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Ducati 620 SPORT Owner's Manual

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DUCATI620Sport
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  • Page 1 Owner’s manual DUCATI620Sport...
  • Page 3 Ducati motorcycle for long whatsoever for any mistakes incurred in drawing up this journeys as well as short daily trips. Ducati Motor Holding manual. The information contained herein is valid at the S.p.A. wishes you smooth and enjoyable riding.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Rear brake pedal 24 Gear change pedal 24 Setting the gear change and rear brake pedals 25 Main components and devices Location 26 Tank filler plug 27 Seat catch and helmet hooks 28 General Side stand 29 Warranty 6 Shock absorber adjusters 30 Symbols 6...
  • Page 5 Charging the battery 50 Routine maintenance record Chain adjustment 51 Chain lubrication 52 Replacing bulbs 53 Beam setting 57 Tyre pressures 58 Checking engine oil level 60 Cleaning and replacing the spark plugs 61 Cleaning the motorcycle 62 Storing the bike away 63 Important notes 63 Technical data Overall dimensions 64...

  • Page 6: General

    Ducati Motor Holding S.p.A. advises you to read this booklet carefully so as to become familiar with your motorcycle. In case of any doubts, please call a Ducati Dealer or Authorised Workshop. The information contained herein will prove useful on your trips - and Ducati Motor Holding S.p.A.

  • Page 7: Useful Information For Safe Riding

    Useful information for safe riding Always signal your intention to turn or pull to the next lane in good time using the suitable turn indicators. Warning Be sure you are clearly visible and do not ride within the Read this section before riding your motorcycle. blind spot of vehicles ahead.

  • Page 8: Carrying The Maximum Load Allowed

    Carrying the maximum load allowed Your motorcycle is designed for long-distance riding, carrying the maximum load allowed in full safety. Even weight distribution is critical to preserving these safety features and avoiding trouble when performing sudden manoeuvres or riding on bumpy roads. Information about carrying capacity The total weight of the motorcycle in running order including rider, pillion passenger, luggage and additional...

  • Page 9: Identification Data

    Identification data All Ducati motorcycles have two identification numbers, for frame (fig. 1) and engine (fig. 2). Frame number Engine number Note These numbers identify the motorcycle model and should always be indicated when ordering spare parts. fig. 1 fig. 2...

  • Page 10: Controls

    CONTROLS Warning This section details the position and function of all the controls you need to drive your motorcycle. Be sure to read this information carefully before you use the controls. Position of motorcycle controls (fig. 3) 1) Instrument panel. 2) Key-operated ignition switch and steering lock.

  • Page 11: Instrument Panel

    7) Orange EOBD light Instrument panel (fig. 4) When on, engine operation is inhibited. It goes out after a 1) Blue light few seconds (usually 1.8 - 2 sec.). Comes on when high beam is on. 8) Speedometer (km/h). 2) Green light Gives road speed.
  • Page 12 LCD unit functions When the ignition key is turned to ON, the instrument panel carries out a Check of all instruments (pointers, display, lights) (see fig. 5 and 6). LCD (1) Turn the key to ON and press (B) (fig. 6) to display trip meter and odometer alternatively.
  • Page 13 Oil temperature When the oil temperature goes below 50 °C (122 °F), "LO" will be displayed. "HI" will be displayed when the temperature exceeds 170 °C (338 °F). Fuel light "FUEL" will be displayed when the fuel warning light comes on. Maintenance indicator After the first 1,000 Km/621 m and then every 10,000 Km/ 6210 m, "MAInt"...

  • Page 14: The Immobilizer System

    The immobilizer system The key A performs the same functions as the keys B, For improved anti-theft protection, the motorcycle is and is also used to wipe off and re-program other black equipped with an IMMOBILIZER, an electronic system keys, if needed. that inhibits engine operation whenever the ignition switch is turned off.

  • Page 15: Code Card

    A) (fig. 9) the electronic code to be used to be used in case of engine block, i.e. bike did not start after key-ON. B) (fig. 9) the part no. code for the keys to be reported to the DUCATI Service network when you are ordering any duplicate keys. Important Keep the CODE CARD in a safe place.

