pin may slip out of the ring nut recess and you may hurt your hand hitting motorcycle parts Warning The shock absorber is filled with gas under pressure and may cause severe damage if taken apart by unskilled persons 30 Shock absorber STANDARD setting e Compression damping adjuster 1 fig 27 18 clicks e Rebound damping adjuster 2 fig 28 8 clicks STANDARD spring length 177mm DIRECTIONS FOR USE Running in recommendations Max rotation speed fig 29 Rotation speed for running in period and during standard use rpm 1 up to 1000 km 2 from 1000 to 2500 km 3 after 2500 km min X1000 11 ETTER fig 29 32 Up to 1000 km During the first 1000 km keep an eye on the revolution meter The indicator must not exceed 5500 6000 rpm During the first hours of riding it is advisable to run the engine at varying load and rom though still within recommended limit To this end roads with plenty of bends and even hilly areas are ideal for a most efficient running in of engine brakes and suspensions For the first 100 km use the brakes gently Do not brake violently or keep brake applied for too long This will enable a correct b
38. l Disc diameter 245 mm Hydraulically operated by a pedal on FH side Braking surface 32 sq cm Make BREMBO Type P34C Friction material FERIT I D 450 FF Master cylinder type PS 11 Warning Brake fluid can dissolve paintwork and cause severe eye and skin injuries in the event of accidental spilling Wash the affected area with abundant running water 67 Transmission Clutch wet multi plate clutch Clutch is operated by a control lever on left handlebar Drive is transmitted from engine to gearbox main shaft via spur gears Gear ratio 33 61 Gearbox 5 speed Gearbox with constant mesh gears gear change pedal on left side of motorcycle Front rear sprocket ratio 15 44 Total gear ratios 1 gear 16 40 24 gear 21 36 3 gear 24 32 4 gear 27 29 5 gear 2928 Drive chain from gearbox to rear wheel Make DID Type 520 VLA 68 Size 5 8 x1 4 Links 100 Important The above gear ratios are part of the homologated specifications and under no circumstances must they be modified If you wish to tune up your motorcycle for competitive trials you may refer to Ducati Motor Holding S p A who will be glad to provide information about the special ratios available Relevant instructions and original spare parts are available from your local Dealer or authorised workshop Warning If the rear sprocket needs replacing contact a Ducati Dealer or an authorised workshop If
39. lack to negative terminal Important Make sure the charger is off when you connect the battery to it or you might get sparks at the battery terminals that could ignite the gases inside the cells Always connect the red positive terminal first WN Warning Keep the battery out of the reach of children Charge the battery at 1 A for 5 10 hours 50 Chain adjustment Turn the rear wheel slowly until you find the position where chain tension is tightest Put motorcycle on the side stand and push the chain up pressing with a finger at mid length of swingarm The lower stretch of chain must have a slack of 25 30 mm chain tension is adjusted as follows Slacken the nut 1 fig 56 of the wheel shaft tighten turn clockwise or slacken the screw 2 on either side of the swingarm equally to increase or reduce chain tension If you are slackening the chain you will have to push the wheel forward Important Improper chain tension will lead to early wear of transmission parts Make sure you have adjusted to the same setting marks on both sides of the swingarm Refer to pointer on slider 3 fig 56 This will ensure perfect wheel alignment Grease the thread of the wheel shaft nut 1 with SHELL Retinax HDX2 grease and torque nut to 72 Nm Chain lubrication The chain fitted on your motorcycle has O rings that keep dirt out of and lubricant inside the sliding parts The seals might be irrepa
40. ling after starting Rough idle Misfiring or backfiring during acceleration After burning backfiring Poor performance driveability and poor economy Riding safety The points given below are applicable for every day motorcycle use and shoud be carefully observed for safe and effective vehicle operation A motorcycle does not provide the impact protection of an automobile so defensive riding in addition to wearing protective apparel is extremely important Do not let protective apparel give you a false sense of security Before changing lanes look over your shoulder to make sure the way is clear Do not rely solely on the rear view mirror you may misjudge a vehicle s distance and speed or you may not see it at all When going up steep slopes shift to a lower gear so that there is plenty of power to spare rather than overloading the engine When applying the brakes use both the front and rear brakes Applying only one brake for sudden braking may cause the motorcycle to skid and lose control When going down long slopes control vehicle speed by closing the throttle Use the front and rear brakes for auxiliary braking Riding at the proper rate of speed and avoiding unnecessarily fast acceleration are important not only for safety and low fuel consumption but also for long vehicle life and quieter operation When riding in wet conditions or on loose roadway surfaces the ability to maneuver will be reduced All of your
