Ducati 1098 2007 User manual

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Draft copy
0
General 0
Information about the model 0
Technical data 0
Use and maintenance 0
Fairings 0
Controls - Devices 0
Wheels - Suspension - Brakes 0
Frame 0
Fuel / Exhaust System 0
Injection - ignition system 0
Engine 0
Electric system 0
GENERAL SUMMARY 0
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21098/1098S - M.Y. 2007 - edition 00
General summary
Section A
General 0
1 - How to use this manual 3
Layout of the manual 4
2 - Symbols - Abbreviations - References 5
Product specifications 6
3 - Hazardous Products - Warnings 8
General safety rules 8
General maintenance indications 10
Section B
Information about the model 0
1 - Identification data 3
Identification data for the Superbike 1098 3
Section C
Technical data 0
1.1 - Technical specifications 3
General 3
Colours 4
Transmission 4
Timing system/valves 5
Crankshaft 5
Cylinder/Piston 5
Gearbox 6
Cooling system 6
Front wheel 6
Front suspension (1098) 6
Front suspension (1098S) 7
Rear wheel 7
Rear suspension (1098) 7
Rear suspension (1098S) 7
Hydraulic brakes 8
Charging system/alternator 8
Injection - ignition system 8
Fuel system 8
Lights/instrument panel 9
1.2 - Dimensions 10
2 - Fuel, lubricants and other fluids 11
3 - Torque settings 12
Frame torque settings 12
Engine torque settings 13
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General summary
4 - Service tools 16
Special tools for the engine 16
Special tools for the frame 22
Section D
Use and maintenance 0
1 - Preliminary checks 3
Running-in precautions 3
Pre-ride checks 4
2 - Starting - Engine warmup 5
Starting the engine 5
3 - Routine maintenance table 6
Programmed maintenance plan: operations to be carried out by the dealer 6
Programmed maintenance plan: operations to be carried out by the dealer 8
4 - Maintenance operations 9
Checking the engine oil level 9
Changing the engine oil and filter cartridge 10
Checking valve clearances 13
Adjusting the valve clearances 14
Checking the coolant level 15
Change the coolant 16
Changing and cleaning the air filters 17
Changing the brake fluid 19
Draining the braking circuit 22
Fill the brake system with fluid 24
Changing the clutch fluid 27
Draining the clutch hydraulic circuit 28
Filling the clutch circuit 30
Adjusting the steering head bearings 32
Adjusting the chain tension 33
Checking brake pad wear and changing brake pads 35
Adjusting the throttle cable 38
Adjusting the clutch lever and front brake lever 40
Adjusting the position of the gearchange and rear brake pedals 41
Adjusting the front fork 42
Adjusting the rear shock absorber 43
Adjusting the rear ride height 45
5 - Diagnostic instruments 47
Description of the Ducati Diagnostic System instrument 48
Tester power supply 50
DDS tester 53
Checking and adjusting timing belt tension 54
Resetting the throttle position sensor (TPS) 58
Adjusting the idle speed 62
Checking the engine oil pressure 66
Cylinder compression test 71
Fuel pressure test 74
Immobilizer override procedure 77
Guided diagnosis 81
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Testing the battery charging system 84
Deactivating the “maintenance” indication on the instrument panel 87
Icons table 90
Section E
Fairings 0
1 - Headlight shell - rear-view mirrors 3
Removal of the rear-view mirrors 4
Refitting the rear-view mirrors 5
Removal of the headlight shell 6
Refitting the headlight shell 8
2 - Fairing panels 11
Removal of the side fairings 12
Removal of the front shield 14
Refitting the front shield 14
Refitting the side fairings 15
3 - Seat - seat cowling and side panels 17
Removal of the seat 18
Removal of the side panels and seat cowling 19
Refitting the side panels and seat cowling 22
Refitting the seats 26
Refitting the pillion seat 27
4 - Front mudguard 28