  • Page 16: Procedure To Disable Immobilizer Engine Block Through

    Procedure to disable immobilizer engine block Note through throttle twistgrip Should the throttle twistgrip be released before the 1) Turn the key to ON and fully open throttle. Keep it set time, the warning light turns on again. It is then open.

  • Page 17: Duplicate Keys

    Operation Duplicate keys When the ignition key is turned to OFF, the immobilizer If you need any duplicate keys, contact the DUCATI inhibits engine operation. Service network with all the keys you have left and your When the ignition key is turned back to ON to start the CODE CARD.

  • Page 18: Ignition Swich And Steering Lock

    Ignition switch and steering lock (fig. 10) It is located in front of the fuel tank and has four positions: A) ON: lights and engine on; B) OFF: lights and engine off; C) LOCK: steering locked; D) P: parking light and steering lock. Note To move the key to the last two positions, press it down before turning it.

  • Page 19: Left Switch

    Left switch (fig. 11) 1) Dip switch, light dip switch, two positions: position = low beam on; position = high beam on. 2) Switch = 3-position turn indicator: centre position = OFF; position = left turn; position = right turn. To reset turn indicators, turn switch to central position and push in.

  • Page 20: Clutch Lever

    Clutch lever (fig. 12) When you pull in the lever (1), you will disengage the engine from the gearbox and therefore from the driving wheel. Using the clutch properly is essential to smooth riding, especially when moving off. Important Using the clutch properly will avoid damage to transmission parts and spare the engine.

  • Page 21: Cold Start Lever

    Cold start lever (fig. 13) Use this device to start the engine from cold. It will increase the engine idling speed after starting. Lever positions: A) = closed B) = fully open. The lever can be opened and closed gradually to adjust speed until engine is fully warm (see pages 34-35).

  • Page 22: Right Switch

    Right switch (fig. 14) 1) Switch, light switch, three positions: right position = light off; centre position = front and rear parking lights, number plate and instrument panel lights on; left position = headlight, front and rear parking lights, number plate and instrument panel lights on. Note This device is not fitted on the Australia and Japan versions.

  • Page 23: Throttle Twistgrip

    Throttle twistgrip (fig. 15) The twistgrip (1) on the right handlebar opens the throttles. When released, it will spring back to the initial position (idling speed). fig. 15 Front brake lever (fig. 15) Pull in the lever (2) towards the twistgrip to operate the front brake.

  • Page 24: Rear Brake Pedal

    Rear brake pedal (fig. 16) Push down on the pedal (1) to apply the rear brake. The system is hydraulically operated. fig. 16 Gear change pedal (fig. 17) The gear change pedal is at rest when in the central position N, is moved up and down to change gears and then returns to the central position.

  • Page 25: Setting The Gear Change And Rear Brake Pedals

    Setting the gear change and rear brake pedals The gear change and rear brake pedals can be adjusted to suit the preferred riding position of each rider. To set the gear change pedal, lock linkage (1) and loosen the check nuts (2) and (3). Note Nut (2) has a left-hand thread.

  • Page 26: Main Components And Devices

    MAIN COMPONENTS AND DEVICES Location (fig. 20) 1) Tank filler plug. 2) Seat catch and helmet hooks. 3) Side stand. 4) Rear view mirrors. 5) Rear shock absorber adjusters. 6) Cataliser fig. 20...

  • Page 27: Tank Filler Plug

    Tank filler plug (fig. 21) Opening Lift the protection lid (1) and fit the ignition key into the lock. Turn the key clockwise 1/4 turn to unlock. Lift the OPEN plug. Closing Refit the plug with the key in it and push it down into its seat.

  • Page 28: Seat Catch And Helmet Hooks

    Seat catch and helmet hooks Opening (fig. 22) Fit the ignition key into the lock (1) and turn the key clockwise until the rear end of the seat lifts up. Pull the seat backward (3) to slide it off its front holders. At the front end of the compartment underneath the seat, there are the helmet hooks (2, fig.

  • Page 29: Side Stand

    Side stand (fig. 24) Note Check for proper operation of the stand mechanism Important (two springs, one into the other) and the safety sensor (2) Before lowering the side stand, make sure that the at regular intervals. bearing surface is hard and flat. Note Do not park on soft or pebbled ground or on asphalt melt It is possible to start the engine with side stand...

