Ducati 900SS Instruction manual

..
I
900 s.s. 750 s. s.
Manuale d' officina
Workshop Manual
Manuel d'Atelier
Werkstatthandbuch
Manual de taller

..,..
...
Foreword
T~is publication intended for DUCAT/ Workshops has been prepared for the purpose of
helping the auth or izedpersonnel in the maintenance and repair works of the motorcycl es
her ewith discussed. A perfectknowledge of th e technicaldata contained herein is essent ial
for a more complete professional training of the mechanic.
The paragraphs have been completed with schematic illustrations pointing out the sub; ect
con cerned, in order to enable a m ore immediate und ersta nding .
This manual contains information-remarks of particular meaning:
Accident prevention rules for the operator and for the personnel working near
by.
Possibility of damaging the vehicle and/ or its components.
Additional information concerning the operation under execution.
Useful suggestions
Ducati Meccanica suggests, in order to prevent troubles and in order to have an excellent
final result, to generally comply with the following instructions:
- in case of repair, weigh the im pressions of the Cust ome r, who complains about the
improper operation of the motorcycle, and formulate prop er clearing questions about
the symptoms of the trouble.
-detect clearly the cause of the trouble. This manual gives the th eoretical bases, whi ch
however mu st be integrated by th e personal experience and by the attendance to
training courses periodically organized by DUCAT/ .
- rationally plan the repair work, in order to pr event dead time as for instance
pr ocu rement of spare par ts, tool prep arati on, etc.
-reach the component to be repaired and perform only the required operations.
In this connection, it will be useful to consult the disassembly sequence shown in this
manua l.
General instructions for repair works
1 Always replace gasket s, seal rings and split pins with new components.
2 When loosening or tightening nuts or bolt s, always start from th e bi gger ones or from
the center. Lock at the prescribed torque wrench selling following a crossed run .
3 Alwaysmarkthecomponentsorpositionswhichcould beexchangedwhen reass embling.
4 Us e original DUCAT/ spare paris and th e lubricants of t he recommended brands.
5 Use spe cial tools/ where specified.
6 Consu lt the Se rvice Bulletins as they may contain up-to-dated adjustment data and
repair meth
odolo gie s.
;
3

Summary
Section
General......................... ...... ....... .. .. . A
Maintenance .................................... 8
Troubles and remedies ........................ C
Settings and adjus tm en ts ..................... D
General operatio ns ............................ E
Engine disassembly ............................ F
Engine overhaul .. ... ...................... ...... G
Engine reassembly ............................. H
Suspensions and wheels...................... I
Brakes .............. .... .................. . .. ...... L
Electri c sys tem ................ ,.................. M
Hydraulic cont rol clutch release ............ N
Carburetor........... .. .................... ....... 0
From e ........ .. . ......... .. ..... ........... ........ Q
Specific tools .................................... W
Torque wrench settings................ . ....... X
Analytical index ............. .. ............. ..... Z

GENERAUTA
GENERAL
NOTES GENERALES
ALLGEMEINE$
GENERALIDADES
Sezione A
Sec t ion
Sec tion
Se k ti on
Secc i6n

