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Table Of Contents - Ducati Multistrada 1000ds Workshop Manual

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Owner's manual (102 pages)

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Table of Contents

General Summary2

How To Use The Manual13

Manual Layout14

Symbols, Abbreviations, References15

Product Specifications18

General Safety Rules20

Hot Component Parts20

Used Engine Oil21

Brake Lining Debris21

Brake Fluid Warning21

Coolant Warning21

General Maintenance Indications22

Battery Warning22

General Advice On Repair Work23

Model-Specific Information27

Identification Data27

Data Punched On Frame27

Vehicle Code Printed On Ec Nameplate27

Data Punched On Engine28

Technical Specification30

Technical Data38

Vehicle Dimensions38

Timing/Valves39

Lubrication System Data40

Cylinder / Piston Data40

Cooling System Data41

Front Wheel Data41

Front Suspension Data41

Rear Wheel Data42

Rear Suspension Data42

Hydraulic Brakes Data42

Charging System / Generator Data43

Ignition System Data43

Control Unit Data43

Lights / Instrument Panel Data43

Overall Dimensions44

Frame Torque Settings55

Engine Torque Settings60

Engine Special Tools70

Frame Specific Tools75

Use And Maintenance Operations78

Preliminary Checks79

Running-In Precautions79

Max. Rotation Speed79

Pre-Ride Checks80

Starting The Engine82

Routine Maintenance Table85

Turning Off The "Service" Warning On The Instrument Panel87

Checking The Engine Oil Level88

Changing The Engine Oil And Filter Cartridge89

Checking Valve Clearances91

Changing The Fuel Filter93

Changing And Cleaning The Air Filter94

Changing The Brake Fluid95

Draining The Brake Circuits97

Filling The Brake Circuits98

Changing The Clutch Fluid100

Draining The Clutch Circuit101

Filling The Clutch Circuit102

Adjusting Steering Bearings Play104

Adjusting The Clutch Lever And The Front Brake Lever105

Chain Adjustment106

Checking Brake Pad Wear. Changing Brake Pads108

Adjusting The Throttle Cables110

Adjusting The Position Of The Gear Change And Rear Brake Pedals112

Adjusting The Rear Shock Absorber113

Adjusting The Front Fork114

Changing Motorcycle Track Alignment115

Changing The Tail Height115

Mathesis Tester Description117

Tester Technical Features117

Tester Connection To The Bike118

Components Supplied With The Tester118

Checking And Adjusting Timing Belt Tension120

Adjusting The Throttle Body124

Zero Setting The Throttle Position Sensor125

Balancing The Air Flows126

Adjusting The Idle Mixture And The Co Level127

Checking Engine Oil Pressure128

Checking Cylinder Compression130

Headlight Fairing - Rear-View Mirrors135

Removing The Rear-View Mirrirs136

Refitting The Rear-View Mirrors136

Removing The Mobile Headlight Fairing137

Refitting The Mobile Headlight Fairing137

Removing The Fixed Headlight Fairing138

Refitting The Fixed Headlight Fairing139

Fairing Diagram140

Removing The Left Fairing141

Refitting The Left Fairing141

Removing The Front Conveyor142

Refitting The Front Conveyor142

Removing The Upper Left Fairing143

Refitting The Upper Left Fairing143

Removing The Upper Right Fairing144

Refitting The Right Fairing146

Fuel Tank-And-Seat Assembly, Side Panels And Front Mudguard Diagram147

Removing The Passenger Seat149

Refitting The Passenger Seat149

Adjusting The Seat Plates149

Removing The Rear Side Panels150

Notes On Rear Side Panel Installation150

Removing The Fuel Tank-And-Seat Assembly151

Refitting The Fuel Tank-And-Seat Assembly153

Removing The Front Mudguard155

Refitting The Front Mudguard155

Controls - Devices158

Throttle Control - Starter159

Removing The Throttle Control160

Refitting The Throttle Control160

Choke/Throttle Cables Routing161

Clutch Hydraulic Control162

Removing The Clutch Cylinder Assembly163

Fitting The Clutch Cylinder Assembly163

Removing The Clutch Transmission Unit164

Refitting The Clutch Transmission Unit165

Clutch Hose Routing166

Front Brake Control Diagram167

Removing The Front Brake Master Cylinder168

Refitting The Front Brake Master Cylinder169

Rear Brake Control170

Removing The Rear Brake Master Cylinder171

Refitting The Rear Brake Master Cylinder173

Refitting The Pivot Pin173

Refitting The Rear Brake Footpeg173

Rear Brake Line Routing176

