Table Of Contents - Ducati SCRAMBLER 800 Workshop Manual

Table of Contents

Symbols - Abbreviations - References8
Product Specifications8
General Maintenance Instructions11
Useful Tips11
General Advice On Repair Work11
General Safety Rules12
Carbon Monoxide12
Used Engine Oil12
Brake Dust12
Identification Data13
Data Stamped On The Frame13
Lights/Instrument Panel15
Fuel System17
Ignition System18
Injection System18
Charging System/Generator19
Hydraulic Brakes20
Rear Suspension21
Rear Wheel22
Front Suspension23
Front Wheel24
Gearbox26
Cylinder/Piston27
Crankshaft28
Timing System/Valves29
Transmission30
Colours31
General32
Dimensions34
Fuel, Lubricants And Other Fluids35
Engine Oil35
Viscosity35
Engine Tightening Torque Values37
Frame Tightening Torque Values40
Diagnosis Special Tools46
Frame Special Tools47
Engine Special Tools49
Vehicle Pre-Delivery53
Scheduled Maintenance Chart: Operations To Be Carried Out By The Customer54
Scheduled Maintenance Chart: Operations To Be Carried Out By The Dealer55
Adjusting The Rear Shock Absorber57
Adjusting The Position Of The Gearchange Pedal And Rear Brake Pedal58
Adjusting The Front Brake Control Lever59
Adjusting The Throttle Cable60
Checking Rear Brake Pad Wear And Replacing Brake Pads62
Checking Front Brake Pad Wear And Replacing Brake Pads65
Adjusting The Chain Tension70
Adjusting The Steering Head Bearing Play73
Clutch Control Cable Adjustment75
Changing The Fluid In The Rear Brake Circuit78
Changing The Fluid In The Front Brake Circuit80
Changing And Cleaning The Air Filters86
Replacing The Spark Plugs88
Changing The Timing Belts90
Checking Valve Clearance100
Changing The Engine Oil And Filter Cartridge104
Filter Cartridge105
Check Engine Oil Level108
Refitting The Rear-View Mirrors109
Removing The Rear-View Mirrors110
Refitting The Tail Guard111
Removing The Tail Guard116
Refitting The Seat Release Mechanism118
Removing The Seat Release Mechanism121
Refitting The Rear Side Body Panels130
Removing The Rear Side Body Panels133
Rh Side Body Panel133
Lh Side Body Panel134
Refitting The Seat137
Removing The Seat139
Refitting The Front Mudguard140
Removing The Front Mudguard141
Refitting The Belly Pan147
Removing The Belly Pan151
Table Z152
Table Aa153
Table Bb154
Table Cc155
Table Dd156
Table Y158
Table X159
Table W160
Table V162
Table U163
Table T164
Table S165
Table R166
Table Q167
Table P169
Table O171
Table N172
Table M175
Table L176
Table K177
Table J180
Table H182
Table G183
Table F185
Table E186
Table D187
Table C188
Table A189
Routing Of Wiring On Frame191
Table Of Contents192
Fuse Box Key193
Wire Colour Coding194
Key To Wiring Diagram195
Rear Wheel Speed Sensor195
Tail Light Cable195
Rear Turn Indicator195
47 Front Speed Sensor195
Rectifier-Regulator196
Removing The Regulator196
Refitting The Regulator198
Regulator Fuse198
Alternator/Generator201
Removing The Generator201
Refitting The Generator201
Battery202
Battery Safety Rules202
Instructions For Battery Use202
Removing The Battery202
Refitting The Battery203
Topping Up The Electrolyte205
Recharging The Battery209
Storing The Battery209
Checking The Battery Charging System210
Solenoid Starter211
Removal Procedure211
Checking Operation Of The Solenoid Starter212
Refitting Procedure212
Starter Motor214
Electric Features214
Electric Starting System215
Aligning The Headlight216
Replacing The Light Bulbs - Headlight218
Removing The Light Assembly218
Refitting The Light Assembly220
Changing Bulbs222
Entering Pin Code Function For Overriding Purposes224