41. met hooks Opening fig 22 Fit the ignition key into the lock 1 and turn the key clockwise until the rear end of the seat lifts up Pull the seat backward 3 to slide it off its front holders At the front end of the compartment underneath the seat there are the helmet hooks 2 fig 23 for rider and pillion rider helmets Hook the helmet straps onto the hooks and leave the helmets hanging outside They will be locked safely when you refit the seat Warning This system is intended to lock your helmet safely when you park your motorcycle Never leave the helmet hanging from the hook when riding or it may get in the way and make you lose control of the motorcycle Closing Make sure that all parts are arranged and secured properly inside the compartment under the seat Slide the front ends 3 of the seat bottom underneath the frame U bolt and push down on the rear end of the seat until you hear the catch click Make sure the seat is firmly secured to the frame and take the key out of the lock 1 28 J L fg 23 Side stand fig 24 Important Before lowering the side stand make sure that the bearing surface is hard and flat Do not park on soft or pebbled ground or on asphalt melt by the sun heat and similar or the motorcycle may fall over When parking in downhill road tracts always park the motorcycle with its rear wheel facing downhill To pull down the side stand hold the motorcycle
42. n weight distribution is critical to preserving these safety features and avoiding trouble when performing sudden manoeuvres or riding on bumpy roads Information about carrying capacity The total weight of the motorcycle in running order including rider pillion passenger luggage and additional accessories should not exceed 385 Kg Arrange your luggage or heavy accessories in the lowest possible position and close to motorcycle centre Be sure to secure the luggage to the supports provided on the motorcycle as firmly as possible Improperly secured luggage may affect stability Never fix bulky or heavy objects to the handlebar or to the front mudguard as this would affect stability and cause danger Do not insert any objects you may need to carry into the gaps of the frame as these may foul moving parts Make sure the tyres are inflated to the proper pressure indicated at page 58 and that they are in good condition Identification data All Ducati motorcycles have two identification numbers for frame fig 1 and engine fig 2 Frame number Engine number Note These numbers identify the motorcycle model and should always be indicated when ordering spare parts CONTROLS Warning This section details the position and function of all the controls you need to drive your motorcycle Be sure to read this information carefully before you use the controls Position of motorcycle controls fig 3
43. new 1998 and later Ducati motorcycle that includes as standard equipment a headlight tail light and stoplight and is street legal A is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board and B is free from defects in material and workmanship which cause such motorcycle to fail to conform with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for a period of use depending on the engine displacement of 12 000 kilometers 7 456 miles if the motorcycle s engine displacement is less than 170 cubic centimeters of 18 000 kilometers 11 185 miles if the motorcycle s engine displacement is equal to or greater than 170 cubic centimeters but less than 280 cubic centimeters or of 30 000 kilometers 18 641 miles if the motorcycle s engine displacement is 280 cubic centimeters or greater or 5 five years from the date of initial retail delivery whichever first occurs I Coverage Warranty defects shall be remedied during customary business hours at any authorized Ducati motorcycle dealer located within the United States of America in 81 vsa compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board Any part or pa
44. ngine oil level Check oil level in the sump through the sight glass Top up if needed page 60 Brake and clutch fluid Check fluid level in the relevant reservoirs Tyre condition Check tyre pressure and condition page 58 Controls Work the brake clutch throttle and gear change controls levers pedals and twistgrips and check for proper operation Lights and indicators Make sure lights indicators and horn work properly Replace any burnt out bulbs page 53 Key operated locks Check that fuel filler plug and seat catch locks are closed firmly Stand Make sure side stand operates smoothly and is in the correct position page 29 Warning In case of malfunctioning do not start the motorcycle and call a Ducati Dealer or authorised workshop 33 Starting the engine Note Follow the High ambient temperature procedure to start the engine when it is warm Warning Before starting the engine become familiar with the controls you will need to use when riding Regular ambient temperature 10 C 50 F to 35 C 95 F 1 Move the ignition key to ON fig 30 Make sure both the green light N and the red light on the instrument panel come on Important The oil pressure light should go out a few seconds after the engine has started page 11 Warning The side stand must be fully up in a horizontal position as its safety sensor prevents engine start when down Note It is possible to start
