Ducati Monster S2R1000 Manuals

Manuals and User Guides for Ducati Monster S2R1000. We have 1 Ducati Monster S2R1000 manual available for free PDF download: Workshop Manual

Ducati Monster S2R1000 Workshop Manual (541 pages)

Brand: Ducati | Category: Motorcycle | Size: 33.36 MB

General Summary
2
Description
13
Symbols
15
Text References
15
Product Specifications
18
Hazardous Products
20
General Safety Rules
20
Carbon Monoxide
20
Fuel
20
Used Engine Oil
21
Brake Pad Dust
21
Brake Fluid
21
Coolant
21
General Maintenance
22
Battery
22
Useful Tips
22
General Advice on Repair Work
23
Model-Specific Information
25
Identification Data
27
Data Stamped on the Frame
27
Data Stamped on Engine
28
Technical Specification
29
Technical Data
37
Dimensions
43
Fuel, Lubricants and Other Fluids
44
Engine Oil
44
Oil Viscosity
44
Torque Settings
52
Engine Torque Settings
56
Service Tools
59
Special Tools for the Engine
59
Use and Maintenance Operations
65
Preliminary Checks
67
Running-In Precautions
67
Max. Engine Speed
67
Pre-Ride Checks
68
Fuel Level in the Tank
68
Engine Oil Level
68
Brake and Clutch Fluid
68
Key Locks
69
Stand
69
Starting - Engine Warmup
70
Starting the Engine
70
Routine Maintenance Table
74
Key to Routine Maintenance Table
74
Maintenance Operations
76
Checking the Engine Oil Level
76
Changing the Engine Oil and Filter Cartridge
77
Checking Valve Clearances
78
Adjusting the Valve Clearances
79
Closing Rocker Arm
79
Changing and Cleaning the Air Filters
80
Changing the Brake Fluid
81
Filing the Front Brake Circuit
81
Filling the Rear Brake Circuit
82
Draining the Brake Circuit
83
Filling the Brake Circuits
84
Changing the Clutch Fluid
86
Draining the Clutch Hydraulic Circuit
87
Filling the Clutch Circuit
88
Adjusting the Steering Head Bearings
90
Adjusting the Clutch Lever and Front Brake Lever
91
Adjusting the Chain Tension
92
Checking Brake Pad Wear and Changing Brake Pads
93
Checking Front Brake Pad Wear
93
Checking Rear Brake Pad Wear
94
Adjusting the Throttle Cables
95
Adjusting the Position of the Gearchange and Rear Brake Pedals
97
Adjusting the Front Fork
98
Adjusting the Rear Shock Absorber
99
Standard Settings
99
Changing the Frame Geometry
100
Modifying the Rear Height
100
Diagnostic Instruments
101
Description of the Ducati Diagnostic System Instrument
102
Components Supplied with the DDS Tester
103
Tester Power Supply
103
Connection to the Motorcycle
104
DDS Tester
105
Checking and Adjusting Timing Belt Tension
106
Use and Maintenance
108
Resetting the Throttle Position Sensor (TPS)
109
Cylinder Synchronisation
112
Checking the Engine Oil Pressure
113
Cylinder Compression Test
116
An Excess Pressure Value
117
An Excessively Low Pressure Value
117
Fuel Pressure Test
118
Immobilizer Override Procedure
120
Guided Diagnosis
123
Testing the Battery Charging System
125
Icons Table
127
Fairing
129
Headlight Shell - Rear-View Mirrors
131
Removing the Rear-View Mirrors
132
Refitting the Rear-View Mirrors
132
Removing the Headlight Shell
133
Disassembly of the Headlight Shell
133
Reassembly of the Headlight Shell
133
Refitting the Headlight Shell
133
Seat
134
Removing the Seat
135
Disassembly of the Seat
135
Reassembly of the Seat
136
Refitting the Seat
136
Removal of the Splashguard
137
Refitting the Splashguard
137
Removal of the Side Panels
138
Refitting the Side Panels
138
Front and Rear Mudguards
139