Removal of the front mudguard 28
Refitting the front mudguard 29
Section F
Controls - Devices 0
1 - Throttle and choke controls 3
Adjusting the throttle cable 4
Removal of the throttle cable 4
Refitting the throttle twistgrip 5
2 - Hydraulic clutch control 7
Removal of the clutch master cylinder assembly 8
Refitting the clutch master cylinder assembly 9
Removal of the clutch slave cylinder 11
Refitting the clutch slave cylinder 13
3 - Front brake control 16
Removal of the front brake master cylinder 17
Refitting the front brake master cylinder 18
4 - Rear brake control 19
Removal of the complete rear brake control 20
Disassembly of the rear brake master control 21
Refitting the rear brake control 22
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General summary
5 - Gearchange control 23
Removal of the complete gearchange control 24
Disassembly of the gearchange control 25
Refitting the gearchange control 26
Section G
Wheels - Suspension - Brakes 0
1 - Front wheel 3
Removal of the front wheel 4
Overhauling the front wheel 6
Refitting the front wheel 9
2 - Front fork (1098) 11
Removal of the front forks 12
Overhauling the front forks 13
Refitting the front forks 20
3 - Hydraulic front brake 22
Maintenance operations 23
Removal of the front brake system 24
Refitting the brake discs 26
Overhauling the front brake components 27
Refitting the front brake system 28
4 - Rear wheel 30
Removal of the rear wheel 31
Overhauling the rear wheel 32
Refitting the rear wheel 33
5 - Rear swingarm 34
Removal of the rear eccentric hub 35
Removal of the rear eccentric hub 37
Removal of the swingarm 39
Inspecting the swingarm pivot shaft 41
Overhauling the rear swingarm 42
Refitting the swingarm 46
6 - Hydraulic rear brake 48
Removal of the rear brake caliper 49
Removal of the rear brake disc 50
Refitting the rear brake caliper 51
7 - Rear suspension 52
Rear suspension system 53
Removal of the rear shock absorber 54
Overhauling the rear shock absorber 55
Removal of the rear suspension rocker arm 56
Overhauling the rear suspension rocker arm 57
Disassembly and overhaul of the shock absorber tie-rod 58
Refitting the rear suspension 59
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8 - Final drive 61
Inspecting the final drive 62
Removal of the front sprocket 63
Refitting the front sprocket 65
Renewal of the rear sprocket 67
Refitting the rear sprocket 68
Washing the chain 69
Lubricating the chain 69
Section H
Frame 0
1 - Handlebars 3
Removal of the handlebars 4
Refitting the handlebars 5
2 - Steering 6
Adjusting the steering head bearings 7
Steering angle adjustment 8
Removal of the steering head components 9
Refitting the steering head components 11
3 - Steering damper (1098) 14
Removal of the steering damper 15
Refitting the steering damper 16
4 - Footrest brackets 17
Removal of the footrests 18
Refitting the footrests 19
5 - Stands 20
Removal of the sidestand. 21
Refitting the sidestand 23
6 - Frame inspection 24
Disassembly of structural components and the frame 25
Checking the frame 29
Reassembly of structural components and the frame 31
7 - Number plate holder 33
Removal of the number plate holder 34
Section L
Fuel / Exhaust System 0
2 - Fuel tank 3
Removal of the fuel tank 4
Removal of the fuel filler cap assembly 6
Refitting the fuel filler cap assembly 7
Renewal of the fuel tank flange 8
Refitting the fuel tank flange 9
Refitting the fuel tank 10
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6 - Airbox - Throttle Body 14
Removal of the throttle body 15
Refitting the airbox and throttle body 23
7 - Air intake 29
Removal of the air filters 30
Refitting the air filters 31
8 - Exhaust system 32
Removal of the exhaust system 33
Refitting the exhaust system 37
Section M
Injection - ignition system 0
2 - Fuel injection-ignition system 3
3 - System components 4