  • Page 30: Shock Absorber Adjusters

    Shock absorber adjusters Rear shock absorbers feature spring preload, rebound and compression adjustment. The adjuster (1, fig. 26) on the shock absorber expansion reservoir - LH side of the frame - controls compression damping. The adjuster (2, fig. 25) on the left of the connection holding the shock absorber to the swingarm controls rebound damping.

  • Page 31: Shock Absorber

    Shock absorber STANDARD setting: • Compression damping adjuster (1, fig. 27): 18 clicks. • Rebound damping adjuster (2, fig. 28): 8 clicks. STANDARD spring length: 177 mm fig. 27 fig. 28...

  • Page 32: Directions For Use

    DIRECTIONS FOR USE Up to 1000 km During the first 1000 km, keep an eye on the revolution meter. The indicator must not exceed: 5500-6000 rpm. During the first hours of riding, it is advisable to run the engine at varying load and rpm, though still within recommended limit.

  • Page 33: Pre-Ride Checks

    Brake and clutch fluid performed as recommended in the Warranty Card. Check fluid level in the relevant reservoirs. Failure to comply with these rules will release Ducati Tyre condition Motor Holding S.p.A. from any liability whatsoever for Check tyre pressure and condition (page 58).

  • Page 34: Starting The Engine

    Starting the engine 2) Move the cold start lever to the B position (fig. 32). 3) Check that the stop switch (1, fig. 31) is positioned to Note (RUN), then press the starter button (2). Follow the “High ambient temperature” procedure Let the engine start without using the throttle control.
  • Page 35 4) Move the cold start lever to the vertical position (A) to let engine idle at about 1400-1500 rpm. Important Do not rev up the engine when it is cold. Allow some time for oil to reach all points that need lubricating. 5) As the engine warms up, move the cold start lever gradually towards the vertical position (A).

  • Page 36: Moving Off

    Moving off Important 1) Disengage the clutch squeezing the control lever. Avoid harsh accelerations, as this may lead to 2) Push down on gear change lever sharply with the tip misfiring and transmission snatching. The clutch lever of your foot to engage the first gear. should not be pulled longer than necessary after gear is 3) Speed up engine, by turning the throttle twistgrip and engaged, or friction parts may overheat and wear out.

  • Page 37: Braking

    Stopping the motorcycle Braking If you let go of the throttle twistgrip, the motorcycle will Slow down in time, shift down to engine-brake first and slow down gradually and smoothly. Then, shift down then brake applying both brakes. Pull the clutch lever releasing the clutch, and finally change from first to before stopping the motorcycle, to avoid sudden engine neutral.

  • Page 38: Parking

    Parking Refuelling Stop the motorcycle, then put it on the side stand (see Never overfill the tank when refuelling. Fuel should never page 29). be touching the rim of filler recess (fig. 33). Turn the handlebar fully left and block it by pushing in the ignition key and turning it to the LOCK position.

  • Page 39: Tool Kit And Accessories

    Tool kit and accessories (fig. 34) Accommodated in the compartment under the seat is a bag (1) holding: an Owner’s manual; a helmet fastening cable; a tool kit for usual maintenance and checks stored in the top pocket. To access this compartment, lift the seat by opening the catch (page 28).

  • Page 40: Main Maintenance Operations

    MAIN MAINTENANCE OPERATIONS Removing the fairing Some servicing operations need the motorcycle fairing to be removed. Warning Firmly secure all removed parts when refitting fig. 36 them, otherwise some of them might suddenly come off when riding and you may loose control of your motorcycle.
  • Page 41 Half-faired version (fig. 38) Unscrew the screw (3) that holds each body panel to the lower support bracket. Disconnect the indicator connectors and remove the body panels. fig. 38 Fully-faired version (fig. 39) Unscrew the screw (4) that holds the left body panel to the side stand fixing plate.
  • Page 42 Headlamp fairing Unscrew the two nuts (1, fig. 40) that hold the rear view mirrors to the headlamp fairing and remove the rear view mirrors. Unscrew the three screws (2, fig. 41) that hold each body panel to the headlamp fairing. Move the body panels slightly apart and unscrew the four screws (3, fig.

  • Page 43: Lifting The Fuel Tank

    Lifting the fuel tank (fig. 43 and 44) Remove the seat (see page 28). Pull the clip (1, fig. 43) upwards to disengage it from the tank catch. Lift the tank and unhook the service rod (2, fig. 44) from its retainer (3).