Removing the Front Mudguard
140
Refitting the Front Mudguard
140
Controls - Devices
141
Throttle Twistgrip
143
Adjusting the Throttle Cable
144
Removal of the Throttle Cable
144
Refitting the Throttle Twistgrip
144
Throttle Cable Routing
145
Clutch Hydraulic Control
146
Removing the Clutch Master Cylinder Assembly
147
Refitting the Clutch Master Cylinder Assembly
147
Removing the Clutch Slave Cylinder
148
Refitting the Clutch Slave Cylinder
149
Routing the Clutch Hose
150
Front Brake Control
151
Removing the Front Brake Master Cylinder
152
Refitting the Front Brake Master Cylinder
152
Routing of Front Brake Hose
153
Rear Brake Control
155
Removing the Complete Rear Brake Control
156
Disassembly of the Rear Brake Master Cylinder
157
Refitting the Rear Brake Pedal
157
Routing of Rear Brake Hose
159
Gearchange Control
160
Removal of the Gearchange Control
161
Disassembly of the Gearchange Control
161
Refitting the Gearchange Control
161
Seat Release Mechanism
162
Removing the Seat Release Mechanism
163
Refitting the Seat Release Mechanism
163
Wheels - Suspensions - Brakes
165
Front Wheel
167
Removal of the Front Wheel
168
Overhauling the Front Wheel
169
Overhauling the Front Wheel Bearings
169
Overhauling the Front Wheel Axle
170
Overhauling the Front Wheel Rim
170
Refitting the Front Wheel
171
Adjustable Front Fork
172
Removing the Front Forks
173
Overhauling the Front Forks
174
Disassembly of the Front Fork
174
Inspection of the Adjustable Front Fork
177
Reassembling the Front Fork
178
Refitting the Front Forks
181
Hydraulic Front Brake
182
Removing the Front Brake System
183
Refitting the Brake Discs
184
Overhauling the Front Brake Components
184
Refitting the Front Brake System
185
Rear Wheel
187
Removing the Rear Wheel
188
Overhauling the Rear Wheel
189
Overhauling the Wheel
189
Refitting the Rear Wheel
190
Swingarm
191
Removal of the Rear Eccentric Hub
192
Removing the Swingarm
195
Inspecting the Swingarm Pivot Shaft
198
Checking Swingarm Endfloat
198
Refitting the Swingarm
199
Rear Hydraulic Brake
201
Removing the Rear Brake Caliper
202
Removing the Rear Brake Disc
203
Refitting the Rear Brake Caliper
204
Rear Suspension
205
Rear Suspension System
206
Removing the Rear Shock Absorber
206
Overhauling the Rear Shock Absorber
207
Disassembly of the Rear Shock Absorber
207
Reassembly of the Rear Shock Absorber
207
Removing the Rear Suspension Rocker Arm
208
Overhauling the Rear Suspension Rocker Arm
209
Disassembly of the Rear Suspension Rocker Arm
209
Reassembly of the Rear Suspension Rocker Arm
209
Disassembly and Overhaul of the Monoshock Tie-Rod
210
Refitting the Rear Suspension
211
Final Drive
213
Inspecting the Final Drive
214
Renewal of the Front Sprocket
215
Refitting the Front Sprocket
216
Renewal of the Rear Sprocket
217
Refitting the Rear Sprocket
217
Washing the Chain
218
Lubricating the Chain
218
Frame
219
Handlebar
221
Removal of the Handlebar
222
Refitting the Handlebar
223
Steering
224
Steering Angle Adjustment
225
Removing the Steering Head Components
226
Refitting the Steering Head Components
227
Footrest Brackets
229
Removing the Footrests
230
Removal of the Rear Footrests
232
Refitting the Front Footrests
233
Refitting the Rear Footrests
235
Stands
236
Removing the Sidestand
237
Disassembly of the Sidestand
237
Inspecting the Sidestand
237
Refitting the Sidestand
237
Checking the Frame
238