45. nt 12V 55 60 W iodine bulb 12V 5W parking light Electrical controls on handlebar Turn indicators 12V 10W bulbs Horn Stop light switches Battery 12V 10 Ah Generator 12V 520W Electronic voltage regulator rectifier protected by a 40 A fuse located on the side of the battery Starter motor 12V 0 7 kW Tail light 12V 5 21W double filament bulb for stop light and parking light 12V 5W bulb for number plate light Note See Replacing bulbs on page 53 for relevant instructions Fuses The main fuse box is located on the left side of the battery fig 71 To expose the fuses take off the box protective cover 1 Mounting position and ampere capacity are marked on box cover Only 6 fuses are connected There are two spare fuses The 40A fuse 2 placed on the RH side of the battery fig 71 protects the electronic regulator Remove the fuse cap 3 to expose it A blown fuse is identified by the interrupted inner filament 4 fig 72 Important Switch the ignition key to OFF before replacing a fuse to avoid possible short circuits Warning A Never use a fuse with a rating other than specified Failure to observe this rule may damage the electric system or even lead to fire 71 Injection electric system diagram key 1 RH switch 2 Transponder Aerial 3 Key operated switch 4 Main relay 5 Fuse box 6 Horn 7 Starter motor 8 Starter contactor 9 Battery 10 Regulato
46. ntification data 9 Controls 10 Position of motorcycle controls 10 Instrument panel 11 The immobilizer system 14 Keys 14 Code card 15 Procedure to disable immobilizer engine block through trottle twistgrip 16 Duplicate keys 17 Ignition swich and steering lock 18 Left switch 19 Clutch lever 20 Cold start lever 21 Right switch 22 Throttle twistgrip 23 Front brake lever 23 4 Rear brake pedal 24 Gear change pedal 24 Setting the gear change and rear brake pedals 25 Main components and devices 26 Location 26 Tank filler plug 27 Seat catch and helmet hooks 28 Side stand 29 Shock absorber adjusters 30 Shock absorber 31 Directions for use 32 Running in recommendations 32 Pre ride checks 33 Starting the engine 34 Moving off 36 Braking 37 Stopping the motorcycle 37 Parking 38 Refuelling 38 Tool kit and accessories 39 Main maintenance operations 40 Removing the fairing 40 Lifting the fuel tank 43 Changing the air filter 44 Checking brake and clutch fluid level 45 Checking brake pads for wear 47 Lubricating joints 48 Throttle cable adjustment 49 Charging the battery 50 Chain adjustment 51 Chain lubrication 52 Replacing bulbs 53 Beam setting 57 Tyre pressures 58 Checking engine oil level 60 Cleaning and replacing the spark plugs 61 Cleaning the motorcycle 62 Storing the bike away 63 Important notes 63 Technical data 64 Overall dimensions 64 Weights 64 Top ups 65 Engine 66 Timing s
47. othing that fully covers your legs Do not wear loose clothing which could catch on the control levers footrests wheels or chain Any amount of alcohol will significantly interfere with your ability to safely operate your motorcycle Don t drink and ride Vehicle identification number VIN Every Ducati motorcycle is identified by two identification numbers see page 9 Figure A specifically shows the frame identification numbers DUCATI TYPE OF MOTORCYCLE PLANT OF MANUFACTURE SEQUENTIAL NUMBER MODEL YEAR _ ZDM ILA2K 3 B 000000 Varies can be thru 9 or X Check digit fig A Label location fig B E vsn fig B only for California 79 usa EJ WARNING DO NOT ATTEMPT TO LOOK THROUGH THIS FAIRING THIS IS NOT A WINDSHIELD BUT AN AERODYNAMIC FAIRING ONLY FAILURE TO OBSERVE THIS WARNING COULD RESULT IN A COLLISION OR UPSET AND CONSEQUENT SERIOUS BODILY INJURY 2 OBJECT IN MIRROR ARE CLOSER THAN THEY APPEAR Tensione catena sul cavalletto centrale HELMET HOLDER UNDER THE SEAT 3 MOTORCYCLE NOISE EMISSION CONTROL INFORMATION THIS E S VOTORCYC 2 aa MEETS EPA NOISE EMISSION REQUIREMENTS OF 8 BA AT 4 0EEEEP M BY THE FEDERAL TEST PROCEDURE MODIFICATIONS WHICH CAUSE THIS MOTORCYCLE TO EXCEED FEDERAL NOISE STANDARDS ARE PROHIBITED BY FEDERAL LAW SEE OWNER S MANUAL Manufactured by DUCATIMOTOR spa GVWR BE Lbs SEE kg DATE 97 GAWA front Mamma L
