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Table Of Contents - Ducati MONSTER S4R Repair Manual

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Owner's manual (86 pages)

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Use and maintenance manual (94 pages)

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Table of Contents

Description: Table Of Contents12

Product Specifications18

General Safety Rules20

General Maintenance Indications22

General Advice On Repair Work23

Model-Specific Information24

Model-Specific Information: Table Of Contents25

Identification Data26

Technical Specification28

Technical Specification: Table Of Contents29

Overall Dimensions37

Use And Maintenance Operations53

Use And Maintenance Operations: Table Of Contents54

Preliminary Checks55

Running-In Precautions55

Pre-Ride Checks56

Starting/Engine Warm-Up58

Starting The Engine58

Routine Maintenance Table62

Checking The Engine Oil Level64

Changing The Engine Oil And Filter Cartridge65

Checking Valve Clearances67

Adjusting Valve Clearances67

Checking The Coolant Level68

Changing The Coolant69

Changing The Fuel Filter70

Refitting The Fuel Filter71

Changing And Cleaning The Air Filter72

Changing The Brake Fluid73

Fitting The Front Braking System73

Fitting The Rear Braking System74

Draining The Brake Circuit75

Filling The Braking Circuit76

Changing The Clutch Fluid78

Draining The Clutch Circuit79

Filling The Clutch Circuit80

Adjusting Steering Bearings Play82

Adjusting The Clutch Lever And The Front Brake Lever83

Adjusting Chain Tension84

Checking Brake Pad Wear85

Changing Brake Pads85

Checking Rear Brake Wear86

Adjusting The Throttle And Choke Cables87

Adjusting The Position Of The Gear Change And Rear Brake Pedals89

Adjusting The Rear Shock Absorber90

Adjusting The Front Fork91

Changing Motorcycle Track Alignment92

Tester Description94

Connection To The Bike95

Mathesis Tester96

Checking And Adjusting Timing Belt Tension97

Adjusting The Throttle Body101

Positioning The Throttle Sensor102

Adjusting The Throttle Position Sensor102

Adjusting The Idling Mixture103

Adjusting The Throttle Set Screw103

Balancing The Air Flows103

Adjusting The Co Rate104

Adjusting The Choke Control104

Checking Engine Oil Pressure105

Checking Cylinder Compression107

Checking Fuel Pressure109

Fairing: Table Of Contents111

Headlight Fairing - Rear-View Mirrors112

Removing The Rear View Mirrors113

Fitting The Rear-View Mirrors113

Removing The Headlight Fairing114

Disassembling The Headlight Fairing114

Reassembling The Headlight Fairing114

Fitting The Headlight Fairing114

Removing The Tail Guard116

Disassembling The Tail Guard116

Reassembling The Tail Guard117

Refitting The Tail Guard117

Fitting The Under Seat118

Refitting The Under Seat118

Removing The Side Panels119

Refitting The Side Panels119

Removing The Front Mudguard120

Controls - Devices121

Controls - Devices: Table Of Contents122

Throttle - Choke Control123

Disassembling The Throttle Control125

Removing The Choke Control126

Refitting The Choke Control127

Throttle Cable Routing128

Choke Cable Routing129

Clutch Hydraulic Control130

Removing The Clutch Cylinder Assembly131

Removing The Clutch Transmission Unit132

Refitting The Clutch Transmission Unit133

Clutch Hose Routing134

Front Brake Control135

Removing The Front Brake Master Cylinder136

Refitting The Front Brake Master Cylinder136

Front Brake Line Routing137

Rear Brake Control139

Removing The Complete Rear Brake Master Cylinder140

Disassembling The Rear Brake Master Cylinder141

Refitting The Rear Brake Cylinder141

Rear Brake Line Routing143

Gear Change Control145

Removing The Gear Change Control146

Disassembling The Gear Change Control146

Refitting The Gear Change Control146

Releasing Mechanisms147

Removing The Seat Releasing Mechanism148

Refitting The Seat Releasing Mechanism148

Wheels - Suspensions - Brakes149

Wheels - Suspensions - Brakes: Table Of Contents150

Removing The Front Wheel152

Overhauling The Front Wheel153

Overhauling The Front Wheel Bearings153

Overhauling The Front Wheel Shaft154