Entering The Code (A)224
Key Duplication226
Operation227
Keys228
Immobilizer System229
Activations Through Diagnosis Instrument229
Programming The Immobilizer System229
Programming Procedure229
Light Control230
Low/High Beam230
Turn Indications230
Hazard Function230
Setting The Units Of Measurement231
Speed231
Temperature232
Default Setting232
Changing The Pin Code234
Entering The "Old" Code234
Entering The "New" Code234
Pin Code Reset236
Pin Code237
Entering The Pin Code237
Vin Code238
Clock Setting Function (Clock)239
Instrument Panel Back-Lighting Setting (B.light)240
Battery Voltage241
Abs Control Unit Enabling/Disabling242
Setting Menu244
Desmo Service Indication245
Desmo Service Countdown Indication246
Oil Service Zero Warning247
Service Indication (Service)248
High Engine Temperature249
Clock250
Displayed Errors Description251
Error Icons Table252
Error Warnings253
Errors254
Ambient Air Temperature (Air)255
Partial Fuel Reverse Counter (Trip Fuel)256
Trip Meter 2 (Trip 2)257
Trip Meter 1 (Trip 1)258
Odometer (Tot)259
Odometer Update259
Menu 1 Functions260
Engine Rpm Indication (Rpm)261
Motorcycle Speed263
Main Functions264
Main Information264
Additional Information264
Parameter Setting/Displaying265
Function Buttons267
Technology Dictionary268
Acronyms And Abbreviations Used In The Manual269
Instrument Panel270
Sw Update271
Diagnosis Socket272
Left-Hand Switch272
Left-Hand Switch Control272
Electric Diagram272
Controls On Left-Hand Switch273
Right-Hand Switch274
Right-Hand Switch Control274
Controls On Right-Hand Switch275
Engine Stop Button276
Starter Button276
Rear Stop Switch276
Rear Stop Switch Control276
Gear/Neutral Sensor277
Horn278
Clutch Switch279
Clutch Switch Control280
Main Relay And Injection282
Timing/Rpm Sensor283
Throttle Position Potentiometer (Tps)286
Tps Electric Diagram286
Coil287
Controls289
Ignition Spark Plug291
Temperature Sensor292
Map Sensor292
Oil Pressure Sensor294
Lambda Sensor295
Stepper Motor298
Electric Injector299
Electric Control Unit300
Remova/Reassembly300
Overhauling The Front Wheel302
Wheel Bearings302
Inspecting The Wheel Shaft303
Overhauling The Front Wheel Rim, Spokes And Nipples304
Checking The Nipple Minimum Tightening Torque304
Checking For Radial Or Axial Runout306
Changing The Spokes307
Tensioning And Centering Operation308
Checking The Radial Or Axial Runout315
Refitting The Front Wheel320
Overhauling The Wheel Rim329
Removing The Front Wheel331
Overhauling The Rear Wheel337
Refitting The Rear Wheel339
Removing The Rear Wheel343
Refitting The Front Brake System345
Refitting The Brake Disc349
Overhauling The Front Brake Components350
Removing The Brake Disc351
Removing The Front Brake System352
Maintenance Operations355
Refitting The Front Brake Master Cylinder356
Removing The Front Brake Master Cylinder359
Refitting The Rear Brake Disc361
Removing The Rear Brake Disc362
Refitting The Rear Brake Calliper363
Removing The Rear Brake Calliper366
Refitting The Rear Brake Control368
Disassembling The Rear Brake Control374
Removing The Rear Brake Control375
Routing Wiring Harnesses/Hoses382
Refitting The Abs Control Unit388
Removing The Abs Control Unit390
Changing The Rear Phonic Wheel Sensor395
Changing The Front Phonic Wheel Sensor396
Bleeding Of The Abs Hydraulic System398
Adjusting The Air-Gap Of Phonic Wheel Sensor400
Air-Gap Adjustment Procedure400
Refitting The Throttle Control404
Removing The Throttle Control406
Refitting The Handlebar408
Removing The Handlebar417
