Ducati Supersport 800 - Service, Repair Manual - Manuale di Officina, Riparazione

DUCATI SUPERSPORT 800 - WORKSHOP, SERVICE, REPAIR MANUAL - MANUALE DI OFFICINA, RIPARAZIONE


- English Service Manual / Repair Manual, for motorcycles Ducati SuperSport 800.
- Manuale di Officina in italiano, ai moto Ducati SuperSport 800.
 

CONTENTS:

GENERAL SUMMARY
A - Description
1 - HOW TO USE THE MANUAL
- Manual layout
2 - SYMBOLS - ABBREVIATIONS - REFERENCES
- Product specifications
3 - DANGEROUS PRODUCTS - WARNINGS
- General safety rules
- General maintenance indications
B - Model-specific information
1 - IDENTIFICATION DATA
C - Specifications
1.1 - TECHNICAL DATA
- Description
- Colors
- Transmission
- Timing/valves
- Lubrication system
- Cylinder / piston
- Gearbox
- Cooling system
- Front wheel
- Front suspension
- Rear wheel
- Rear suspension
- Hydraulic brakes
- Charging system / generator
- Ignition system
- Control unit
- Lights / instrument panel
1.2 - DIMENSIONS
2 - FUELS AND LUBRICANTS
3 - TORQUE SETTINGS
- Frame torque settings
- Engine torque settings
4 - SERVICE TOOLS
- Engine special tools
- Frame specific tools
D - Use and maintenance operations
1 - PRELIMINARY CHECKS
- Running-in precautions
- Pre-ride checks
2 - STARTING - ENGINE WARM-UP
- Starting the engine
3 - ROUTINE MAINTENANCE TABLE
4 - MAINTENANCE OPERATIONS
- Checking the engine oil level
- Changing the engine oil and filter cartridge
- Checking valve clearances
- Adjusting valve clearances
- Changing the fuel filter
- Changing and cleaning the air filters
- Changing the brake fluid
- Draining the braking circuit
- Filling the brake circuits
- Changing the clutch fluid
- Draining the clutch circuit
- Filling the clutch circuit
- Adjusting steering bearings play
- Adjusting chain tension
- Checking brake pad wear. Changing brake pads
- Adjusting the throttle and choke cables
- Adjusting the position of the gear change and rear brake pedals
- Adjusting the rear shock absorber
5 - DIAGNOSIS INSTRUMENTS
- Tester description
- Instrument power supply
- DDS diagnosis instrument
- Checking and adjusting timing belt tension
- Resetting the throttle position sensor (TPS)
- Adjusting the throttle body
- Checking engine oil pressure
- Checking cylinder compression
- Checking fuel pressure
- Procedure to override the immobilizer system
- Guided diagnosis
- Checking the charging system
- Icons table
E - Fairing
1 - HEADLIGHT FAIRING - REAR-VIEW MIRRORS
- Removing the rear-view mirrors
- Refitting the rear-view mirrors
- Removing the headlight fairing
- Refitting the headlight fairing
2 - FAIRING
- Removing the fairings
- Refitting the fairings
3 - TAIL GUARD
- Removing the tail guard
- Refitting the tail guard
4 - FRONT AND REAR MUDGUARD
- Removing the front mudguard
- Refitting the front mudguard
- Removing the rear mudguard
- Refitting the rear mudguard
F - Controls - Devices
1 - THROTTLE CONTROL - CHOKE
- Adjusting the throttle and choke cables
- Disassembling the throttle control
- Reassembling the throttle control
- Removing the choke control
- Refitting the choke control
2 - CLUTCH HYDRAULIC CONTROL
- Removing the clutch master cylinder assembly
- Refitting the clutch master cylinder assembly
- Removing the clutch transmission unit
- Refitting the clutch transmission assembly
3 - FRONT BRAKE CONTROL
- Removing the front brake control
- Refitting the front brake control
4 - REAR BRAKE CONTROL
- Removing the rear brake control
- Disassembling the rear brake control
- Reassembling the rear brake control
5 - GEAR CHANGE CONTROL
- Removing the gear change control
- Disassembling the gear change control
- Refitting the gear change control
6 - SEAT LOCK AND RELEASING MECHANISMS
- Removing the seat releasing mechanism
- Refitting the seat releasing mechanism
