Ducati 916 Sport Production Manuals

Manuals and User Guides for Ducati 916 Sport Production. We have 2 Ducati 916 Sport Production manuals available for free PDF download: Workshop Manual

Ducati 916 Sport Production Workshop Manual (485 pages)

Brand: Ducati | Category: Motorcycle | Size: 67.16 MB

Useful Hints
3
General Rules for Repair Works
3
Identification Data
7
Motorcycle Number
7
Engine Number
7
Contents
8
Timing System
19
Fuel System - Ignition System
19
Spark Plugs
21
Lubrication
21
Cooling
21
Fuel System Inside the Tank
21
Transmission
22
Brakes
22
Frame
22
Suspensions
22
Tyres
23
Electric System
23
Overall Dimensions
23
Fuse Box
23
Topping-Ups and Lubricants
24
Electronic Injection - Ignition System
49
Influence of Air Fuel Ratio and of Spark Advance
53
Fuel Circuit
68
Electric Fuel Pump
68
Pressure Regulator
72
Air Circuit
73
Absolute Pressure Sensor
73
Air Temperature and Coolant Temperature Sensors
75
Coil and Power Module
76
Check of Primary Resistance Circuit
76
Check of Secondary Resistance Circuit
76
Throttle Position Sensor
77
Pick up
78
Timing Sensors
78
How to Use the Check Lamp
82
Meaning of Check Lamp Error Codes
86
How to Delete Error Codes Using the Check Lamp
90
Wiring Diagram of the Ignition Injection System
94
Legend of Wiring Diagram
97
Wire Color Code
98
Settings and Adjustments
99
Checking and Adjusting Valve Clearance
102
Checking Timing Belt Tension
107
Adjusting the Throttle Control Cable
108
Throttle Body Setting
110
Changing Engine Oil and Filter Cartridge
116
Draining and Filling Coolant
117
Replacing and Cleaning Air Filter
119
Adjusting Chain Tension
121
Adjusting Brake and Clutch Levers
122
Changing Brake and Clutch Fluid
122
Adjusting the Position of Gear Change and Rear Brake Pedals
124
Adjusting Steering Bearing Play
126
Adjusting the Front Fork
127
Adjusting the Rear Shock Absorber
130
Motorcycle Geometry Adjustment
132
Replacing the Fuel Filter
138
General Operations
141
Flow Chart of Dismantling Sequence
144
Removing Headlamp Fairing and Body Panels
148
Seat Removal
149
Removing Battery Box Mount
150
Removing Fuel Tank
151
Removing Air Box and Filter Casings
153
Draining Coolant
154
Removing the Exhaust System
156
Removing Oil Breather Tank and Auxiliary Expansion Tank
159
Removing Electrical Connections
160
Removing Side Stand, Gear Change Lever Linkage, and Clutch Relay Unit
162
Removing Final Drive Chain
163
Removing Throttle Body and Rear Cylinder Intake Manifold
164
Removing the Engine from the Frame
165
Engine Disassembly
167
Timing Belts and Belt Rollers
174
Oil Cooler
176
Cylinder Head
177
Cylinder End Piston
177
L.H. Side Cover
179
Generator
181
Electronic Ignition Flywheel
182
Timing Drive Gear
183
Starter Idle Gear and Starter Motor
184
Gear Selector
185
Clutch Assembly
185
Oil Pump
189
Primary Drive Gear
190
Hald Crankcases
192
Gearbox
194
Cylinder Head Covers
195
Rear Cylinder Head
197
Camshaft Rollers
198
Camshaft Supports and Camshaft
200
Upper Rockers
201
Valves
201
Lower Rockers
202
Engine Overhaul
203
Cleaning the Components
206
Fits
206
Cylinder
207
Piston
208
Piston-Cylinder Fit
208