Overhauling The Front Wheel Rim154

Refitting The Front Wheel155

Adjustable Front Fork156

Removing The Front Fork157

Overhauling The Front Fork158

Disassembling The Front Fork158

Checking The Front Fork161

Reassembling The Front Fork162

Fitting The Front Fork165

Braking System Maintenance167

Removing The Front Brake System167

Removing The Brake Discs168

Overhauling The Front Brake Components168

Refitting The Front Brake System169

Removing The Rear Wheel172

Overhauling The Rear Wheel173

Overhauling The Wheel Rim173

Refitting The Rear Wheel174

Rear Swingarm175

Removing The Rear Eccentric Hub176

Refitting The Rear Eccentric Hub178

Removing The Rear Swingarm179

Inspecting The Swingarm Shaft182

Checking Swingarm Axial Play182

Refitting The Rear Swingarm183

Removing The Rear Brake Caliper186

Removing The Rear Brake Disc187

Refitting The Rear Brake Caliper188

Rear Suspension189

Rear Suspension Unit190

Removing The Monoshock Absorber190

Overhauling The Monoshock Absorber191

Removing The Rear Suspension Rocker Arm192

Overhauling The Rear Suspension Rocker Arm193

Disassembling The Rear Suspension Rocker Arm193

Reassembling The Rear Suspension Rocker Arm193

Removing And Overhauling The Shock Absorber Linkage194

Refitting The Rear Suspension195

Inspecting The Final Drive198

Removing The Front Sprocket199

Refitting The Front Sprocket200

Changing The Rear Sprocket201

Refitting The Rear Sprocket201

Washing The Chain202

Lubricating The Chain202

Frame: Table Of Contents204

Removing The Handlebar206

Fitting The Handlebar207

Adjusting Steering Bearing Play209

Adjusting The Steering Angle209

Disassembling The Headstock Parts210

Reassembling The Headstock Parts211

Footpeg Supports214

Removing The Footpegs215

Removing The Rear Footpegs217

Refitting The Front Footpegs218

Refitting The Rear Footpegs220

Removing The Side Stand222

Disassembling/Assembling The Side Stand222

Checking The Side Stand222

Fitting The Side Stand222

Checking The Frame223

Removing Frame And Structural Parts224

Refitting Frame And Structural Parts224

Overhaul Dimensions - Frame227

Tail Light And Number Plate Holder228

Removing The Tail Light And The Number Plate Holder229

Fitting The Tail Light And The Number Plate Holder229

Fuel System/Exhaust System230

Fuel System/Exhaust System: Table Of Contents231

Description Of Fuel System232

Removing The Fuel Tank236

Removing And Changing The Filler Plug Unit237

Reassembling The Filler Plug Unit238

Refitting The Fuel Tank239

Fuel Tank Drain And Breather Pipes Routing240

Removing The Fuel Pump242

Replacing The Fuel Sensor243

Refitting The Fuel Pump244

Removing The Fuel Filter/Refitting The Fuel Filter246

Pressure Regulator247

Changing The Pressure Regulator248

Throttle Body249

Removing The Throttle Body250

Removing The Injectors250

Refitting The Injectors250

Refitting The Throttle Body251

Removing The Air Box253

Refitting The Air Box255

Air Box Drain Hose Routing257

Exhaust System258

Catalytic Converter Operating Principle (Eu Only)260

Removing The Exhaust System262

Refitting The Exhaust System265

Canister Filter267

Canister Filter (Usa Versions Only)268

Removing The Canister Filter269

Refitting The Canister Filter270

Routing Of Hoses, Clamps And Canister Filter Position271

Ignition - Injection System275

Ignition - Injection System: Table Of Contents276

Description Of The Fuel Injection - Ignition System277

General Information On The Fuel Injection - Ignition System277

Importance Of The Air-Fuel Mixture And Of The Ignition Advance277

Marelli Injection-Ignition System278

Legend To Sensor Position Diagram279

Fuel Circuit281

Intake Air Circuit282

Operating Stages283

Normal Operation283

Acceleration/Deceleration283

Fuel Injection-Ignition System Diagram284

Electronic Control Unit286

Removing The Electronic Control Unit287

Refitting The Electronic Control Unit287

Electric Injector289

Water Temperature Sensor290

Removing Water Temperature Sensor290

Refitting The Water Temperature Sensor290

Air Temperature/Presssure Sensor291

Removing The Air Temperature/Pressure Sensor291

Refitting The Air Pressure/Temperature Sensor291