G - Wheels - Suspension - Brakes
1 - FRONT WHEEL
- Removing the front wheel
- Overhauling the front wheel
- Refitting the front wheel
2 - FRONT FORK
- Removing the front fork
- Overhauling the front fork
- Refitting the front fork
3 - FRONT BRAKE
- Braking system maintenance
- Removing the front brake system
- Overhauling the front brake components
- Refitting the front brake system
4 - REAR WHEEL
- Removing the rear wheel
- Overhauling the rear wheel
- Refitting the rear wheel
5 - REAR SWINGARM
- Removing the swingarm
- Inspecting the swingarm shaft
- Checking swingarm axial play
- Refitting the rear swingarm
6 - REAR BRAKE
- Removing the rear brake system
- Refitting the rear brake system
7 - REAR SUSPENSION
- Rear suspension
- Removing the rear shock absorber
- Overhauling the rear shock absorber
- Refitting the rear shock absorber
8 - FINAL DRIVE
- Final drive inspection
- Removing the chain sprocket
- Refitting the chain sprocket
- Removing the rear sprocket
- Refitting the rear sprocket
- Wash the chain
- Chain lubrication
H - Frame
1 - HANDLEBARS
- Removing the handlebars
- Refitting the handlebars
2 - STEERING
- Adjusting steering bearing play
- Adjusting the steering angle
- Disassembling the steering tube components
- Refitting the steering tube components
4 - FOOTPEG SUPPORTS
- Removing the footpegs
- Refitting the footpegs
5 - STANDS
- Removing the side stand
- Disassembling the side stand
- Reassembling the side stand
- Refitting the side stand
6 - FRAME INSPECTION
- Removing the frame and related components
- Checking the frame
- Refitting frame and related components
- Refitting the headlight support
7 - TAIL LIGHT AND NUMBER PLATE HOLDER
- Removing the tail light and number plate holder
- Refitting the tail light and number plate holder
L - Fuel system - Exhaust system
1 - FUEL SYSTEM DESCRIPTION
2 - FUEL TANK
- Removing the fuel tank
- Removing the filler plug unit
- Refitting the filler plug unit
- Refitting the fuel tank
3 - FUEL PUMP
- Removing the fuel pump
- Refitting the fuel pump
4 - FUEL FILTER
- Changing the fuel filter
5 - PRESSURE REGULATOR
- Changing the pressure regulator
6 - THROTTLE BODY
- Removing the throttle body
- Refitting the throttle body
7 - AIRBOX
- Removing the airbox
- Refitting the airbox
8 - EXHAUST SYSTEM
- Operating principle of catalytic converter (EU only)
- Disassembling the exhaust system
- Reassembling the exhaust system
10 - CANISTER FILTER
- Removing the Canister filter
- Refitting the Canister filter
M - Ignition - injection system
1 - DESCRIPTION OF THE FUEL INJECTION- IGNITION SYSTEM
- General information on the fuel injection-ignition system
- Fuel circuit
- Intake air circuit
- Operating stages
2 - SYSTEM DIAGRAM
- Fuel injection-ignition system diagram
3 - FUEL INJECTION- IGNITION SYSTEM COMPONENTS
- Electronic control unit
- Electric injector
- Air temperature / pressure sensor
- Spark plug
- Coil
- Throttle position sensor
- Rpm/timing sensor
- Main and injection relays
N - Engine
1 - REMOVING - REASSEMBLING THE COMPLETE ENGINE
- Removing the engine
- Reassembling the engine
2.1 - LUBRICATION SYSTEM: OIL PUMP
- Lubrication system diagram
- Removing the oil pump
- Disassembling the oil pump
- Overhauling the oil pump
- Reassembling the oil pump
- Refitting the oil pump
2.2 - LUBRICATION SYSTEM: OIL COOLER
- Removing the oil cooler
- Checking the oil cooler
- Refitting the oil cooler
2.3 - LUBRICATION SYSTEM: OIL BREATHER RESERVOIR
- Removing the oil breather reservoir
- Refitting the oil breather reservoir
4.1 - HEAD UNIT: CHECKS AND ADJUSTMENTS
- Checking and adjusting valve clearance
- Checking engine timing
4.2 - HEAD UNITS: SIDE COVERS / TIMING SYSTEM
- Removing the timing side covers
- Disassembling the timing system
- Disassembling the mobile tensioner