GENERALITA
GENERAL
==================================~
Motore ···· ··· ··· ······· ··········· ····--------··--·--··--····--- A.4
Dis tr ibuzio ne -·· · -- --···-·····--·--·--·--········- -· ······--· ·· A.4
Alimentoz io ne ···-·· ·· ·· ·············- -· -······· ····· ·········- A.4
Lubrificazione .... ..... . .. .... __ .._.... __ .................. _... A.4
Raffr e dd amento ...._............._. ..... .... ...... ....... .. _.. A. 5
Accensione ..._ ..... ...... ........ ...... .........._ .. ..... ___ __ · A.5
Trasmissione ..... ... .... .. ...... ..... ................. ......... A.5
Freni ......... .. ... ...... ......... ..... ...... ............ .... .... A.5
Teloio .......... ................ . .... ..... ....... A.5
Sospensioni . .. ............ ...... ..... ................. ... ...... A. 5
Ru ote . ...... ...... .. .......... .. .... ..... ....... ......... . .... ... A .5
Pneumotici ....... ........... ........ .......... .. ...... A.5
lmpianro elettrico .. ....................... ........ .. ....... ... A.6
Scotolo fusibili ............... .. .. .. .. ............ ............. A.6
P res t ozio ni ... .. ... ..... .. ..... ... ... ...... ....... .... ...... .... A. 6
P esi ...... ............................. .. .......... ... ............ A.6
lngombri ............. .......... .. .. ................ .. ........... A.6
Rif ornime nt i ....................... .. .............. ............. A. 7
Engine
......... ....... ....... ..... ................ .......... ....
Timing system .............
.. ......... ..... ....................
Fuel system ..... . ..... ......... ............................. ....
Lub r ic a ti on .... .. .... .. .... ........ ... .. .. .. ... .. .. .. ... ..... ...
Cooling system . ... ............ . .. ..............
Ignition sys tem ............. .. ... ....... . .. ......... ..
Transmission ..........
... . ................................ ..
Br a kes ..... ....... __ .... ........ .. ........ ... __ .. _.._.. ....... ...
Frame ... ....... ...... ..... ...... .............. . .... ...... .......
Suspen si ons ............................. ... ..........
Wh eels ........... ... .... ...... . ....... ............. ............
Tyres ..
.......... ............ ............. . ...................... .
Electric system ...... ... ...... ..... ....... .._ ..... .. .......... .
Fuse box ....... ..... ... ..... ................... ..... .......... .
Pe rf orm ance data . .. ...._. ....... ... ........ .... ... .. ... .. ...
Weights . ..... ...... .......................... ..,...............
Overall dim ensions ......... ........... ...... ..... ...........
Refuelings .... .. ........... . .. ............ . ........... ..........
A.8
A.8
A.8
A. 8
A.9
A. 9
A.9
A.9
A.9
A.9
A.9
A. 9
A.lO
A.lO
A.IO
A. lO
A. lO ,
A 11 ~

GENERAL
. m•
....
================================~rF
ENGINE 750 s.s . 900 s.s .
Twin -c ylinder, 90 ° l lype con fi gurolion, 4·s tr ok e.
Bore in. ·.. .... .... .... ...... .. .. .... .. .. .. .. ........ .. ... 3.4 64 5 3.62 20
Stroke in ................................................ 2. 4212 2.6771
Total disploment cu . in ..... ... ............ ........... 45.63 55.14