Handlebar Counterweight417
Refitting The Clutch Assembly422
Removing The Clutch Assembly424
Refitting The Ignition Switch426
Removing The Ignition Switch427
Refitting The Gear Change Control428
Disassembling The Gear Change Control430
Removing The Gear Change Control431
Refitting The Front Fork434
Overhauling The Front Fork437
Removing The Rh Leg437
Removing The Front Fork449
Refitting The Steering Tube Components451
Removing The Steering Tube Components454
Steering Angle Adjustment458
Adjusting The Steering Head Bearing Clearance459
Refitting The Rear Suspension460
Overhauling The Rear Shock Absorber462
Removing The Rear Shock Absorber463
Rear Suspension System465
Refitting The Rear Swinging Arm466
Overhauling The Rear Swinging Arm471
Inspecting The Swinging Arm Shaft473
Removing The Swinging Arm474
Lubricating The Chain477
Washing The Chain478
Refitting The Rear Sprocket479
Removing The Rear Sprocket483
Refitting The Front Sprocket485
Removing The Front Sprocket488
Inspection Of The Final Drive491
Refitting The Rear Footpegs492
Removing The Rear Footpegs493
Refitting The Front Footpeg Support494
Lh Footpeg Holder494
Rh Footpeg Holder495
Removing The Front Footpeg Support496
Refitting The Front Footpeg498
Removing The Front Footpeg499
Refitting The Side Stand500
Removing The Side Stand503
Disassembling The Side Stand504
Checking The Frame507
Refitting The Structural Parts On Frame509
Removing Structural Components And Frame513
Refitting The Tail Light514
Removing The Tail Light516
Refitting The Number Plate Holder518
Removing The Number Plate Holder523
Refitting The Electric Components Compartment528
Removing The Electric Components Compartment533
Refitting The Tank535
Refitting The Tank Side Body Panels537
Refitting The Fuel Tank Flange542
Removing The Fuel Tank Flange545
Refitting The Tank Filler Plug546
Removing The Tank Filler Plug547
Removing The Fuel Tank548
Refitting The Throttle Body554
Refitting The Intake Manifold And Injectors554
Removing The Throttle Body560
Removing The Intake Manifold And Injectors560
Refitting The Airbox564
Airbox Cover Assembly581
Rh Airbox Cover581
Lh Airbox Cover582
Removing The Airbox584
Removing The Airbox Cover590
Lh Cover591
Refitting The Secondary Air System593
Removing The Secondary Air System600
Refitting The Air Filter603
Removing The Air Filters606
Refitting The Silencer609
Reassembling The Silencer610
Removing The Silencer614
Refitting The Exhaust System618
Removing The Exhaust System623
Refitting The Canister Filter632
Canister Filter System634
Refitting The Engine635
Removing The Engine638
Refitting The Oil Pump641
Reassembling The Oil Pump643
Disassembling The Oil Pump Gear645
Removing The Oil Pump646
Refitting The Lubrication System648
Inspecting The Oil Cooler650
Removing The Lubrication System651
Checking The Engine Timing653
Checking Valve Lift655
Checking And Adjusting The Valve Clearance657
Refitting The Timing Outer Covers661
Refitting The Timing Belts662
Refitting The Cylinder Heads Pulleys/Idler Pulleys663
Reassembling The Timing Pulleys666
Refitting The Timing Layshaft Pulley667
Removing The Timing Layshaft Pulleys670
Disassembling The Camshaft Pulleys673
Removing The Cylinder Head Pulley/Fixed Tensioner674
Removing The Mobile Tensioner/Timing Belt676
Removing The Timing Belt Covers678
Refitting The Intake Manifold679
Removing The Intake Manifold680
Refitting The Camshafts683
Refitting The Side Caps687
Fitting The Timing Internal Cover687
Refitting The Valve Covers688