  • Page 44: Changing The Air Filter

    Changing the air filter (fig. 45 and 46) Replace air filter at the required intervals shown in the routine maintenance chart (see Warranty Card). The air box is accessible after lifting the fuel tank. Undo the clips (1) of the cover on both sides of the air box, then remove cover (2).

  • Page 45: Checking Brake And Clutch Fluid Level

    Brake system If you find exceeding play on brake lever or pedal and brake pads are still in good condition, contact your Ducati Dealer or Authorised Workshop to have the system inspected and any air drained out of the circuit.
  • Page 46 If the control lever has exceeding play and the transmission snatches or jams as you try to engage a gear, it means that there is air in the circuit. Contact your Ducati Dealer or Authorised Workshop to have the system inspected and air drained out. Warning Brake fluid level will increase as clutch plate friction material wears down.

  • Page 47: Checking Brake Pads For Wear

    Rear brake The friction material on each pad should be at least 1 mm thick. Important Have the brake pads replaced at a Ducati Dealer or fig. 50 Authorised Workshop.

  • Page 48: Lubricating Joints

    Work the controls to make sure the cable slides smoothly inside the sheath: if you feel any friction or hard spots, have the cable replaced by your Ducati Dealer or Authorised Workshop. To prevent these failures, smear the ends of the Bowden cables with SHELL Advance Grease or Retinax LX2 at regular intervals.

  • Page 49: Throttle Cable Adjustment

    Throttle cable adjustment 1,5 ÷ 2 mm ➤ ➤ The throttle twistgrip must have a free play of 1.5 - 2 mm measured at the edge of the twistgrip, at all positions of the handlebars. If it needs adjusting, use the suitable adjuster (1, fig.

  • Page 50: Charging The Battery

    Charging the battery (fig. 54) Before charging the battery, it is best to remove it from the motorcycle. Always disconnect the black negative terminal (-) first, – and then the red positive terminal (+). Undo the straps (1) and remove the battery. Warning Batteries develop explosive gases: keep battery away from heat sources and flames.

  • Page 51: Chain Adjustment

    Chain adjustment Turn the rear wheel slowly until you find the position where chain tension is tightest. Put motorcycle on the side stand and push the chain up pressing with a finger at mid-length of swingarm. The lower stretch of chain must have a slack of 25-30 mm.

  • Page 52: Chain Lubrication

    Chain lubrication The chain fitted on your motorcycle has O-rings that keep dirt out of and lubricant inside the sliding parts. The seals might be irreparably damaged if the chain is cleaned using any solvent other than those specific for O-ring chains or washed using steam or water jets.

  • Page 53: Replacing Bulbs

    Replacing bulbs Before replacing a burnt-out bulb, make sure that the new bulb complies with voltage and wattage as specified on page 71, “Electric System”, for that lighting device. Always test the new lamp before refitting the parts you have removed. Headlamp To gain access to headlamp bulbs you will need to work behind the headlamp fairing.
  • Page 54 Reassembly Insert the locating pegs of the bulb base into their seats to obtain correct alignment. Hook the clip (2) to the headlamp holders; reconnect the connector (1) you have detached previously and refit the rubber cover. The parking light bulb is fitted on the top section of the headlamp body.
  • Page 55 Turn indicators (fig. 60) Remove the screw (1) and detach the glass (2) from the indicator body holder. The bulb has a bayonet-type fitting: press and rotate anti- clockwise to remove; fit the spare bulb by pressing and turning clockwise until it clicks. Refit the glass sliding the small tab (A) into the suitable slot in the indicator body and tighten the screw (1).
  • Page 56 Stop light To replace the stop and parking light bulb, unscrew the two screws (1, fig. 62) that secure the glass and remove glass. The bulb has a bayonet-type fitting: press and rotate anti-clockwise to remove; fit the spare bulb by pressing and turning clockwise until it clicks (fig.

  • Page 57: Beam Setting

    Beam setting (fig. 64) When checking beam setting, put the motorcycle upright. Tyres should be inflated at the correct pressure and one person should be sitting astride the motorcycle, keeping it at right angles to its longitudinal axis. Place the motorcycle opposite a wall or a screen, 10 meters apart from it, then draw a horizontal line dictated by headlamp centre and a vertical one in line with the longitudinal axis...