Compression ratio .. ............ ............ I:9±0.5 I:9, 2±0 ,5
Max. po wer (at the wheel) kW [ HP) ... .. . .. £14 .1[601 56 .3 (731
at r pm ... ............. .......... ....... 8. 50 0 7. 000
Max . engine speed ................................ 9.000
IMPORTANT · Under no circumstances th e engine must goes over
9000 rpm.
TIMING SYSTEM
•DE SMODROMIC• tim ing system, twova lves eachcylinder, controlled
by four rocker arms (two opening and two closing rocker arms) and
by four lobes O.H . C.
It is co n tr olled by the dri vi ng shaft th ro ugh cy lindrical gears, p ull e ys
and toothed be lt s. The va l ve opening and cl osi ng diagr am is the
following.
Checking
data with o clearance of: in ......... 0 . 008 0 . 04
Inlet valve: diameter in ... ........ ........ .. ........ 1 .6 14 1.693
Op ens before T.D.C. . .. ...... .. .. ...... ... .. ... 3 1° 20 °
Cl
oses after B.D.C. ....... .. .......... .. ........... 8 8° 60 °
Exhaust valve: diamet er in..... ......... ........ .. 1. 378 1.496
Opens before B .D C... .. .. ..................... 72o 58°
Closes aher T.D. C. . .. ............ ... .. ............ 46° 20°
O pe ra tion cl ea rance of val ve lapp ets, wi th co ld engin e, mu st b e:
Op ening rocker arm:
0 . 0031 +0 . 0039 in . (Inlet)
0 . 0039 +0 . 0047 in. ( Exhaust )
Closing rocker arm. 0+0 . 00078 in. (Inlet and Exh aust )
Lift:
(check in g doto with a clearance of 0 in .)
Induction i n. ......... . .. ........ .. .. ..... .. ........... 0. 36 8 0.4 63
Exhaust in ..... .............................. .......... 0.334 0.415
FUEL SYSTEM
The fuel feed sy stem comp on e nt sore located i nsi de t he f uel ton k, so
th ey ore not visible from ou tsid e.
Dry air inlet ond cleaner, located under the fuel tonk. Th e fuel feed
system is so constituted.
l )
Fu el filler c op :
2)Fuel level indicating device,
3)
Fu el hand cock fo r st op ping the fuel feed;
4)
Fuel fille r;
5) Electric pump; a) Delivery pipe;
6)
Pu mp fi lt er
b) Ret ur n pipe;
7) B
re a th er valve, c) Drain p
ip e.
A.8
750 S.S.)900 s. ~
Provided wi th a carbure to r: . ... ....... .. . . .. M IKUNI
Type .... .. .............................. .......... ....... BDST 3B·B70 I BDST 38·867
Carb. Main specifications I
-Choke (m m) .. ........ ..... ............... ... 38
- Needle valve j et .. .. ...... . ... ................ Y-6 ! Y·2
-
Ma in j et. .. .. ............. 1 40
- Star ting jet ..................... ...... . ....... ... 70
-Idling jet........... .......... ......... ... ........... 37 .5 I 42 .5
-Needle jet
.. .... .. ................ .. .. ... ......... 5C 19
{ pos. fr om top) ........ ... ......... .......... 3 rd I 4th
LUBRICATION
By pressure thr ough o gear pump, oil purification through o net filter,
filter with cortdridge and
low pr essure temperature indicator pla ced
on the instr
um en t board. Lubricant cooling ra dia tor ( 900 S.S.)
Lu b ri colion cir cu it:
1) Pipe un io n for oil sum p breat her w ith recovery chamber
2)
Oil filling plug.
3)
Oil level indicator.
4)
Oi l drain pl ug .
5)Net
fi lter.
6)Filter cartridge.
7) Pr
essur e s wi tch.
8)
Rad iator.
1
1
5
750 s. s.
5 6
900 s. s.
6 8
I
\
(
)
'
'
,.
'-..../