48. r fuse 11 Regulator 12 Generator 13 RH rear turn indicator 14 Tail light 15 Number plate light 16 LH rear turn indicator 17 Fuel tank 18 Self diagnosis connection 19 Speed sensor 20 Self diagnosis power outlet 21 Side stand switch 22 Rear stop light switch 23 Horizontal cylinder coil 24 Vertical cylinder coil 25 Horizontal cylinder spark plug 7 IN GOOD CONDITION BLOWN 26 Vertical cylinder spark plug 2 27 Injection relay 28 Horizontal cylinder injector 29 Vertical cylinder injector fig 72 30 Throttle position sensor 72 Timing rpm sensor Oil temperature sensor control unit 5 9 M E C U Neutral switch Oil pressure switch Front stop light switch Clutch switch Oil temperature sensor instrument panel LH switch Air temperature oressure sensor Instrument panel LH front turn indicator Headlight RH front turn indicator 24 pole release conn Wiring Colour Coding B Blue W White V Violet Bk Black Y Yellow R Red Lb Light Blue Gr Grey G Green Bn Brown O Orange P Pink 73 Fuse box key 4 Pos El item Val 1 9 Main 30A 2 10 Parking light HIGH LOW beam 15A speed sensor and solenoid starter 3 11 ECU 3A 4 12 Stop horn passing and key on 15A 5 13 Instrument panel 3A 6 14 Injection injector pump coil 20A Note The system wiring diagram is at the end of this manual 74
49. rably damaged if the chain is cleaned using any solvent other than those specific for O ring chains or washed using steam or water jets After cleaning blow the chain dry or dry it using absorbent material and apply SHELL Advance Chain or Advance Teflon Chain on each link Important Using non specific lubricants may lead to severe damage to chain front and rear sprocket 52 Replacing bulbs Before replacing a burnt out bulb make sure that the new bulb complies with voltage and wattage as specified on page 71 Electric System for that lighting device Always test the new lamp before refitting the parts you have removed Headlamp To gain access to headlamp bulbs you will need to work behind the headlamp fairing Remove connector 1 fig 57 from the bulb Pull the tab A to remove the protective cap Release the clip 2 fig 58 that holds the bulb in place and take the bulb out of its socket Fit a new bulb Note Be careful to hold the new bulb at the base only Never touch the transparent body with your fingers or it will blacken resulting in reduced bulb brilliancy Reassembly Insert the locating pegs of the bulb base into their seats to obtain correct alignment Hook the clip 2 to the headlamp holders reconnect the connector 1 you have detached previously and refit the rubber cover The parking light bulb is fitted on the top section of the headlamp body To change it pull ou
50. reak in of friction material on brake pads against brake discs For all mechanical moving parts to adapt to one another and above all not to adversely affect the life of basic engine parts it is advisable to avoid harsh accelerations and not to run the engine at high rom for too long especially uphill Furthermore the drive chain should be inspected frequently Lubricate as required From 1000 to 2500 km At this point you can squeeze some more power out of your engine being careful however to never exceed 7000 rpm Important During the whole running in period the maintenance and service rules recommended in this manual should be observed carefully Have the service inspections performed as recommended in the Warranty Card Failure to comply with these rules will release Ducati Motor Holding S p A from any liability whatsoever for resulting engine damage or shorter engine life After 2500 km After running in never exceed the following values during the motorcycle standard use 10 500 rom Strict observance of running in recommendations will ensure longer engine life and reduce the likelihood of overhauls and tune ups Pre ride checks Warning Failure to carry out these checks before riding may lead to motorcycle damage and injury to rider and passenger Before riding perform a thorough check up on your bike as follows Fuel level in the tank Check fuel level in the tank Fill tank if needed page 38 E
51. rts replaced under this warranty shall become the property of Ducati In the state of California only emissions related warranted parts are specifically defined by that state s Emissions Warranty Parts List These warranted parts are carburetor and internal parts intake manifold fuel tank fuel injection system spark advance mechanism crankcase breather air cutoff valves fuel tank cap for evaporative emission controlled vehicles oil filler cap pressure control valve fuel vapor separator canister igniters breaker governors ignition coils ignition wires ignition points condensers and spark plugs if failure occors prior to the first scheduled replacement and hoses clamps fittings and tubing used directly in these parts Since emission related parts may vary from model to model certain models may not contain all of these parts and certain models may contain functionally equivalent parts In the state of California only Emission Control System emergency repairs as provided for in the California Administrative Code may be performed by other than an authorized Ducati dealer An emergency situation occurs when an authorized Ducati dealer is not reasonably available a part is not available within 30 days or a repair is not complete within 30 days Any replacement part can be used in an emergency repair Ducati will reimburse the owner for the expenses including diagnosis not to exceed Ducati s suggested retail price for all