Piston Pins
209
Piston Rings
209
Piston Rings-Piston Slots Fit
210
Piston Rings - Cylinder Fit
211
Piston Pin - Small End Bush Fit
212
Connecting Rods
213
Replacing Small End Bush
214
Big End Bearings
215
Big End Bearings - Crank Pin Fit
218
Grinding the Crank Pin
219
Valve Seat
220
Valve Guide
220
Valve
221
Valve - Valve Guide Fit
222
Valve Seat Fit
222
Valve Guide Replacement
223
Valve Seat Replacement
224
Rockers
226
Rocker Springs
226
Rocker Shaft - Rocker Fit
227
Camshaft
227
Camshaft Supports
228
Belt Rollers - Belts - Belt Tensioners
229
Starter Clutch and Starter Assembly
230
Crankcase
231
Oil Seals Replacement
231
Reassembling Connecting Rods
232
Bearings
235
Engine Lubricating Circuit
240
Lubrication Diagram
240
Coolant Pump
249
Clutch Plates
254
Clutch Springs
254
Fork Operating Drum
260
Gear Selector Forks
261
Engine Reassembly
263
General Directions
265
Reassembling Head Components
266
Reassembling Gear Shifter and Timing Rollers
281
Reassembling Primary Drive Gear and Oil Pump
282
Reassembling the Clutch
283
Reassembling the Gear Selector
287
Reassembling the Timing Gear
289
Reassembling the Flywheel
290
Reassembling the Coolant Pump
292
Reassembling the L.H. Cover
293
Reassembling Cylinder, Piston and Head
295
Adjusting the Belt Rollers
300
Checking Position of the Timing and Rpm Sensor and Engine Sensor
302
Suspensions and Wheels
312
Front Wheel Removal
316
Removing and Reassembling the Front Fork
317
Special Tools
334
Overhauling the Front Wheel
335
Checking Wear on Final Drive
346
Washing the Chain
346
Chain Lubrication
347
Replacing the Rear Sprocket
348
Removing and Overhauling the Rear Eccentric Hub
350
Removing and Overhauling the Rear Swing Arm
353
Removing the Rear Shock Absorber
357
Overhaul of the Rear Shock Absorber
358
Shock Absorber Inspection
360
Replacing the Bladder
361
Removing Bladder Cap and Bladder
364
Bladder and Bladder Cap
365
Disassembling the Shock Absorber
366
Reassembling the Shock Absorber
368
Installing the Damper Rod Assembly
370
Installing the Damping Adjuster
373
Installing the End Plate
373
Filling the Reservoir with Nitrogen Gas
374
Spring Adjusting Nut
375
Braking System
382
Brake Calipers and Master Cylinder
383
Brake Disc
384
Checking Wear on Brake Pads
385
Draining Brake Fluid
387
Bleeding the Braking System
388
Positioning the Brake Lines
389
Charging a New Battery
397
Recharging the Battery
399
Regulator - Rectifier
401
Efficiency Checks on the Charging System
402
Test Outcomes
403
Regulator Check
404
Operations to be Performed with the Engine Running
404
Starter Motor
408
Connectors
409
Left Handlebar Switch
415
Right Handlebar Switch
417
Key-Operated Switch
418
Ignition and Injection Relays
419
Solenoid Starters and Electric Fan Contactor
420
Checking Instrument Panel Warning Lights and Dial Lights
422
Arrangement of Cables and Hydraulic Lines on the Frame
424
Disengaging the Hydraulic Clutch
445
Clutch Operating Pump
448
Draining Hydraulic System Fluid
449
Cooling System
452
Checking Coolant Level
454
Overhaul of Engine Cooling System
455
Replacing Steering Bearings
459
Specific Tools
464