- Disassembling the belt rollers
- Reassembling the timing system
- Refitting the timing side covers
4.3 - HEAD UNIT: CAMSHAFTS
- Removing the engine oil temperature sensor
- Refitting the engine oil temperature sensor
- Disassembling the intake manifolds
- Refitting the intake manifolds
- Removing the side caps
- Removing the valve covers
- Refitting the valve covers
- Removing the camshafts
- Checking camshafts
- Checking the oil seals
- Checking the circlips
- Checking the bearings
- Refitting the camshafts
- Refitting the cam covers
4.4 - HEAD UNIT: VALVES - ROCKER ARMS
- Disassembling the engine heads
- Overhauling the head parts
- Reassembling the head
5 - CYLINDER / PISTON ASSEMBLY
- Removing cylinder / piston assy
- Overhauling the cylinder / piston assy
- Refitting cylinder / piston assy
6.1 - CLUTCH UNIT: CLUTCH
- Clutch unit
- Disassembling the clutch
- Checking and overhauling the clutch unit
- Reassembling the clutch
6.2 - CLUTCH UNIT: CLUTCH COVER
- Removing the clutch cover
- Disassembling the clutch cover
- Reassembling the clutch cover
- Refitting the clutch cover
6.3 - CLUTCH UNIT: PRIMARY GEARS
- Disassembling the primary drive gears
- Fitting the primary drive gear and checking meshing play
7.1 - GEARBOX ASSEMBLY: GEAR SELECTOR LEVERS
- Removing the gear selector levers
- Disassembling the gear selector levers
- Removing the gear stopper and ratchet
- Reassembling gear stopper and ratchet
- Reassembling the gear selector lever
- Reassembling the gear selector lever
7.2 - GEARBOX ASSEMBLY: GEARBOX SHAFTS
- Removing the gearbox
- Disassembling the gearbox shafts
- Overhauling the gearbox
- Reassembling the gearbox shafts
- Inspecting the gear selector forks
- Inspecting the fork selector drum
- Reassembling the gearbox
8 - FLYWHEEL - GENERATOR
- Removing the generator cover
- Disassembling the generator cover
- Removing the flywheel - generator assembly
- Checking the flywheel - generator assembly
- Refitting flywheel/ generator assembly
- Reassembling generator cover
- Checking the engine sensor air gap
9.1 - CASING UNIT: OUTER COMPONENTS
- Removing outer components
- Reassembling the outer parts
- Removing the timing lay gear
- Reassembling the timing lay gear
- Removing the starter motor driven gear
- Refitting the starter motor driven gear
9.2 - CASING UNIT: CRANKCASES
- Opening the casings
- Overhauling the casings
- Main bearings
- Reassembling the casings
- Shimming the shafts
- Closing the casings
9.3 - CASING UNIT: CONNECTING RODS
- Removing the connecting rods
- Disassembling the connecting rods
- Overhauling the connecting rods
- Reassembling the connecting rods
- Refitting the connecting rod unit
P - Electric system
1 - WIRING DIAGRAM
- Wiring diagram key
- Wire color coding - wiring diagram
- Legend of fuse box
- Arrangement of wiring on the frame
- Diagram A
- Diagram B
- Diagram C
- Diagram D
- Diagram E
- Diagram F
- Diagram G
- Diagram H
- Diagram J
- Diagram K
- Diagram L
- Diagram M
- Diagram N
- Diagram P
- Diagram Q
- Diagram R
- Diagram S
- Diagram T
- Diagram U
- Diagram V
2 - CHARGING SYSTEM - BATTERY
- Checking the charging system
- Recharging the battery
- Adding electrolyte
- Battery
- Battery mount
- Generator
- Rectifier - regulator
3 - ELECTRIC STARTING
- Electric starting system
- Starter motor
- Starter contactor
4 - LIGHTING DEVICES
- Changing light bulbs
- Beam setting
5 - INDICATORS AND LIGHTING SYSTEM
- Checking the indicators and lighting system components
- Changing light bulbs
6 - PROTECTION AND SAFETY DEVICES
- Checking protection and safety devices components
- Checking the fuses
7 - WARNING LIGHTS AND INDICATORS
- Instrument panel
8 - IMMOBILIZER AND TRANSPONDER
9 - DIAGNOSIS INSTRUMENTS
- How to use the multimeter to check electric systems
Subject index