Electronic Control Unit (ECU) 4
Removal of the battery support 6
Refitting the battery support 9
Electric injector 14
Air pressure sensor 15
Coolant temperature sensor 16
Air temperature sensor 17
Ignition coils 18
Throttle Position Sensor (TPS) 21
Rpm/timing sensor 22
Injection relay 23
CAN Line 24
Section N
Engine 0
1 - Removal–refitting of the engine assembly 5
Removal of the engine 6
Refitting the engine 9
2.1 - Lubrication system: oil pump 10
Removal of the oil pump 11
Disassembly of the oil pump 12
Reassembly of the oil pump 13
Refitting the oil pump 14
2.2 - Lubrication system: oil cooler 15
Removal of the lubrication system 16
Oil cooler inspection 18
Refitting the lubrication system 18
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3.2 - Cooling system: radiator 20
Removal of the radiator 21
Renewal of the cooling fan 23
Refitting the radiator 24
Removal of the cooling system hoses and unions 26
Refitting the cooling system hoses and unions 29
3.3 - Cooling system: water pump 32
Removal of the water pump 33
Refitting the water pump 36
4.1 - Cylinder head assemblies: checks and adjustments 41
Checking and adjusting the valve clearances 42
Checking valve lift 44
Checking the engine timing 46
4.2 - Cylinder head assemblies: timing 49
Removal of the timing belt covers 50
Removal of the tensioner pulley/timing belt 51
Removal of the camshaft pulleys/idler pulley 51
Removal of the tensioner and idler pulley mounting studs 52
Disassembly of the camshaft pulleys 53
Removal of the timing belt driveshaft pulleys 54
Refitting the timing belt driveshaft pulleys 56
Refitting the idler and tensioner pulley mounting studs 58
Reassembly of the timing pulleys 59
Refitting the camshaft pulley/idler pulley 60
Refitting the timing belts 63
Refitting the timing covers 65
4.4 - Cylinder head assemblies: camshafts 66
Removal of the camshafts 67
Checking the camshafts and supports 69
Refitting the camshafts 70
Removal of the intake manifold and coolant union 76
Refitting the intake manifold and coolant union 77
4.5 - Cylinder head assemblies: valves–rocker arms 78
Removal of the cylinder heads 79
Removal of the valves 80
Removal of the valve rocker arms 81
Overhaul of cylinder head components 84
Reassembly of the cylinder head 91
Fitting the cylinder head assemblies 98
5 - Cylinder/piston assemblies 100
Disassembly of the cylinder/piston 101
Overhaul of the cylinder barrel/piston components 104
Refitting the cylinder/piston assembly 109
6.1 - Clutch assembly: clutch 113
Description 114
Disassembly of the clutch 115
Inspection and overhaul of the clutch components 120
Reassembly of the clutch 122
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6.2 - Clutch assembly: right-hand side crankcase cover 126
Removal of the right-hand side crankcase cover 127
Disassembly of the right-hand side crankcase cover 128
Reassembly of the right-hand crankcase cover 129
Refitting the right-hand side crankcase cover 131
6.3 - Clutch assembly: primary drive gears 133
Removal of the primary drive gears 134
Refitting the primary drive gears and checking backlash 137
7.1 - Gearbox assembly: gearchange mechanism 140
Removal of the gearchange mechanism 141
Disassembly of gear interlock plunger and pawl assembly 143
Refitting the gear interlock plunger and pawl assembly 144
Refitting the gearchange mechanism 145
7.2 - Gearbox assembly: gearbox shafts 147
Removal of the gearbox assembly 148
Disassembly of the gearbox shafts 150
Overhaul of the gearbox 155
Inspection of the gear selector forks 156
Inspection of the gear selector drum 157
Reassembly of the gearbox shafts 158
Reassembly of the gearbox 162
8 - Flywheel/alternator 163
Removal of the left-hand side crankcase cover 164
Disassembly of the left-hand crankcase cover 166
Removal of the flywheel/alternator assembly 167