Disassembly of Structural Components and the Frame
239
Reassembly of Structural Components and the Frame
239
General Dimensions (MM)
242
Tail Light and Number Plate Holder
243
Removing the Tail Light and Number Plate Holder
244
Refitting the Rear Number Plate Holder
244
Fuel System / Exhaust System
245
Description of Fuel System
247
Fuel System Diagram
248
Fuel Tank
250
Removing the Fuel Tank
251
Replacing the Tank Flange
252
Refitting the Tank Flange
252
Removing the Tank Cap Unit
253
Refitting the Tank Cap Unit
253
Refitting the Fuel Tank
254
Positioning of Fuel Tank Breather and Drain Hoses
255
Positioning of Throttle Body – Tank Fuel Hoses
256
Throttle Body
257
Removing the Throttle Body
258
Removing the Throttle Position Sensor
258
Removing the Injectors
258
Refitting the Injectors
258
Refitting the Throttle Body
259
Positioning of the Stepper Motor – Air Filter Box Hose
260
Air Intake
261
Removing the Air Filter Box
262
Disassembling the Air Filter Box
264
Reassembling the Air Filter Box
264
Refitting the Air Filter Box
265
Positioning the Airbox Drain Hose
267
Exhaust System
268
Catalytic Converter Operating Principle
270
Precautions
271
Removing the Exhaust System
272
Reinstalling the Exhaust System
275
Canister Filter
277
Canister Filter System
278
Removing the Canister Filter
279
Positioning the Hoses, Clamps and Canister Filter
280
Ignition - Injection System
281
Description of the Fuel Injection–Ignition System
283
General Information on the Fuel Injection-Ignition System
283
Influence of the Air-Fuel Ratio and Ignition Advance
283
Marelli Injection-Ignition System (I.A.W.)
284
Legend to Sensor Position Diagram
285
Fuel Circuit
286
Intake Air Circuit
287
Operating Stages
288
Normal Operation
288
Starting
288
Acceleration/Deceleration
288
Injection-Ignition System
289
Electronic Control Unit
290
Removing the Electronic Control Unit
291
Refitting the Control Unit
291
Electric Injector
293
Stepper Motor
294
Lambda Sensor
295
Air Temperature/Pressure Sensor
297
Removing the Air Temperature/Pressure Sensor
297
Refitting the Air Temperature/Pressure Sensor
297
Spark Plug
298
Coils
299
Positioning of Spark Plug Cables on Horizontal Coil
301
Positioning of Spark Plug Cables on Vertical Coil
302
Throttle Position Sensor
304
Rpm/Timing Sensor
304
Main and Injection Relays
305
Removing – Refitting the Complete Engine
310
Removing the Engine
312
Lubrication System: Oil Pump
314
Lubrication System
315
Description of the Lubrication System
316
Operation of the Lubrication System
316
Removing the Oil Pump
318
Disassembly of the Oil Pump
318
Oil Pump Overhaul
319
Reassembly of the Oil Pump
319
Refitting the Oil Pump
320
Lubrication System: Oil Cooler
321
Removing the Oil Cooler
322
Oil Cooler Inspection
322
Refitting the Oil Cooler
323
Lubrication System: Oil Breather Tank
324
Removing the Oil Breather Tank
325
Refitting the Oil Breather Tank
325
Head Assembly: Checks and Adjustment
326
Checking and Adjusting Valve Clearance
327
Checking and Adjusting Opening Clearance (Sa)
328
Checking and Adjusting Closing Clearance (Sc)
329
Checking Valve Lift
330
Checking the Engine Timing
331
Head Assembly: Side Covers / Timing System
333
Removing the Lateral Timing Covers
334
Disassembly of Timing Assy
335
Disassembly of the Mobile Tensioner
337
Disassembly of the Rollers
337
Reassembling the Timing Unit
338
Refitting the Camshaft Rollers
338