GENERAL
~ / ':::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ::
COOLING SYSTEM
Ai r. cool ing through the Iorge cooling fin surface of cylind ers heads.
The cylinders ore fur ther coo led by the motor oil.
IGNITION SYSTEM
Electronic type with inductive di sc harge s ys t em .
Make ............. .... .. ........... .................. . .. .. KOKUSAN
Automat ic advance:
-up to
1700 rpm±200 .... .. ........ .. ........ ... .. ........... 6°
- 1 700 to 2600 rpm±300 ...progr essive up to 32 °
(Check us ing a stroboscopic light)
Spark plugs
Make ... ........ ..... .........
Type
Electrode
gop
TRANSMISSION
7 so s.s. 1900 s.s.
C HAM PION
RA6 HC I RA6YC
0. 0236 in .
Mu ltiple-di sk dryclutch: 7+7with 13 fri ction su r fa ces (900 S.S.) ;multiple
dry c
lu tc h 8+7 wi th 17 fr iction surfaces (750 S.S .) controlled by on
hydraulic circuitoperated by a lever on the left side of
the handlebar.
T rosm iss ione be tween engine and main shaft of ge obox w ith stra ight
t
oo thed ge a rs
Rat io ... ............ ..... .............. 7 1/ 36 I 62/3 1
5 rat ios (750 S.S.) 6 ratios (900 S.S .)gearbox wi th costont mes hed
gears ; the idle geors ore supported by ro
ll er coges. change kick to
the lef
t.
Gear ratios 750 S.S . !900 S.S.
I st speed . . . ... .. .... .. .. ....... ................ . 40 / 16=25 37/1 5=2 .46
2nd speed . ..
.. ... .......... ........ ....... 36 /2 1= 1.71 30/17= 1.7 6
3rd speed .. ...................
.. ........... .... .. . .. 32/2 4= 1.33 27/2 0= 135
4th speed ... ...... .. ... . ..... . .. ........ .. .... 29/27=1.07 24/2 2= 1. 09
5th speed ........ ........ .. ................... ...... ... 28/29=0 96 23/24=0 95
6th speed ...... .. .... .. . .. .. .. ................ .. .. .. . 24/28=0 .85
Transmission between gearbox and rear wheel through chain:
Make ................... .. ..... .. . .. ................ ..... D ID
Type .. .. .. .......... .. ........ .. .... .. ....... .. ... .. . 520 VL 2
Di mensio ns ... ........... ............................. I I 4"x5/8"
N° links ................ .. ..... ..... .. . .. ....... .. ... .. . 96 ! 98
Final drive ratio (pinion · crown). .. .. ............ 1 5/37
BRAKES
Front
Fl oa ted drill ed disc type, bi-metallic (n°2 for 900 S.S .and n° I for 750
S.S.).
Di sc dio. ....... .. ........ .. ........................ .. . .. .. ....... .. 12 .6 i n.
Hydraulic lever control on the R/H side of handlebar.
Braking surface
.. .. ...... .. ............. .... 13.64 sq .in.
Br
oke ca lipe rs 750 S.S. 900 S.S.
Make . .. ... ....... .. .. ..... .. . .. ... . BREMBO
Ty pe . ...... .. ..... .. .... .. ..... .. .... .. ... .. P4 30/34 : P4 32d
j (Up To 1600)
P4 30/34
(F rom 16 01}
Pump type ........ .. .... . .. ....... .. .... PS 13 i PS 15
Frict ion materi al.. ........ .. .. .. .. .......... FREN - DO 965
Rear
Fix ed and dri ll ed disc in stee l.
Disc diameter ......................
.. .......... .. .... .............. ..... 9 . 64 i n.
Hydraulic peda l control on the R/H side of the bi ke.
Braking surface.. .... .. ........ . .. . ........... . .. ..........4 . 1 23 sq. in.
Broke caliper:
Mak e ....... .. .. ....... . . .. .. ............. BR EM BO
Ty pe ............... .................................................... .. P2 1 05N
Pump type ....... .. ... . ........ ......... . PS 11
Fric tion material .. ....... ..... .............. .. ..... FREN -D O FD 72 GG
FRAME
Th e fram e is a tu bular type with Chrome-Molybdenum steel tr est le.
Sleeve inclination (motorbike without pi
lot) . ... 25°
Stee ring angle (each side} ...................... .................... .. . 25°
Forward stroke . ............. .. . .. ..... ...... .. .. .... .. 4.055 in
SUSPENSIONS
Front 750 S.S. 1 900 S.S.
Oi l-dynamic fork with overturned legs and wi th outer broke setti ng
system of rebound, comp ress ion and spri ng preload (900 S.S. ).
Make ..... .. .. .. ......................... .. ..... .. . .. . .. SHOWA
Type ... .. ....... ..... . .. ........... ...... .. .. GD03 1 I G D011
Barrel diamete r: in. .. ........................ .. ..... 1. 614
S tr oke: in. ....................... .. ...... .. .... .. ...... 4 .724
Oi l quantity each leg: cu.in. ... .. ... .. . .. 27.8 7 i 26.84
Oil level to the bar rel: in. ............ .. ............ 3.126 I 4.252
Rear
Swinging arm in al um inium 1wi th ad justable oil-p neum a ti c mono·
da mper du ri ng rebound and compression.
Mak e ..... ............... .. .... .............. .... SH OWA
Type ...... ...... .... .. ... ...... ........................ GD 022-00 7-QX
Stroke ... ......... .. .................... ...... ... ................... ....2. 56 in
The fork rotat es around a journal passing th rough the engine; th is
configuration makes the motorcycle more sturdy.
WHEELS
Li gh t-all oy rims with t hre e spok es .
Front 750 S.S. 900 S. S.
Make .......................................... BREMB O
Dimensions . ..... .. .......... .. . ...... .. . .. 3. SOx 1 7" i3. SOx 17 "
Rear i
Make .................................................... BR E MBO
Di mens ions ......... .... .. .... 4. 50 x 17" 15 . 50x 17 "
Whe els ore of removable-pin type.
The rea r wheel is fitted with a special flexible coupling.To rem ove it
fi rs t toke o ut the chain.
TYRES
Front 750 S.S. j 900 S .S .
Radial "tubel ess" type. i
Mak e ... .. ...... .. .. . .. .. .. . . ......... ... M ICHELIN
Type .. ...... . . . .. . .. . .. .......................... . A59X 1 A59
Dim ensions .................... .... ...... ..... .. .... .. . 1 20/ 6(}17! 120 /70 -17
Rear I
Rad ial "tube less " type.
Make .. .. . .. . .. ................................. .. ....... MICH ELI N
Type ..................................................... M59X I M59
Dimensions............ .. ..... ....... ................... 160/6(}17 170/ 6(} 17
A.9