  • Page 58: Tyre Pressures

    The height of the light beam can be corrected using Tyre pressures the screw (1, fig. 65) on the left side of the headlamp. Front tyre: Turn the screw clockwise to lower the beam, 2.1-2.2 bar anticlockwise to raise it. Rear tyre: 2.1-2.3 bar The side position of the headlamp is adjusted using...
  • Page 59 After replacing a tyre, the wheel must be balanced. Important Do not remove or shift the wheel balancing weights. Note If tyres need replacing, contact a Ducati Dealer or Authorised Workshop to make sure wheels are removed and refitted correctly. fig. 66...

  • Page 60: Checking Engine Oil Level

    Undo the filler plug (2) and top up to correct level. Refit the plug. Important fig. 67 Engine oil and oil filters must be changed by a Ducati dealer or authorized workshop at regular intervals, as specified in the routine maintenance chart (see Warranty Card). Viscosity SAE 10W-40...

  • Page 61: Cleaning And Replacing The Spark Plugs

    Cleaning and replacing the spark plugs (fig. 68) Refit spark plug into cylinder head. Tighten until thread is Spark plugs are essential to smooth engine running and fully into the head. Tighten the spark plug to 20 Nm. should be checked at regular intervals. This is done quite If you do not have a torque wrench, you can use the easily and quickly and provides a good measure of engine wrench supplied with the tool kit to tighten the spark...

  • Page 62: Cleaning The Motorcycle

    Cleaning the motorcycle Warning To preserve the finish of metal parts and paintwork, wash Loss of braking may occur immediately after and clean your motorcycle at regular intervals, anyway washing the motorcycle. according to the road conditions you ride in. Use specific products only.

  • Page 63: Storing The Bike Away

    Battery should be checked and charged whenever the motorcycle has been left unridden for over a month; protect the motorcycle with a suitable canvas available from Ducati Performance. This will protect paintwork and let condensate breathe out.

  • Page 64: Technical Data

    TECHNICAL DATA Overall dimensions (mm) (fig. 69) Weights Dry weight: 182 Kg. Carrying full load: 385 Kg 1405 Warning 2030 Failure to observe weight limits could result in poor handling and impair the performance of your motorcycle, and you may lose control of the motorcycle.

  • Page 65: Top-Ups

    Top-ups Type of fluid cu dm (litres) Fuel tank, including a reserve Unleaded fuel of 4 cu dm (liters) 95 fuel octane rating (at least) Oil sump and oil filter SHELL Advance Ultra 4 Front/Rear brake and clutch circuits Special fluid for hydraulic systems SHELL-Advance Brake DOT 4 Protectant for electric contacts Spray for electric systems...

  • Page 66: Engine

    Timing system Engine Desmodromic (type) with two valves per cylinder, Twin cylinder, four-stroke, 90° “L” type, longitudinal. operated by four rockers (2 opening rockers and 2 closing Bore: rockers) and an overhead camshaft. It is operated by the 80 mm. crankshaft through spur gears, belt rollers and toothed Stroke: belts.

  • Page 67: Performance Data

    Performance data Rear brake Maximum speed in any gear should be reached only after With fixed drilled disc. a correct running-in period with the motorcycle properly Braking surface material: serviced at the recommended intervals. stainless steel. Max. speed (rider alone): Disc diameter: 195 Kph.

  • Page 68: Transmission

    If you wish to tune up your motorcycle for competitive Gearbox with constant mesh gears, gear change pedal trials, you may refer to Ducati Motor Holding S.p.A. who on left side of motorcycle. will be glad to provide information about the special Front/rear sprocket ratio: ratios available.

  • Page 69: Frame

    Frame Tyres Tubular trestle frame with upper section made of high- strength steel. Front tyre Steering angle (on each side): Tubeless, radial tyre. 28° Size: Headstock angle: 120/70-ZR17. 24° Trail: Rear tyre 96 mm. Tubeless, radial tyre. Size: 160/60-ZR17. Wheels Spark plugs Three-spoke, light-alloy rims.