Ducati 916 Sport Production Workshop Manual (347 pages)

Brand: Ducati | Category: Motorcycle | Size: 99.65 MB

Useful Suggestions
5
General Instructions for Repair Works
5
Index
9
General
10
Dimensions
26
Maintenance
39
Routine Maintenance
39
Operations Identification Symbol
39
Settings and Adjustments
57
Valve Clearance Control and Adjustments
59
Opening Adjuster
60
Closing Adjuster
61
Timing Belts Tension Control
63
Ignition Advance Check up
64
Throttle Control Cables Adjustment
65
Engine Oil and Filter Cartridge Replacement
69
Air Filter Replacement and Cleaning
70
Chain Tension Adjustment
71
Brake and Clutch Control Levers Adjustment
72
Adjustment of Steering Bearing Clearance
73
Rear Shock Absorber
74
General Operations
76
Tank Disconnection
78
Exhaust System Disconnection
79
Disconnection of Clutch Cable
80
Removal of Drive Chain and Gear Control Transmission Lever
81
Air Filter Box and Carburetor Disconnection
82
Disconnecting Engine Cables
84
Engine Removal
86
Engine Disassembly
88
Timing System Belts and Pulleys
90
Cylinder Head
92
Cylinder and Piston
93
Left Side Cover
95
Pick-Up Bearing Plate
96
Alternator and Electronic Ignition Flywheel
97
Timing System Gear
98
Starting Device Idling and Starter Motor
99
Gear Selection Leverage
100
Clutch Assembly
100
Oil Pump
104
Primary Transmission Gear
105
Half Crankcases
107
Transmission
108
Valve Covers and Upper Rocker Arms
110
Valves
111
Camshaft and Lower Rocker Arms
112
Engine Overhaul
113
Couplings
117
Cylinder
118
Piston
119
Gudgeon Pins
120
Piston Rings
120
Piston Rings-Piston Slots Coupling
121
Piston Rings-Cylinder Coupling
122
Gudgeon Pin-Piston Coupling
123
Gudgeon Pin-Connecting Rod Small End Bush Coupling
123
Connecting Rods
124
Replacement of the Connecting Rod Small End Bush
125
Connecting Rod Half-Bearings
126
Driving Shaft
127
Grinding of the Connecting Rod Journal
128
Connecting Rod-Driving Shaft Coupling for Balancing
129
Half Bearings Connecting Rod Journal Couplings
130
Connecting Rod Assy Reassembly
131
Valve Guide
133
Valve
133
Valve-Valve Guide Coupling
134
Valve-Valve Seat Coupling
135
Replacement of the Valve Guide
136
Replacement of the Valve Seat
137
Rocker Arms
138
Rocker Arms Springs
138
Rocket Arm Pin-Rocker Coupling
139
Camshaft and Relevant Bearings
139
Pulleys - Belts - Stretchers
140
Free Wheel and Starting Device
141
Cylinder Block
142
Check of Shafts Straightness
143
Oil Seals Replacement
143
Clutch Assy.
147
Clutch Control Piston Assy.
148
Play between Clutch Bell and Driving Plate
148
Clutch Disc.
149
Clutch Springs
149
Gearbox
150
Chain Side
151
Clutch Side
151
Revision Motor
153
Fork Control Drum
154
Gear Selection Forks
155
Engine Reassembly
156
Head Elements Reassembly
160
Half-Crankcase Closing
166
Transmission Gear and Oil Pump Reassembly
167
Reassembly of the Timing System Pulleys
168
Clutch Reassembly
170
Gearshift Level-System Reassembly
171
Timing System Gear Reassembly
173
Fluwheel Reassembly
176
Cylinder - Piston - Head Assy Reassembly
178
Pick-Up Reassembly
181
Timing System Pulleys Reassembly on the Heads
182
L.H. Cover Reassembly
183
Timing System Pulleys Phase Adjustment
186
Suspensions and Wheels
190
Rear Wheel
190
Rear Suspension
191
Check Secondary Transmission Wear
193
Washing of Chain
193
Lubrication of Chain
194
Replacing the Crown Wheel
194
Swingarm Removal and Overhaul
196
Overhaul of the Rear Shock-Absorber
198
Front Suspension
205
Front Wheel
206
Front Wheel Removal and Overhaul
207
Front Wheel Reassembly
208
Front Fork Removal and Reassembling
209
Overhaul of Fork
211
Specific Tools
219
Brakes
220
Brake Disc
224
Braking System Fluid Drainage
228
Braking System Bleeding
229
Electrical System
230
Electrical System Scheme Legend
231
Charging a New Battery
232
Fuse Box
236
Regulator-Rectifier
237
Recharge Unit Efficiency Checks
238
Generator
241
Starter Motor
242
Ignition Spark Plugs
243
Check the Components of the Starter, Indicator and Lighting Systems
244
Pick-Up
245
Starter Module
246
Left Handlebar Switch
247
Right Handlebar Switch
249
Key Switch
250
General Relay
251
Starter Contactor
252
Checking Dashboard Pilot Lights and Instrument Panel Light
254
Arrangement of the Cables and the Hydraulic Piping on the Frame
256
Carburetor
264
The Combustion Process
269
Changing Engine Speeds
270
Variations in Engine Loads
272
Changing Engine Temperatures
273
Influence of Air Density on the Air-Fuel Ratio
275
Principles of Carburetion
279
Operation of a Simple Carburetor
279
Basic Principles of Carburetor Operation
280
Functions of Pressure Differences in a Carburetor
282
Types of Carburetors
284
Operation of Circuits Peculiar to the CV Carburetor
288
Identification of Parts, and Operation of Basic Circuits
289
The Float Circuit
289
Measuring the Foat Level
289
The Pilot Circuit
296
The Midrange Circuit
302
The High-Speed Circuit
306
Starter Circuit
307
Accelerator Pump Circuit
310
Coasting Enrichener System
312
Proper Carburetor Cleaning
313
Inspection of Carburetor Components
316
Mixture Control Valve Troubleshooting
320
Troubleshooting Hints
320
Common Causes of Customer Complaints
320
Frame
331
Overall Dimensions
332

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Ducati 916 Sport Production Workshop Manual (485 pages)

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Ducati 916 Sport Production Workshop Manual (347 pages)

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