GENERAL
T . A ti
1 yre m a an pressure
Inflation pressure
Fron t
Rear
ELECTRIC SYSTEM
Main components:
Bar
Kg/cm2
2.2 2.24
2.5 2.55
Headlamp; rec ta ngular shape, iodine, doubl e-f ilamen t, 1 2V - 55/
60W -H4 bulb, with parking light bulb 1 2V · 5W.
Instrument board
Electrical controls on handlebar
Direction indicators; 1 2V ·1 OW bul bs .
Horn
Stop light switches
BaHery; 1 2V- 16 Ah
Alternator ; 12V-300W
Electronic regulator; protected by o 30A fuse
Starter ; l 2V-0,7 Kw
Rear light ; double-filament lamp, 12V-5/21W for stop signaling
light, for tail and number plate light s.
A.10
FUSE BOX
Used fuses are accessible by removing the protect iv e transpare nt
cove r.
On ly fi ve fuses ar e connected to th e elec tr ic sys tem .
Al- 30 A;
B2- CJ- 15 A;
D4 - E5 - 7, 5 A.
Three spare fuses are available { F6 -G7 - H8) .
PERFORMANCE DATA
Max. speed mile/h .............................. ..
Medium fuel consumption mi/1 ........... .. ......
WEIGHTS
On ly engine without oil; lb . .. .. .. .. .. .. .. .. .....
Dry lb . .......... .. ...... ........... . ... ......
Kerb {with driver 15
4.3 lb.) lb ....... .. . ........ .
Full load {with driver and
passenger 1
54 .3 + 154 .3 lb) lb. ...............
OVERALL DIMENSIONS mm (in.)
6)
750 S. S. I900 s.s.
1 30 .5 136.7
10.56
750 s.s.
1 34 .5
38 1.3
562.1
716.5
900 s. s.
143.3
403 .4
582
736.3
750 s.s.
~ 900 s.s.
~
U')
(\J
~
=