  • Page 70: Suspensions

    Suspensions Available colors Front Ducati matt black 248.514 (PPG) Hydraulic upside-down fork. Metal color rims and frame. Stanchion diameter: Silver *0022 (PPG) 43 mm. Black rims and frame. Travel along leg axis: 120 mm. Rear The rear shock absorber enables the adjustment of rebound and compression damping and spring preload.

  • Page 71: Electric System

    Electric system Fuses Basic electric items are: The main fuse box is located on the left side of the Headlamp with double filament 12V-55/60 W iodine battery (fig. 71). bulb. To expose the fuses, take off the box protective cover 12V-5W parking light.
  • Page 72 Injection /electric system diagram key 1) RH switch. 2) Transponder Aerial. 3) Key-operated switch. 4) Main relay. 5) Fuse box. 6) Horn. 7) Starter motor. 8) Starter contactor. 9) Battery. 10) Regulator fuse. 11) Regulator. 12) Generator. 13) RH rear turn indicator. fig.
  • Page 73 31) Timing/rpm sensor. Wiring Colour Coding 32) Oil temperature sensor (control unit). B Blue 33) 5.9 M E.C.U. W White 34) Neutral switch. V Violet 35) Oil pressure switch. Bk Black 36) Front stop light switch. Y Yellow 37) Clutch switch. R Red 38) Oil temperature sensor (instrument panel).
  • Page 74 Fuse box key (4) Pos. El. item Val. Main 30 A 2-10 Parking light, HIGH/LOW beam, 15 A speed sensor and solenoid starter 3-11 4-12 Stop, horn, passing and key on 15 A 5-13 Instrument panel 6-14 Injection (injector pump, coil) 20 A Note The system wiring diagram is at the end of this...

  • Page 75: For United States Of America Version Only

    Such use could lead to upset or other accident. Noise emission warranty Ducati Motor S.p.A. warrants that this exhaust system, at Reporting of safety defects the time of sale, meets all applicable U.S. EPA Federal If you believe that your vehicle has a defect which could noise standards.
  • Page 76 Tampering with Noise Control System Prohibited. Federal If you are aware of any of the following symptoms, have Law prohibits the following acts or causing thereof: the vehicle inspected and repaired by your local Ducati (1) the removal or rendering inoperative by any person, dealer.
  • Page 77 Riding safety When the roadway is wet, rely more on the throttle to The points given below are applicable for every day control vehicle speed and less on the front and rear motorcycle use and shoud be carefully observed for safe brakes.
  • Page 78 Do not inhale exhaust gases and never run the Vehicle identification number (VIN); engine in a closed garage or confined area. Every Ducati motorcycle is identified by two identification Use only Ducati approved parts and accessories. numbers (see page 9). Figure A specifically shows the This motorcycle was not intended to be equipped with a frame identification numbers.
  • Page 79 Label location (fig. B) 7• 9• 8• G only for California fig. B...
  • Page 80 APPLICABLE TO 1998 MODEL YEAR NEW MOTORCYCLES. NITROGEN GAS. OTHER GASES EVAP FAMILY : MAY CAUSE EXPLOSION. DO NOT INCINERATE. REFER TO OWNER'S TO HORIZONTAL MANIFOLD MANUAL FOR REGULATING GAS. Via A.C.Ducati,3 40132 BOLOGNA ITALY TO VERTICAL MANIFOLD WARM AIR INLET...
  • Page 81 Ducati limited warranty on emission control This system consists of (fig. C): system 1) Warn air inlet; Ducati North America, Inc., 237 West Parkway, Pompton 2) Canister; Plains, New Jersey 07444-1028 warrants that each new 3) Dell’Orto jet; 1998 and later Ducati motorcycle, that includes as 4) Intake manifolds;...
  • Page 82 30 days. Any replacement part can defects in material or workmanship by an authorized be used in an emergency repair. Ducati will reimburse the Ducati motorcycle dealer at its place of business during owner for the expenses, including diagnosis, not to customary business hours.
  • Page 83 Ducati maintenance or repairs. However, Ducati is not liable for dealer. Ducati shall not be liable for any other expenses, these parts. The owner is responsible for the loss or damage, whether direct, incidental, consequential performance of all required maintenance.
  • Page 84 ROUTINE MAINTENANCE RECORD Ducati Mileage Date Service Name 1000 10000 20000 30000 40000 50000...

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