52. serviceable in case they have been lost Note If you sell your motorcycle do not forget to give all keys and the CODE CARD to the new owner 17 Ignition switch and steering lock fig 10 It is located in front of the fuel tank and has four positions A ON lights and engine on B OFF lights and engine off C LOCK steering locked D P parking light and steering lock Note To move the key to the last two positions press it down before turning it Switching to B C and D you will be able to take the key out Warning This vehicle is equipped with an energy saving CPU If the key stays ON for a long period but the ignition button is not pressed within 15 seconds the CPU will stop operating to avoid current absorption Move the key to OFF and then to ON again Left switch fig 11 1 Dip switch light dip switch two positions position 20 low beam on position D high beam on 2 Switch 3 position turn indicator centre position OFF position left turn position 9 right turn To reset turn indicators turn switch to central position and push in 3 Button We warning horn 4 Button 20 high beam flasher 19 Clutch lever fig 12 When you pull in the lever 1 you will disengage the engine from the gearbox and therefore from the driving wheel Using the clutch properly is essential to smooth riding especially when moving off
53. t the bulb holder 3 fig 59 from headlamp body Remove the bulb and fit a new one 54 Turn indicators fig 60 Remove the screw 1 and detach the glass 2 from the indicator body holder The bulb has a bayonet type fitting press and rotate anti clockwise to remove fit the spare bulb by pressing and turning clockwise until it clicks Refit the glass sliding the small tab A into the suitable slot in the indicator body and tighten the screw 1 Number plate light fig 61 To expose the number plate light bulb withdraw the lamp holder from the number plate holder then extract the bulb and replace it Note The bulb holder has a tag A to aid removal from number plate holder without risking to tear the cables Stop light To replace the stop and parking light bulb unscrew the two screws 1 fig 62 that secure the glass and remove glass The bulb has a bayonet type fitting press and rotate anti clockwise to remove fit the spare bulb by pressing and turning clockwise until it clicks fig 63 Refit the glass and tighten the screws 1 56 Beam setting fig 64 When checking beam setting put the motorcycle upright Tyres should be inflated at the correct pressure and one person should be sitting astride the motorcycle keeping it at right angles to its longitudinal axis Place the motorcycle opposite a wall or a screen 10 meters apart
54. the ignition key in the switch when you are leaving your bike unattended Warning The exhaust system might be hot even after engine is switched off pay particular attention not to touch exhaust system with any body part and do not park the vehicle next to inflammable material wood leaves etc Warning Using padlocks or locks that prevent motion such as brake disc or crown sprocket locks and so on is very dangerous and may affect motorcycle operation as well as the safety of rider and passenger 38 Refuelling Never overfill the tank when refuelling Fuel should never be touching the rim of filler recess fig 33 Warning Use low lead fuel having at least 95 fuel octane rating Be sure there is no fuel trapped in the filler recess Max level Cre _ fig 33 Tool kit and accessories fig 34 Accommodated in the compartment under the seat is a bag 1 holding an Owner s manual a helmet fastening cable a tool kit for usual maintenance and checks stored in the top pocket To access this compartment lift the seat by opening the catch page 28 The tool bag fig 35 holds box wrench for spark plugs 2 tommy bar 3 double bit screwdriver 4 helmet cable 5 fig 35 39 MAIN MAINTENANCE OPERATIONS Removing the fairing Some servicing operations need the motorcycle fairing to be removed Warning Firmly secure all remov