REFUEUNGS
Fuel tonk, 0. 1 06 cu . ft. (litresl reseNe includ ed
Crankcase sump and filter
Front fork
Front / rear broke ci r cu it and clu tch
Cha in
Speedome terand revo luti on i ndi ca tor cabl es
F olk pin bear in gs
Prot ec ti on f or elec tric co nt actson t he fr ame
GENERAL
TYPE
QUANTITY
cu.ft.
Gaso line NO 94+96 RM 0.617
AGIP nuovo SINT 2000 0.123
SHOWA S. S8 or AGIP F1 . A.T.F . DEXRON ___j 900 S.S. = 5. 31 in. (to th e l iner!
I750 S.S .= 3. 12 in . (to th e lin er!
AGIP F1 BRAKE FLUID SU PER HD DOT
AGIP ROCOL CHAIN LUBE Sp ray •
AGIP F1 G rease 30
AGIP GR MU3 Grease
AGIP PI 1 60 Sp ray
m WARNING! -U se of additives in fuel or lubricants is not allowed.

MANUTENZIONE
MAINTENANCE
ENTRETIEN
WARTUNG
MANTENIMIENTO
Sezione 8
Section
Sec tion
Sek tion
Secc i6n

.... .
--
MAINTENANCE
·· -===== ======= === ===
ROUTINE MAINTENANCE
OPERATIONS Operations After the first Every
km/mi .
identifications
Set up
symbo l
10 00 /600 1000 /600 5000/ 3000 10000 / 6000
20000 / 12000
Engine orl level c • •
Engine o il
• s • •
Engrne oil l dt er • S • •
Intake eng.ne oil filter • P • •
Tighten engine cylinder heads • C •
Valve clear ance
• c • •
Ti ming belts • C • •
Timing belts chonge . s •
Spark plugs CIS • •
Ig niti on advance • c •
f uel filter •
PIS
• •
Carburetor: synchronization and min. •CIP • •
Air filler
PIS
• •
Eng ine oil pr ess ure • c • •
Cy li nders compression • C • •
Broke and clutch oil level c • • •
Broke and clutch oil
• s •
Broke and clutch hydr. controls • c • • •
Mo tor co ntrols •
C/ V •
Dashboard instruments •
C/V
•
Circuits seolmg •
C/V
•
leds and lights sys tem
• v •
Head-light posi ti on • c •
Locks and hi~g es
. c •
Bollery chorger for about I0 hours • c •
General clean • P •
Mo torcycle l es t • c • • • I
Flexible cab l es
C/L
• • •
Tyres : consumption and pre$5Ures c • • •
Steering bearings ploy • c • • •
Dr ive cha in tension and ol rgnme nt c • •
Fi nal dr ive • c • • •
Broke pods wear •
CIS
• •
Wheel bearings • c •
Flex ib le coupling • C • •
F ue l tonk • P •
front fork oil
• S •
Nuts, bolts and fastener tighteness . c • • •
Ge neral lu brica ti on and gra issoge • L • •
Bollery electrolyte leve! c • •
OPERAT I ONS IDE NTIFICATION SYMBOL:
• Th
is mark indicates t hat t he operation should be ent ru sted to DUCATI Service Networ k wh ere hi gh trained personnel and special equipment ore ovo il ob le.
C Check an d/or ad ju stm en t ·
l Lubr ificotion an d/ or groissage
P Clean
S Change
' V Test with nunning motor
8.3

II(
li
INCONVENIENT! E RIMEDI
TROUBLES AND REMEDIES
INCONVENIENT$ ET REMEDES
STORUNGEN UNO ABHILFE
INCONVENIENTES Y REMEDIOS
Sezione c
Section
Section
Sek ti on
Secci6n

TROUBLES AND REMEDIES
So me of th e tro ubl es whi ch moy occ ur and t he relevant co usese ore
l
is ted hereunder.
Difficult ignition or ignition failure.
First of all check th e gasoline level and whet her th e g as oli ne cock is
open lplocedon the R/H side of fuel tonk) . Ifeverything is normal, the
following causes may hove occurred:
CAUSE
Gasoline pipes are clogged.
The fuel filter is dirty.
Gasoline cock filter
is dirty.
Electric pump
doesn't work.
The carburetor float is jammed.
The float
ha s an hole.
The jet is obstructed.
Spark plugs
ore dirty or defective.
There is no compression.
Lack of spark at spark plugs.
C.6
REMEDY
Clea n th em wi th on air jetel im inating
any extraneous body .
Replace the filte
rin g element of the
50 me.
Oi50~semble the filter and clean it by
on air jet on the wire gau ze .
Verifya
ll elec tr ic connection s, a nd in
case replace.
Remove the floatandclean thecham·
be r.
Rep l ace .
Apply a strong air jet into it inorderto
free the passage.
Rep l ace or clean the sp ar k plugs
making
~u r e that the ins ul ating piece
co re is in tact, th at th ere is no car bo n
depos
it s on th e electrodes, and th at
the
gop between the elec tr od es is
0. 023 in .
Check whether th e spa rk plugs ore
tight, that the valves ore well dosed,
and the perfect seal of the piston
rings.
Checkthat thekey
sw it ch isn ot de fec·
live; il so, replace.
Check that
th e wires of th e i gn i ti on
ci rc uit ore well co nn ected and not
interrupted; replace,
th e de fective
wire, if necess ry .
CAUSE
Lock of spark at a single
spark plug.
Lights do not work properly.
CAUSE
Battery is down or often runs
down.
REMEDY
Replace or dean th e spark plug and
check that the gop between elec·
trades is 0. 023 in.
Checkthat the wrre from the H .V. coil
to the spark plug is not interrupted or
does not spark externally; replace as
required.
Check that
th e wir es co nn ec ti ng the
electronic control un
it to th e H. V. co il
are we ll connected and not inter·
r up te d; when required r ep lace the
fou lly wire.
Check the proper electronic con tr ol
unit and H. V. coil operation replace
the defective item .
REMEDY
Check the condition of the banery,
and th e rechar ge circuit.
Check
the regulotore; if it is defective
it must be replaced being impossible
to repair il. Aller having de tected the
de fect, recharge th e bo Ne ry .
To check th e rechar ge c ur rent op e r·
ate ad fo ll ows.
Di sc onnectthe wire from te rm ina l+ of
th e battery and placea directc urr ent
ammeter between terminal a nd wire
!possibly
wi th 0 in t he center).
Start theengineuntila ~peed of 5000
rpm i~ reached. The ammeter must
display the following values:
o) max. current- I0 A if the ba tt ery is
(}
almost co mpletely down; :
b) min imu mcu rr e nt - I A i/the ba ttery
is completely charged.
Ac
co rding to the co ndi ti on of the
ba tt e ry char ge , int ermediate values
o re recor ded .
These tests mus t be carried out w it h
lights of.
Caution: the ammetermust be con·
nected
alway s with th e engine off .