Gear Change Control Diagram177

Removing The Gear Change Control178

Disassembling The Gear Change Control178

Refitting The Gear Change Control178

Releasing Mechanisms179

Removing The Passenger Seat Releasing Mechanism180

Removing The Glove Compartment Releasing Mechanism180

Seat Lock Cable Routing181

Wheels - Suspensions - Brakes184

Removing The Front Wheel186

Overhauling The Front Wheel187

Wheel Bearings Check187

Front Wheel Shaft Check188

Overhauling The Front Wheel Rim188

Refitting The Front Wheel189

Removing The Front Fork191

Overhauling The Front Fork192

Checking The Front Fork196

Reassembling The Front Fork197

Fitting The Front Fork200

Braking System Maintenance202

Removing The Front Brake System202

Removing The Brake Discs203

Overhauling The Front Brake Components203

Refitting The Front Brake System204

Removing The Rear Wheel207

Overhauling The Rear Wheel208

Overhauling The Rear Wheel Rim208

Refitting The Rear Wheel209

Rear Swingarm210

Removing The Rear Eccentric Hub212

Refitting The Rear Eccentric Hub213

Removing The Rear Swingarm214

Checking The Swingarm Pivot215

Overhauling The Rear Swingarm216

Refitting The Rear Swingarm218

Removing The Rear Brake System221

Rear Brake Caliper And Master Cylinder221

Rear Brake Disc222

Refitting The Rear Brake System223

Rear Suspension224

Rear Suspension Unit225

Removing The Monoshock Absorber226

Overhauling The Monoshock Absorber226

Removing The Rear Suspension Rocker Arm227

Overhauling The Rear Suspension Rocker Arm228

Removing And Overhauling The Shock Absorber Linkage229

Refitting The Rear Suspension230

Inspecting The Final Drive233

Removing The Chain Front Sprocket234

Changing The Gearbox Secondary Shaft Seal235

Removing The Rear Sprocket236

Washing The Chain237

Lubricating The Chain237

Removing The Handlebar242

Refitting The Handlebars243

Adjusting Steering Bearing Play245

Adjusting The Steering Angle245

Disassembling The Headstock Parts246

Reassembling The Headstock Parts247

Footpeg Supports250

Removing The Footpegs251

Refitting The Footpegs253

Removing The Side Stand257

Disassembling The Side Stand257

Inspecting The Side Stand257

Reassembling The Side Stand257

Refitting The Side Stand258

Frame Inspection259

Removing The Frame And Related Components260

Removing The Front Subframe260

Removing The Rear Grab Handle260

Checking The Frame260

Frame Size Diagram261

Front Subframe Size Diagram262

Refitting The Rear Grab Handle263

Refitting The Front Subframe263

Tail Light And Number Plate Holder264

Removing The Tail Light And Number Plate Holder265

Refitting The Tail Light And Number Plate Holder266

Accessories: Center Stand267

Installing The Center Stand268

Removing The Center Stand272

Refitting The Center Stand272

Fuel System / Exhaust System274

Description Of Fuel System275

Fuel Tank Assembly277

Removing And Refitting The Fuel Tank Assembly278

Replacing The Breather Valve And The Fluid Recovery Reservoir279

Replacing The Fuel Tank Flange And The Fuel Sensor281

Replacing The Fuel Filler Plug Assembly284

Routing Of The Breather And Drain Hoses Of The Fuel Tank285

Routing Of The Fuel Tubes286

Throttle Body287

Removing The Throttle Body288

Removing The Throttle Position Sensor288

Removing The Injectors288

Refitting The Injectors288

Removing The Stepper Motor289

Refitting The Stepper Motor289

Refitting The Throttle Body290

Stepper Motor Position291

Removing The Air Box293

Refitting The Airbox295

Routing Of The Airbox Drain Hose297

Exhaust System298

Catalytic Converter Operating Principle299

Precautions On The Catalytic Converter300

Removing The Exhaust System301

Removing The Silencer Assembly301

Removing The Exhaust Pipes And The Presilencer301

Refitting The Exhaust System304

Refitting The Exhaust Pipes And The Presilencers304

Refitting The Silencer Assembly306

Canister Filter308

Canister Filter System (Usa Versions Only)309

Removing The Canister Filter310

Routing Of Hoses, Clamps And Canister Filter Position311

Ignition - Injection System314

Description Of The Fuel Injection-Ignition System315

Importance Of The Air-Fuel Mixture And Of The Ignition Advance315

Marelli Injection-Ignition System (I.a.w.)316

Layout Diagram Of Sensors And Actuators Of The Fuel Injection/Ignition Systems317