Refitting the Timing Belt Driveshaft Rollers
339
Refitting the Timing Belt Tensioners
340
Refitting the Lateral Timing Covers
343
Head Assembly: Camshafts
344
Disassembling the Engine Oil Temperature Sensor
345
Refitting the Engine Oil Temperature Sensor
345
Removing the Intake Manifolds
346
Refitting the Intake Manifolds
346
Removing Side Covers
347
Removing the Valve Covers
348
Refitting the Valve Covers
348
Removing the Camshafts
349
Checking Camshafts
350
Refitting the Camshaft
351
Refitting the Timing Covers
352
Head Assembly: Valves - Rocker Arms
353
Removing the Cylinder Heads Assy
354
Removing the Heads
354
Removing the Valves
354
Removing the Valve Rocker Arms
357
Overhauling the Head Parts
358
Overhauling the Valve
359
Overhauling the Valve Seat
359
Changing the Valve Seat
360
Mating of Valve - Valve Seat
360
Overhauling Valve Guides
361
Valve - Valve Guide Mating
361
Changing the Valve Guide
361
Overhauling the Rocker Arms
362
Coupling of Rocker Arm Pin - Rocker Arm
362
Checking the Rocker Arm Springs
362
Refitting the Head Assy
363
Reassembling the Rocker Arms
364
Reinstalling the Valves
367
Refitting the Cylinder Heads
369
Cylinders / Pistons Assy
370
Disassembly of the Cylinder / Piston
371
Overhauling the Cylinder / Piston Assembly Components
373
Overhauling the Piston
374
Piston-Cylinder Coupling
374
Overhauling the Gudgeon Pins
375
Overhauling the Piston Rings
375
Piston Rings-Piston Grooves Coupling
375
Gudgeon Pin - Piston Coupling
376
Piston Rings-Cylinder Coupling
376
Refitting the Cylinder /Piston Assembly
377
Clutch Assembly: Clutch
379
Clutch Unit Description
380
A Clutch Which Does Not Disengage
381
A Clutch Which Slips
381
A Noisy Clutch
381
Disassembling the Clutch
382
Checking and Overhauling the Clutch Components
386
Clearance between Clutch Housing and Drive Plate
386
Overhauling the Clutch Plates
386
Overhauling the Pressure Plate
386
Reassembling the Clutch
387
Clutch Assembly: Clutch Cover
390
Removing the Clutch Cover
391
Disassembly of the Clutch Cover
392
Reassembly of the Clutch Cover
393
Refitting the Clutch Cover
394
Clutch Assembly: Primary Drive Gears
395
Removing the Primary Drive Gears
396
Fitting the Primary Drive Gear Pair and Checking Backlash
398
Gearbox: Levers
400
Disassembling the Gear Selector Lever
401
Disassembly of Gear Stopper and Ratchet Unit
402
Reinstalling the Gear Stopper and Ratchet Unit
402
Reinstalling the Gear Selector Lever
403
Gearbox: Gearbox Shafts
404
Removing the Gearbox
406
Gearbox Shafts Disassembly
407
Secondary Shaft Disassembly
407
Primary Shaft Disassembly
409
Overhauling the Gearbox
411
Inspecting the Gear Selector Forks
413
Gearbox Shafts Reassembly
414
Gearbox Reassembly
415
Flywheel - Generator
417
Removing the Generator Cover
419
Generator Cover Disassembly
420
Removing the Flywheel - Generator Assembly
421
Checking the Flywheel - Generator Assembly
422
Disassembling the Flywheel - Generator Assy
422
Flywheel - Generator Assembly Reassembly
423
Reinstalling the Flywheel / Generator Assembly
424
Reinstalling the Generator Cover
425
Checking the Engine Sensor Air Gap
426
Casing Unit: External Components
427
Removing the External Components
428
Reinstalling the External Components
430
Removing the Timing Lay Gear
432
Refitting the Timing Lay Gear
432
Removing the Starter Motor Lay Gear
433
Refitting the Starter Motor Lay Gear
433
Casing Unit: Casings
434