TROUBLES AND REMEDIES
~ ·--=====================
CAUSE
With the key disconn ected,
the battery quickly runs down.
The engine
is not efficient.
CAUSE
Gasoline inflow to carburetor is
not constant.
Corburator jets are obstructed.
Corburator throttl e valves do
not open fully.
The needle of the float does
not dose correctly .
Poor quality gasoline.
Unsuitable type of spark plugs.
One spark plug is loo se.
REMEDY
Check of electrical inputs .
M ak e sure that all the bulds are
efficient.
a}
Wi th the lights off (dayt ime) t he
ammeter must readzeroatapprox.
1000rpm.
b)
With pa rk ing li ghts on (nighttime)
th e ammeter mu st r ead zero ot
opp ro x. 1 200 rpm;
c)
With the anti -d azzle li ghts on t he
ammeter mus tread zeroat opp rox;
2200 rpm;
Check that there ore
no earthed
contacts in
the system.
REMEDY
Clean th e f uel filter, th e ca rburato re
filter and th e feedi ng pipes; check th e
proper operation
of the pump.
Cleanthem with o compressed
air Jet.
Ad ju st throllle valves opening ac ti ng
on the
co ntrol wire adjus ti ng sc rew .
Clean
the corburalor and particularly
the needle seat.
Replace gasoline in the lankpossibly
by refueling ata good servicestation.
If the spa rk plug is t oo ho t, preigni·
lions,
kn ocks, misfires, especia ll y at
high rpm
wi ll be noticed; if th e spark
pug is toocold, ignition failure due to
electrodes short circuit will'occur. Fit
the spark plug of proper thermal de ·
gr ee.
Closely t ig ht en the spark plug. A
gasket
mu st always be placed be ·
tween th e spark pug and the head.
CAUSE
A spark plug wire sparks
externally.
The gap between the spark
plug el ec trodes is too wide.
Spark plug electrodes are dirty.
The electronic control unit is
defectiv e.
The H.V. coil is defecti ve.
Th e stato r plate of the electronic
ignition generator is defecti ve.
Silen ce r is obstructed.
The starter does not tum on .
REMEDY
R ep la ce .
Readjust to the prescr
ibed gop i.e .
0.023 in.
Clean.
Repla
ce it.
Replace it.
Replace it.
Restor e the fr ee flow of th e exhaust
gas.
First of all makes sure th e electrical ha rness is regularly fixed ro rhe
boH ery, rhe sol eno id sforfer and rhe starter. If th e wires ore prop erly
offoched it mighr be one of rhe fo ll owing foulrs .
CAUSE
Th e battery is down.
Faulty
control device on RH
handle.
faulty
sole noid starter.
Faulty starter.
REMEDY
Check the banery and recharger if
necessary.
Repl a ce .
Rep l ace .
Replace.
C.7