Fuel Circuit318

Intake Air Circuit319

Ignition-Injection System Operating Stages320

Normal Operation320

Acceleration/Deceleration320

Fuel Injection-Ignition System Diagram321

Fuel Injection-Ignition System Components324

Electronic Control Unit324

Removing The Electronic Control Unit325

Refitting The Electronic Control Unit325

Electric Injector327

Stepper Motor328

Throttle Position Sensor329

Rpm/Timing Sensor329

Air Pressure Sensor329

Air Temperature Sensor330

Injection Relay333

Instrument Panel System335

Instrumentation Check335

Lcd336

Display Functions338

Clock Display - Time Indication - Clock Setting Functions338

Temperature Display Function Oil Temperature Indication338

Main Display Functions: Speed Indication339

Main Display Functions: Service Warning339

Main Display Functions: Beam Vertical Adjustment340

Electronic Injection / Ignition Diagnostics341

Main Display Functions: Setting Special343

Fuel Display Function: Fuel Level Indication345

Auxiliary Display Functions Scroll Display346

Average Speed Indication346

Instant Consumption Indication347

Average Fuel Consumption347

Fuel Used Indication347

Range Indication348

Digital Fuel Level Indication348

Instrument Panel Functions349

Auto-Off Headlights Operation349

How To Turn The Headlights Back On Again349

Automatic Operation Of Lcd And Rev Counter Backlighting - Automatic Setting Of Warning Lights Brightness350