Ignition Coils292

Checking The Spark Plugs292

Checking The Coils293

Throttle Position Sensor294

Rpm/Timing Sensor294

Main And Injection Relays295

Engine: Table Of Contents297

Removing - Refitting The Complete Engine300

Removing The Engine301

Disassembling The Engine303

Reassembling The Engine304

Lubrication System: Oil Cooler305

Lubrication System Diagram306

Description Of The Lubrication System307

Lubrication System Operation307

Crankcase Vapor Breather Circuit308

Removing The Oil Filters308

Removing The Oil Cooler And Pipes309

Checking The Oil Cooler310

Removing The Oil Delivery Pipes To Heads311

Reassembling The Oil Cooler And Pipes312

Oil Cooler Pipes Routing313

Lubrication System: Oil Pump315

Removing The Oil Pump316

Disassembling The Oil Pump316

Overhauling The Oil Pump317

Reassembling The Oil Pump317

Refitting The Oil Pump318

Lubrication System: Oil Breather Reservoir319

Removing The Oil Breather Reservoir320

Refitting The Oil Breather Reservoir320

Oil Breather Pipe Routing321

Cooling System: Tank323

Cooling System Description324

Cooling System Components Key325

Removing Water Reservoir326

Refitting Water Reservoir327

Cooling System: Radiator328

Removing The Radiator329

Checking The Water Radiator330

Removing The Cooling Fan330

Refitting The Coolant Radiator331

Removing The Engine Cooling System Pipes And Unions332

Refitting The Cooling System Pipes And Unions333

Engine Cooling System Hose Routing334

Cooling System: Coolant Pump336

Removing The Coolant Pump337

Refitting The Coolant Pump338

Head Unit: Check And Adjustments340

Checking And Adjusting Valve Clearance341

Checking And Adjusting Opening Clearance (Sa)342

Checking And Adjusting Closing Clearance (Sc)343

Checking Valve Lift344

Checking Engine Timing345

Head Unit: Side Covers/Timing System347

Removing The Timing System Parts349

Removing Timing Outer Covers349

Removing The Mobile Tensioner/Timing Belt350

Removing Head Belt Rollers351

Removing The Tensioner Pins And Inner Covers351

Removing The Timing Layshaft Belt Rollers352

Disassembling Belt Tensioners353

Disassembling Timing Belt Rollers353

Refitting The Timing System Parts354

Timing Layshaft Belt Rollers354

Refitting Inner Covers And Tensioner Pins355

Refitting The Timing Belts356

Refitting Timing Outer Covers359

Head Unit: Covers/Camshafts360

Removing The Intake Manifolds362

Refitting The Intake Manifolds362

Removing Head Covers363

Refitting Head Covers364

Removing Side Covers And Camshafts365

Disassembling The Timing-Side Head Side Covers366

Disassembling The Generator-Side Head Side Covers366

Reassembling The Generator-Side Head Side Covers366

Reassembling The Timing-Side Head Side Covers366

Checking Camshafts367

Checking Camshaft Covers367

Checking Circlips368

Checking Oil Seals368

Checking Bearings368

Refitting Camshafts And Side Covers369

Head Unit: Head370

Removing The Complete Head371

Removing Opening Rocker Arms372

Removing The Valves373

Removing The Closing Rocker Arms374

Overhauling Head Parts375

Valve Guides377

Checking Valve Sealing Surface378

Opening And Closing Shims379

Reassembling Head Parts380

Reassembling Closing Rocker Arms380

Reassembling Valves And Valve Shims381

Refitting Opening Rocker Arms382

Refitting The Complete Heads383

Cylinder/Piston Assembly384

Removing Cylinder/Piston Assy385

Overhauling And Checking The Components387

Piston Rings388

Piston Ring-Piston Groove Clearance388

Piston Rings-Cylinder Clearance389

Gudgeon Pins389

Con-Rod Small End Bush-Gugeon Pin Clearance389

Refitting Cylinder/Piston Assy390

Clutch Assembly: Clutch393

Disassembling The Clutch396

Clearance Between Clutch Housing And Drive Plate399

Overhauling The Clutch Plates399

Overhauling The Pressure Plate399

Overhauling The Clutch Springs399

Reassembling The Clutch400

Clutch Assembly: Clutch Cover403

Removing The Clutch Cover404

Disassembling The Clutch Cover404

Reassembling The Clutch Cover405

Refitting The Clutch Cover406

Clutch Assembly: Primary Drive Gears407

Disassembling The Primary Drive Gears408

Refitting The Primary Drive Gear And Checking Meshing Play410