Overhaul of the flywheel/alternator assembly 169
Refitting the flywheel/alternator assembly 177
Refitting the left-hand crankcase cover 179
9.1 - Crankcase assembly: external components 182
Removal of external components 183
Refitting the external components 186
Removal of the timing gears 190
Refitting the timing gears 191
Removal of the starter motor idler gear 192
Refitting the starter motor idler gear 193
Checking the engine sensor air gap 194
9.2 - Crankcase assembly: crankcase halves 195
Separation of the crankcase halves 196
Overhaul of the crankcase halves 199
Main bearings 203
Reassembly of the crankcase halves 204
Shimming the shafts 207
Reassembly of the crankcase halves 212
9.3 - Crankcase assembly: connecting rods 218
Removal of the connecting rods assembly 219
Disassembly of the connecting rods 220
Overhaul of the connecting rods 221
Reassembly of the connecting rods 226
Refitting the connecting rods. 228
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10 1098/1098S - M.Y. 2007 - edition 00
General summary
Section P
Electric system 0
1 - Wiring diagram 4
Key to wiring diagram 5
Wiring colour codes 6
Key to fusebox 6
Routing of wiring on frame 7
Plate 1 9
Plate 2 9
Plate 3 10
Plate 4 10
Plate 5 11
Plate 6 11
Plate 7 12
Plate 8 13
Plate 9 14
Plate 10 14
Plate 11 15
Plate 12 15
Plate 13 16
Plate 14 17
Plate 15 18
Plate 16 19
Plate 17 20
Plate 18 21
Plate 19 22
Plate 20 23
Plate 21 24
Plate 22 24
Plate 23 25
Plate 24 26
Plate 25 27
Plate 26 28
Plate 27 29
Plate 28 30
Plate 28 31
Plate 29 32
Plate 30 33
Plate 31 34
Plate 32 35
Plate 33 36
Plate 34 37
Plate 35 38
2 - Battery charging system 39
Checking the battery charging system 39
Recharging the battery 40
Topping up the electrolyte 41
Battery 44
Alternator 46
Regulator/rectifier 49
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General summary
3 - Electric starting system 52
Electric starting system 52
Starter motor 53
Starter contactor 56
4 - Lights and indicating devices 59
Changing light bulbs 59
High beam headlights relay 62
Headlight aim 64
5 - Indicating devices 65
Checking the indicating system components 65
Coolant temperature sensor 72
Fan relay 73
Checking operation of the fan relay 73
Changing light bulbs 74
6 - Protection and safety devices 78
Checking protection and safety device components 78
Checking the fuses 80
7 - Instruments 81
Instrument panel 81
Instrument panel system 82
Display settings and functions 84
8 - Immobilizer and transponder 102
9 - Diagnostic instruments 110
Using a multimeter to check the electrical systems 110
10 - USB Data Acquisition (DAQ) (for 1098S only) 112
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21098/1098S - M.Y. 2007 - edition 00
General
1 - How to use this manual 3
Layout of the manual 4
2 - Symbols - Abbreviations - References 5
Product specifications 6
3 - Hazardous Products - Warnings 8
General safety rules 8
General maintenance indications 10
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31098/1098S - M.Y. 2007 - edition 00
General
1 - How to use this manual
This manual has been prepared for technical personnel at Ducati Authorized Service Centres with aim of providing fundamental
information on how to work in accordance with the modern concepts of “best practice” and “safety in the workplace” during
the maintenance, repair or replacement of original components of the cycle parts and engine of this motorcycle.
All operations described in this manual must be carried out by experienced, skilled technicians, who are required to follow the
Manufacturer's instructions in full.
Some information has been intentionally omitted, since we consider that specialized technical personnel should have a basic
technical background. Additional information on how to install various components is provided in the spare parts catalogue.