Connector Pinout352

Removing-Reassembling The Complete Engine356

Removing The Engine358

Reassembling The Engine359

Lubrication System: Oil Pump360

Lubrication System Diagram361

Description Of The Lubrication System362

Lubrication System Operation362

Removing The Oil Pump364

Disassembling The Oil Pump364

Overhauling The Oil Pump365

Reassembling The Oil Pump365

Refitting The Oil Pump366

Lubrication System: Oil Cooler367

Removing The Oil Cooler368

Checking The Oil Cooler368

Refitting The Oil Cooler369

Oil Cooler Hoses Routing371

Lubrication System: Oil Breather372

Removing The Oil Breather373

Refitting The Oil Breather373

Oil Breather Hose Routing374

Head Unit: Checks And Adjustments375

Checking And Adjusting Valve Clearance376

Checking And Adjusting Opening Clearance (Sa)377

Checking And Adjusting Closing Clearance (Sc)378

Checking Valve Lift379

Checking Engine Timing380

Head Unit: Side Covers/Timing System382

Removing The Timing Side Covers383

Timing System Disassembly384

Disassembling The Mobile Tensioner386

Disassembling The Belt Rollers386

Reassembling The Timing System387

Reassembling The Timing Belt Rollers On Camshafts387

Reassembling Timing Belt Rollers On Layshaft388

Reassembling The Timing Belt Tensioners389

Refitting The Timing Side Covers393

Head Unit: Camshafts394

Removing The Engine Oil Temperature Sensor396

Refitting The Engine Oil Temperature Sensor396

Disassembling The Intake Manifold397

Refitting The Intake Manifolds397

Removing The Side Caps398

Removing The Valve Covers399

Refitting The Valve Covers399

Removing The Camshafts400

Checking Camshafts401

Checking The Oil Seals401

Refitting The Camshaft402

Refitting The Cam Covers403

Head Unit: Valves - Rocker Arms404

Disassembling The Engine Heads405

Removing The Head405

Removing The Valves406

Removing The Valve Rocker Arms408

Overhauling The Head Parts409

Overhauling The Valve410

Overhauling The Valve Seat410

Changing Valve Seats411

Valve-To-Valve Seat Clearance411

Overhauling The Valve Guide412

Valve-To-Valve Guide Clearance412

Changing Valve Guides412

Overhauling The Rocker Arms413

Rocker Arm Shaft-To-Rocker Clearance413

Inspecting The Rocker Arm Springs413

Reassembling The Head414

Reassembling The Rocker Arms415

Refitting The Valves418

Reassembling The Heads420

Cylinder/Piston Assembly421

Removing Cylinder / Piston Assy422

Overhauling The Cylinder424

Overhauling The Piston425

Piston-Cylinder Clearance425

Overhauling The Gudgeon Pins426

Overhauling The Piston Rings426

Piston Ring-Piston Groove Clearance426

Gudgeon Pin-Piston Clearance427

Piston Rings-Cylinder Clearance427

Refitting Cylinder / Piston Assy428

Clutch Assembly: Clutch430

A Clutch Which Does Not Disengage May Be Caused By432

A Clutch Which Slips May Be Caused By432

A Noisy Clutch May Be Caused By432

Disassembling The Clutch433

Checking And Overhauling The Clutch Components437

Clearance Between Clutch Housing And Drive Plate437

Overhauling The Clutch Plates437

Overhauling The Pressure Plate/Clutch Springs437

Reassembling The Clutch438

Clutch Assembly: Clutch Cover441

Removing The Clutch Cover442

Disassembling The Clutch Cover443

Reassembling The Clutch Cover444

Refitting The Clutch Cover445

Clutch Assembly: Primary Drive Gears446

Disassembling The Primary Drive Gears447

Fitting The Primary Drive Gear And Checking Meshing Play449

Gearbox: Lever Assembly451

Removing The Gear Selector Levers452

Removing The Gear Stopper And Ratchet453

Reassembling Gear Stopper And Ratchet453

Reassembling The Gear Selector Lever454

Gearbox Assembly: Gearbox Shafts455

Removing The Gearbox457

Disassembling The Gearbox Shafts458

Disassembling The Secondary Shaft458

Disassembling The Primary Shaft460

Overhauling The Gearbox462

Inspecting The Gear Selector Forks464

Inspecting The Fork Selector Drum464

Reassembling The Gearbox Shafts465

Reassembling The Gearbox466

Flywheel - Generator468

Removing The Generator Cover470

Disassembling The Generator Cover471

Removing The Flywheel - Generator Assembly472

Checking The Flywheel - Generator Assembly473

Disassembling The Flywheel - Generator Assembly473

Reassembling The Flywheel - Generator Assembly474

Refitting Flywheel / Generator Assembly475

Reassembling Generator Cover476

Checking The Engine Sensor Air Gap477

Casing Unit: Outer Components478

Removing Outer Components479

Reassembling The Outer Parts480

Removing The Timing Lay Gear482

Reassembling The Timing Lay Gear482

Removing The Starter Motor Driven Gear483

Reassembling The Starter Motor Driven Gear483

Casing Unit: Crankcase484

Opening The Casings485

Overhauling The Casings486

Main Bearings488

Reassembling The Clutch-Side Casing489

Reassembling The Generator-Side Casing490

Shimming The Shafts491

Shimming The Crankshaft491

Practical Shimming Procedure For The Crankshaft491

Shimming The Gearbox Shafts492

Shimming The Gearbox Drum493

Practical Shimming Procedure For The Selector Drum And Gearbox Shafts494

Checking Gearbox Position497

Closing The Casings499

Casing Unit: Connecting Rods501

Removing The Connecting Rods502

Disassembling The Connecting Rods502

Overhauling The Connecting Rods503

Changing The Connecting Rod Small End Bush503

Changing The Connecting Rod Big End Bearings504

Overhauling The Crankshaft505

Big End Bearings-Crank Pin Clearance506

Reassembling The Connecting Rods507

Refitting The Connecting Rod Unit508

Electric System510

Wiring Diagram512

Wire Color Coding - Wiring Diagram515

Key To Fuse Box515

Arrangement Of Wiring On Frame515

Diagrams Aa, Bb519

Diagrams Ac, Ad520

Diagrams K, L531

Diagrams M, N532

Diagrams O, P533

Charging System - Battery543

Checking The Charging System543

Charging Methods543

Normal Charge (With Constant Voltage)544

Charging The Battery Under Critical Conditions544

Battery - Safety Rules545

Removing The Battery546

Refitting The Battery546

Battery Mount547

Rectifier - Regulator549

Removing The Regulator549

Refitting The Regulator549

Regulator Fuse550

Electric Starting551

Electric Starting System552

Safety Devices Function Table553

Starter Motor554

Starter Contactor556

Lighting Devices557

Removing The Instrument Panel557

Changing Light Bulbs558

Changing The Headlight Bulbs558

Low Beam Bulb (Lo)558

High Beam Bulb (Hi)559

Parking Light Bulb (A)559

Refitting The Bulbs559

Replacing The Number Plate Light Bulbs560

High Beam Relay561

Beam Setting562

Indicators And Lighting System563

Checking The Indicators And Lighting System Components563

Checking The Left Switch563

Turn Indicator Switch564

Low And High Beam (Dimmer)564

Checking The Right Switch565

Engine Stop Button565

Starter Button565

Parking Light/Low Beam Switch565

Checking Front And Rear Stop Switches, Neutral Switch, Oil Pressure Switch And Clutch Switch566

Neutral Light566

Oil Pressure Sensor567

Clutch Switch567

Changing Bulbs568

Replacing The Front Turn Indicator Bulbs568

Replacing The Stop Light Bulbs568

Protection And Safety Devices569

Checking The Key-Operated Switch569

Checking The Side Stand Switch570

Immobilizer And Transponder572

Keys With Transponder572

Immobilizer Aerial573

Operating Principle Of The Immobilizer573

Immobilizer Warning Lights And Indicators574

Programming The Immobilizer575

Checking Immobilizer Programming577

Removing The Immobilizer578

Reassembling The Immobilizer578

Disassembling The Red Key With Transponder579

How To Use The Multimeter To Check Electric Systems580

How To Measure Voltage580

How To Measure Current581

How To Measure Resistance And Electric Continuity581

Multimeter Protections And Precautions582

Subject Index584

Indice Generale584

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