Check Of The Camshafts And Supports689
Oil Seal Check689
Removing The Camshafts691
Removing The Valve Covers691
Removing The Rocker Arm Shaft Cap692
Refitting The Cylinder Heads695
Refitting The Valves And Rocker Arms697
Refitting Rocker Arms, Shims And Valves697
Closing Rocker Arm697
Opening Rocker Arm703
Overhauling The Cylinder Head Components706
Overhauling The Heads706
Checking The Valves706
Checking The Valve Seats707
Valve Guide707
Coupling Valve Seat And Valve708
Checking The Valve - Valve Guide Coupling709
Replacing The Valve Guide709
Overhauling The Rocker Arms709
Rocker Arm-Rocker Arm Shaft Coupling711
Checking The Rocker Arm Springs712
Removing The Valves And Rocker Arms713
Removing The Cylinder Heads717
Refitting The Cylinder/Piston Assembly719
Overhauling The Cylinder/Piston Components721
Overhauling The Cylinder721
Overhauling The Piston722
Piston - Cylinder Coupling723
Overhauling The Gudgeon Pins723
Overhauling The Piston Rings724
Piston Ring-Grooves Coupling725
Piston-Gudgeon Pin Coupling725
Removing The Cylinder/Piston Assembly726
Refitting The Clutch730
Checking And Overhauling The Components735
Clearance Between The Clutch Housing And Friction Plate735
Overhauling The Clutch Plates735
Overhauling The Pressure Plate736
Pusher Plate Springs736
Removing The Clutch737
Description Of The Clutch Assembly741
Refitting The Clutch Cover742
Reassembling The Clutch Cover745
Clutch Layshaft745
Oil Sight Glass748
Disassembling The Clutch Cover751
Oil Filler Cap751
Removing The Clutch Cover752
Refitting The Primary Drive Gears And Checking Backlash754
Removing The Primary Drive Glass757
Refitting The Gearchange Mechanism760
Reassembling The Gearchange Mechanism761
Refitting The Gear Interlock Plunger And Ratchet766
Disassembling Gear Interlock Plunger And Ratchet768
Removing The Gearchange Mechanism770
Disassembling The Gearchange Mechanism770
Reassembling The Gearbox Assembly771
Reassembling The Gearbox Shafts772
Inspection The Fork Selector Drum776
Inspecting The Gear Selector Forks777
Overhauling The Gearbox779
Disassembling The Gearbox Shafts780
Disassembling The Gearbox Secondary Shaft780
Disassembling The Gearbox Primary Shaft788
Removing The Gearbox Assembly796
Refitting The Flywheel/Generator Assembly798
Overhauling The Flywheel/Generator Assembly801
Removing The Flywheel/Generator Assembly802
Checking The Flywheel/Generator Assembly804
Disassembling The Flywheel/Generator Assembly804
Refitting The Generator Cover806
Reassembling The Generator Cover811
Disassembling The Generator Cover813
Removing The Generator Cover815
Refitting The Starter Motor817
Removing The Starter Motor818
Refitting The Starter Motor Idler Gear820
Removing The Starter Motor Idler Gear821
Refitting The Timing Gears822
Removing The Timing Gears824
Refitting The External Components825
Removing Outer Components831
Closing The Crankcase837
Shimming The Shafts845
Shimming The Crankshaft845
Reassembling The Crankcase Halves847
Refitting The Clutch-Side Crankcase Half847
Refitting The Generator-Side Crankcase Half847
Main Bearings849
Overhauling The Crankcase Halves850
Chain-Side Crankcase Half851
Clutch-Side Crankcase Half853
Separating The Crankcase Halves855
Reassembling The Connecting Rod Assembly859
Overhauling The Connecting Rod Assembly865
Replacing Conecting Rod Big End Bearings865
Overhauling The Crankshaft866
Big-End Bearing-Crank Pin Clearance870
Disassembling The Connecting Rod Assembly872
Removing The Connecting Rod Assembly873