Important
This manual also describes the essential checks to be carried out prior to delivery of the motorcycle.
Ducati Motor Holding S.p.A. declines all liability for any technical errors or omissions in this manual and reserves the right to make
changes made necessary by the technical evolution of its products without prior notice.
The information contained herein was correct at the time of going to press.
Important
Reproduction or disclosure of all or part of the contents of this manual is strictly forbidden. All rights on this manual are reserved
for Ducati Motor Holding S.p.A. Applications for authorization for reproduction must be submitted in writing and must specify the
reasons for such reproduction.
Ducati Motor Holding S.p.A
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General
Layout of the manual
This manual is divided into sections (1), each identified by a letter.
Each section (1) includes several chapters (2), which are numbered consecutively.
The chapters (2) may be further subdivided into paragraphs (3).
The manual describes all repair operations starting from the fully assembled motorcycle.
The full procedure is described up to the point in which the motorcycle is restored to its fully assembled starting condition.
Important
Some of the sections of this manual are not included, since the motorcycle in question is not equipped with the relevant parts.
Important
The layout of the manual is designed in such a way as to be applicable to all the different models manufactured by DUCATI
MOTOR HOLDING.
To facilitate reading of the manual, the table of contents of the chapters is identical for all motorcycle models.
1
2
3
2
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General
2 - Symbols - Abbreviations - References
To allow quick and easy consultation, this manual uses graphic symbols to highlight situations in which maximum care is required,
as well as practical advice or information. Pay attention to the meaning of the symbols since they serve to avoid repeating
technical concepts or safety warnings throughout the text. The symbols should therefore be seen as an aid to memory.
Please refer to this page whenever in doubt as to their meaning.
The terms right-hand (RH) and left-hand (LH) are used with reference to the motorcycle's direction of forward travel.
Warning
Failure to comply with these instructions may put you at risk, and could lead to severe injury or even death.
Important
Failure to follow the instructions in text marked with this symbol can lead to serious damage to the motorcycle and its
components.
Notes
This symbol indicates additional useful information for the current operation.
Text references
(X)
References in bold type indicate a part that is not illustrated in the figures next to the text, but which can be found in the exploded
views at the beginning of each chapter.
(X)
References in non-bold type indicate a part that is illustrated in the figures alongside the text.
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General
Product specifications
Symbols in the diagram show the type of threadlocker, sealant or lubricant to be used at the points indicated. The table below
shows the symbols used and the specifications of the various products.
Symbol Specifications Recommended product
Engine oil (for specifications, see Sect. C 2, Fuel,
lubricants and other fluids).
SHELL
Advance Ultra 4
DOT 4 special hydraulic brake fluid. SHELL
Advance Brake DOT 4
SAE 80-90 gear oil or special products for chains with
O-rings.
SHELL
Advance Chain or Advance Teflon Chain
Anti-freeze (nitride, amine and phosphate free) 30 to 40%
solution in water.
SHELL
Advance coolant or Glycoshell
GREASE A Multipurpose, medium fibre, lithium grease. SHELL Alvania R3
GREASE B Molybdenum disulphide grease, high mechanical stress
and high temperature resistant.
SHELL
Retinax HDX2
GREASE C Bearing/joint grease for parts subject to prolonged
mechanical stress. Temperature range: -10 to 110 °C.
SHELL
Retinax LX2
GREASE D Protective grease, with anti-corrosive and waterproofing
properties.
SHELL
Retinax HD2
GREASE E PANKL grease - PLB 05.
GREASE F OPTIMOL grease - PASTE WHITE T.
LOCK 1 Low-strength threadlocker. Loctite 222
LOCK 2 Medium-strength threadlocker, compatible with oil. Loctite 243
LOCK 3 High-strength threadlocker for threaded parts. Loctite 270
LOCK 4 Flange sealant resistant to high mechanical stress and
solvents. Resists high temperatures (up to 200 °C) and
pressures up to 350 Atm; fills gaps up to 0.4 mm.