Opening the Casing
435
Casing Overhaul
436
Main Bearings
438
Casings Reassembly
439
Reinstalling the Clutch Side Casing
439
Reinstalling the Generator Side Casing
440
Shimming the Shafts
441
Shimming the Crankshaft
441
Practical Method for Determining Crankshaft Shimming
441
Shimming the Gearbox Shafts
442
Shimming the Gearbox Drum
443
Gearbox Positioning Check
447
Closing the Casings
449
Casing Unit: Connecting Rods
452
Disassembling the Connecting Rods Assembly
453
Disassembling the Connecting Rods
453
Overhauling the Connecting Rods
454
Replacing the Small End Bushing
454
Changing the Connecting Rod Half Bearings
455
Crankshaft Overhaul
456
Bearing-Crank Pin Coupling
457
Reassembling the Connecting Rods
458
Refitting the Connecting Rods
459
Electric System
461
Wiring Diagram
463
Wiring Diagram Key
465
Wiring Colour Codes
466
Key to Fuseboxes
466
Routing of Wiring on Frame
466
Charging System
485
Checking the Battery Charging System
485
Recharging the Battery
486
Storing the Battery
486
Topping up the Electrolyte
487
Safety Rules
490
Instructions for Use
490
Removing the Battery
490
Battery Support
491
Generator
492
Removing the Generator
492
Refitting the Generator
492
Rectifier - Regulator
493
Removing the Regulator
493
Refitting the Regulator
493
Regulator Fuse
494
Electric Starting System
495
Safety Device Functions Table
496
Starter Motor
497
Starter Motor Removal
497
Refitting the Starter Motor
498
Starter Contactor
499
Checking Operation of the Starter Motor Contactor
499
Changing Light Bulbs
500
Changing Headlight Bulbs
500
Changing the Number Plate Light Bulb
501
Changing the Headlight
502
Headlight Aim
503
Signalling Devices
504
Indicator Device Components Check
504
Left-Hand Selector Switch Check
504
HORN Button
504
Turn Indicator Switch (TURN)
505
Low and High Beam (DIMMER)
505
Right-Hand Selector Switch Check
506
ENGINE STOP Button
506
STARTER Button
506
Parking Light / Low Beam Headlamp Switch
506
Brake Light Switches
507
Neutral Indicator Light
507
Oil Pressure Sensor
508
Changing the Turn Indicator Light Bulbs
509
Changing the Brake Light Bulbs
509
Checking Protection and Safety Device Components
510
Checking the Ignition Switch
510
Checking the Side Stand Switch
511
Checking the Fuses
512
Instrumentation
513
Instrument Panel
513
LCD Unit Functions
514
Resetting LCD Trip Meter
514
Setting the LCD Clock
514
Oil Temperature Function
515
Fuel Level Warning Light
515
Maintenance Indicator Function
515
Display Backlight
515
Immobilizer and Transponder
516
Keys with Transponder
516
Immobilizer Antenna
517
Immobilizer Operating Principle
517
Signals of Warning Lights and Immobilizer Indications
518
Programming the Immobilizer
519
Immobilizer Programming Check
521
First Signal
521
Second Signal
521
Third Signal
521
Emergency Procedure to Unlock the Immobilizer
522
Removing the Immobilizer
524
Refitting the Immobilizer
524
Disassembling the Red Key with Transponder
525
Using a Multimeter to Check the Electrical Systems
526
Multimeter Operation
526
Voltage Measurement
527
Current Measurement
527
Measurement of Resistance Values and Electrical Continuity
528
Safety Devices and Precautions for Correct Use of the Multimeter
529
Subject Index
531
Indice Generale
532

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Ducati Monster S2R1000 Workshop Manual (541 pages)

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