55. ument panel will flash briefly This means that the immobilizer system has recognised the key code and enabled engine ignition When you press the START button the engine will start up 2 If the CODE light stays on it means that the code has not been recognised When this is the case turn the ignition key back to OFF and then to ON again If the engine still does not start try with another black key If the other key does not work out either contact the DUCATI Service network 3 Should the CODE pilot light still be flashing it means that an immobilizer system fault was reset e g with the overriding procedure through throttle grip Turn the key to OFF and back to ON the immobilizer pilot light should go back to its normal operation see point 1 Warning A The keys accommodate electronic components inside If dropped or hit they might damage Use only one key during the procedure Failure to do so might prevent the system from recognizing the code of the key in use Duplicate keys If you need any duplicate keys contact the DUCATI Service network with all the keys you have left and your CODE CARD DUCATI Service will program new keys and re program your original keys up to 8 keys in total You may be asked to identify yourself as the legitimate owner of the motorcycle Be sure you have any documents you might need to this end ready The codes of any keys not submitted will be wiped off from the memory to make those keys un
56. w mirrors to the headlamp fairing and remove the rear view mirrors Unscrew the three screws 2 fig 41 that hold each body panel to the headlamp fairing Move the body panels slightly apart and unscrew the four screws 3 fig 42 that fix the headlamp fairing to headlamp subframe on both sides Lift the headlamp off its front fastening pin 4 fig 41 and over the headlamp Lifting the fuel tank fig 43 and 44 Remove the seat see page 28 Pull the clip 1 fig 43 upwards to disengage it from the tank catch Lift the tank and unhook the service rod 2 fig 44 from its retainer 3 Place the tank onto the rod 2 fitting rod end into the hole in frame cross member When finished reverse the above procedure to refit all the parts you have removed Warning Make sure the fuel in the tank is less than 4 litres the reserve light on the instrument panel should be on or fuel may leak out through the filler plug breather Lift the tank just enough to pull out service rod Do not lift the tank exceedingly or you may damage the fuel sensor wire and the fuel lines When lowering the tank be sure the fuel lines are not squeezed and the fuel sensor wire is not pushed too close to vertical cylinder head Changing the air filter fig 45 and 46 Replace air filter at the required intervals shown in the routine maintenance chart see Warranty Card The air box is acc
57. warranted 82 parts replaced and labor charges based on Ducati s recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate The owner may be required to keep receipts and failed parts in order to receive compensation Il Limitations This Emission Control System Warranty shall not cover any of the following A Repair or replacement required as a result of 1 accident 2 misuse 3 repairs improperly performed or replacements improperly installed 4 use of replacement parts or accessories not conforming to Ducati specifications which adversely affect performance and or 5 use in competitive racing or related events B Inspections replacement of parts and other services and adjustments required for routine maintenance C Any motorcycle on which odometer mileage has been changed so that actual mileage cannot be readily determined Ill Limited liability A The liability of Ducati under this Emission Control Systems Warranty is limited solely to the remedying of defects in material or workmanship by an authorized Ducati motorcycle dealer at its place of business during customary business hours This warranty does not cover inconvenience or loss of use of the motorcycle or transportation of the motorcycle to or from the Ducati dealer Ducati shall not be liable for any other expenses loss or damage whether direct incidental consequential or exemplary arising in conne
58. ystem 66 Performance data 67 Brakes 67 Transmission 68 Frame 69 Wheels 69 Tyres 69 Spark plugs 69 Suspensions 70 Available colors 70 Electric system 71 For United States of America version only 75 Routine maintenance record 84 GENERAL Warranty In your own interest and in order to guarantee product reliability you are strongly advised to refer to a Ducati Dealer or Authorised Workshop for any servicing requiring particular technical expertise Our highly skilled staff have access to the implements required to perform any servicing job at best and use Ducati original spare parts only as the best guarantee for full interchangeability smooth running and long life All Ducati motorcycles come with a Warranty Card The warranty does not apply to the motorcycles used in competitions No motorcycle part may be tampered with altered or replaced with parts other than original Ducati spare parts during the warranty period or the warranty will be automatically invalidated Symbols Ducati Motor Holding S p A advises you to read this booklet carefully so as to become familiar with your motorcycle In case of any doubts please call a Ducati Dealer or Authorised Workshop The information contained herein will prove useful on your trips and Ducati Motor Holding S p A wishes you smooth enjoyable riding and will help you keep the performance of your motorcycle unchanged for a long time Warning Failure to comply w
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