Loctite 510
LOCK 5 Permanent adhesive for smooth or threaded cylindrical
fasteners on mechanical parts. High resistance to
mechanical stress and solvents. Temperature range:
-55 to 175 °C.
Loctite 128455
LOCK 6 Pipe sealant for pipes and medium to large fasteners.
For water and gases (except oxygen). Maximum filling
capacity: 0.40 mm diameter clearance.
Loctite 577
LOCK 7 Speed bonder for rubber and plastics with elastomer
charged ethylic base.
Loctite 480
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LOCK
2
LOCK
3
LOCK
4
LOCK
5
LOCK
6
LOCK
7
LOCK
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General
LOCK 8 High-strength retaining compound for threaded parts,
bearings, bushes, splines and keys. Temperature range:
-55 to 150 °C.
Loctite 601
LOCK 9 Medium-strength threadlocker. Loctite 401
LOCK 10 Product for metal parts to seal and lock cylindrical freely
sliding or threaded couplings. Resistant to high
mechanical stress and high temperature, excellent
resistance to solvents and chemical attack.
Loctite 128443
LOCK 11 Instant adhesive gel offering tensile/shear strength. Loctite 454 gel
DUCATI liquid gasket. 942470014
Exhaust pipe paste. Self-sealing paste, hardens when
heated; resists temperatures exceeding 1000 °C.
Holts Firegum
Spray used to protect electrical systems.
Eliminates moisture and condensation and provides
excellent corrosion resistance. Water repellent.
SHELL
Advance Contact Cleaner
Dry lubricant, polymerizing on contact with air Molycote D321R
Molycote M55 Plus
Symbol Specifications Recommended product
8
LOCK
LOCK
9
LOCK
10
LOCK
11
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81098/1098S - M.Y. 2007 - edition 00
Generalità
3 - Hazardous Products - Warnings
General safety rules
Carbon monoxide
When a maintenance operation must be performed with the engine running, maker sure that the working area is well-ventilated.
Never run the engine in an enclosed space.
Warning
Exhaust fumes contain carbon monoxide, which is a poisonous gas that can cause unconsciousness or even death if inhaled.
Run the engine outdoors or, if working indoors, use an exhaust fume extraction system.
Fuel
Always make sure the working area is well ventilated. Keep any sources of ignition, such as cigarettes, open flames or sparks,
well away from the area in which fuel is stored.
Warning
Petrol is highly flammable and can explode under certain conditions. Keep away from children.
Hot parts
Warning
The engine and exhaust parts become hot when the motorcycle engine is running and will stay hot for some time after the engine
has been stopped. Wear heat-resistant gloves before handling these components or allow the engine and exhaust system to cool
down before proceeding.
Warning
The exhaust system might be hot, even after engine is switched off; take special care not to touch exhaust system with any part
of your body and do not park the motorcycle next to inflammable material (wood, leaves, etc.).
Used engine oil
Warning
Prolonged or repeated contact with used engine oil may cause skin cancer. If working with engine oil on a daily basis, make it a
rule to wash your hands thoroughly with soap immediately afterwards. Keep away from children.
Brake pad dust
Never clean the brake assemblies using compressed air or a dry brush.
Warning
Inhalation of asbestos fibres is a proven cause of respiratory illness and cancer.
Brake fluid
Warning
Avoid spilling brake fluid onto plastic, rubber or painted parts of the motorcycle to avoid the risk of damage. Protect these parts
with a clean shop cloth before proceeding to service the motorcycle. Keep away from children.
Coolant
Engine coolant contains ethylene glycol, which may ignite under particular conditions, producing invisible flames. Although the
flames from burning ethylene glycol are not visible, they are still capable of causing severe burns.
Warning
Take care not to spill engine coolant on the exhaust system or engine parts. These parts may be hot and ignite the coolant, which
will subsequently burn with invisible flames.
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