Gearbox Assembly: Lever Assembly412

Removing The Gear Selector Levers413

Removing The Gear Stopper And Ratchet414

Reassembling Gear Stopper And Ratchet414

Reassembling The Gear Selector Lever415

Gearbox Assembly: Gearbox Shafts416

Removing The Gearbox418

Disassembling The Gearbox Shafts419

Secondary Shaft419

Gearbox Primary Shaft421

Overhauling The Gearbox423

Overhauling The Gear Selector Forks425

Fork Selector Drum425

Reassembling The Gearbox Shafts426

Reassembling The Gearbox428

Flywheel - Generator429

Removing The Generator Cover431

Disassembling The Generator Cover432

Removing The Flywheel - Generator Assembly433

Checking The Flywheel - Generator Assembly434

Disassembling The Flywheel - Generator Assembly434

Reassembling The Flywheel - Generator Assembly435

Refitting Flywheel/Generator Assembly436

Reassembling The Generator Cover437

Checking The Air Gap Of Engine Sensor439

Casing Unit: Outer Components440

Removing Outer Components441

Reassembling The Outer Parts443

Removing The Timing Lay Gear444

Reassembling The Timing Lay Gear444

Removing The Starter Motor Driven Gear445

Reassembling The Starter Motor Driven Gear445

Casing Unit: Crankcases446

Opening The Casings447

Overhauling The Casings449

Main Bearings450

Reassembling The Casings451

Overhauling The Clutch-Side Casing451

Overhauling The Generator-Side Casing452

Shimming The Shafts453

Shimming The Crankshaft453

Shimming The Gearbox Shafts455

Shimming The Gearbox Drum456

Closing The Casings456

Casing Unit: Connecting Rods460

Removing The Connecting Rods461

Disassembling The Connecting Rod461

Overhauling The Connecting Rods462

Changing The Connecting Rod Small End Bush462

Checking The Connecting Rod Big End Bearings463

Checking The Crankshaft464

Checking Big End Bearings-Crank Pin Clearance465

Reassembling The Connecting Rods466

Refitting The Connecting Rod Unit467

Electric System468

Wiring Diagram469

Key To Fuse Box473

Arrangement Of Wiring On Frame473

Charging System Battery - Checking The Charging System489

Charging Methods489

Normal Charge (With Constant Voltage)490

Charging The Battery Under Critical Conditions490

Battery - Safety Rules491

Instructions For Use Of The Battery491

Removing The Battery491

Refitting The Battery491

Battery Mount492

Removing The Generator493

Refitting The Generator493

Rectifier - Regulator494

Removing The Regulator494

Refitting The Regulator494

Removing The Regulator Fuse495

Electric Starting496

Electric Starting System497

Safety Devices Function Table498

Starter Motor499

Removing The Starter Motor499

Refitting The Starter Motor500

Starter Contactor501

Starter Contactor Operational Check501

Lighting Devices502

Changing Light Bulbs502

Changing The Headlight Bulbs502

Changing The Number Plate Lights503

Replacing The Headlight504

Removing The Turn Indicators And Headlight Support504

Beam Setting505

Indicators And Lighting System506

Checking The Indicators And Lighting System Components506

Checking The Left Switch506

Turn Indicator Switch507

Checking The Right Switch508

Checking Front And Rear Stop Switches, Neutral Switch, Oil Pressure Switch And Clutch Switch509

Changing Bulbs511

Changing The Turn Indicator Bulbs511

Changing The Stop Light Bulbs511

Protection And Safety Devices512

Checking Protection And Safety Devices Components512

Checking The Key-Operated Switch512

Checking The Side Stand Switch513

Checking The Fuses514

Instrument Panel515

Immobilizer And Transponder518

Keys With Transponder518

Immobilizer Aerial519

Operating Principle Of The Immobilizer519

Immobilizer Warning Lights And Indicators520

Programming The Immobilizer521

Checking Immobilizer Programming523

Emergency Procedure To Override The Immobilizer System524

Removing The Immobilizer526

Reassembling The Immobilizer526

Disassembling The Red Key With Transporter527

How To Use Multimeter To Check Electric Systems528

How To Measure Voltage528

How To Measure Current529

How To Measure Resistance And Electric Coninuity530

Protections And Precautions531

Subject Index532

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