-r
-
REGISTRAZIONI E REGOLAZIONI
SETTINGS AND ADJUSTMENTS
REGLAGES ET CALAGES
EINSTELLUNGEN UNO REGULIERUNGEN
AJUSTES Y REGULACIONES
Sezione D
Section
Section
Sektion
Sec cio n

REGISTRAZIONI E REGOLAZIONI
SETTINGS AND ADJUSTMENTS
Registrazione minima . .. ...... . ....... ....... ......... ... .. .
Regalaziane cavi di
co mando de l gas e della starter .
Regolazione farcella anteriare (
900 S.S.) ............ .
Regolazione leva
comondo frena e frizione .... .... ..
Regolozione tensione catena ............ ...
.......... ...
Regis trozione gi oco cu sc in e tti della sterzo ........ ....
R egoloz ione ammortizzotore posteriore ........ ..... ..
Sostituzione ol
io motore e cortuccio filtro ............ ..
Sostituzione e pulizio filtro aria....
......... ........ ......
D .4
D .6
D.7
D.8
D.9
D. 10
D.ll
D.l2
D.l3
Id le ad j ustment .......... .....................................
Thr o tt le and starter co ntrol cab l es ad j ust ment .........
Adjustment
of front fo rk (900 S.S. ).......................
Broke and clutch control levers adjustment .... ....... .
Chain tension adjustment
................... .... .. ........ .
Adjustment
of steering bear in g clea ran ce . ........ .. .
Rear shock-absorber ad jus t ment .... .. . .. ..... .......... .
Engine oil ond filter cartridge replacement ............
Ai r filter replacement and cleaning .. .. ...... ..... .. ... .
D.4
D.6
D.7
D.8
D .9
D.IO
D.ll
D.l2
D.l3
._
-

REGISTRAZIONI E REGOLAZIONI
SETTINGS AND ADJUSTMENTS
====================================~rF
Registrazion e minimo.
La registrozione de l titolodellamiscelo olminimae unodei porome tr i di fun zionome nt o
del motore
co ntrolloti do quasi tutte le normat iv e ontinquinomento i nt ernozionole. E'
perton to fa cile co mprendere come Ia registrozione della stesso pu6 essere effettuoto
con due criteri diversi e
SEMPRE co ntr os tont i. II rispetto di queste normative porter6 ad
overe un titolo della miscelo •mogro"(intornool volore 1•5% di CO), I'esigenzo di uno
migliore guidobilit6 portero invece
ad overe un titolo di "mossimo corico" equivolente
ad uno percentuole di CO compreso tro 3 e 6%. Co ns ideri omo quest'ultimo criteria;
le operozioni do effettuore sono le segue nti :
o)scoldore il motore utilizzondolo per uno decino
di minuli o circa 2/3 de l regime di
potenzo e
di co ri co max;
b) equilibrore lo po rtola d'orio sui condolli del corburotore.
Lo strum e nt o di co ntr ollo e il vocuometro a co lonne di mercuric. Occorregoron ti re che
· le colonne sio no equilibrate. Ouesto operozione si effelluo u ti lizz ondo uno solo delle
viti [A) di bypass[I'ol tro deveesserecompletomentechiuso).E owio chebisogno apr ire
Ia vile o cui corrisponde lo colonno piu alto;
c) registrore il titolo della miscelo.
Lo slr
ume nto di co ntrollo e l'onolizzotore di gas di scorico. Pe.r mezzo delle viti (A)
regislro miscelo ottenere per entrombi i cilindri un tenore di CO compreso Ira il 3 ed ,r )
'r,
il6% . N one tonto importonte il volore osso lu to [purche sio compreso Ira i volori s opro
specificoti) quanta che risulti obboston zo simile tr o i due cilindri.
d) per me zzo de ll a vile [B) ondotura regislrare il regime di rotozione ad un valore
compreso
tr a 1 200 e 1 300 giri/ 1'..
L' esecuzione in successio ne di queste operazio ni pu6 olterore il risultoto di quelle
precedenti, e pertonto necessaria roggiungere il compromesso migliore che in questa
coso deve corrispondere a:
colo nn e di mercuric equilibroto; tenore di CO compreso
Ira 3 e 6%; regime minima corrispondente o circa 1 200+ 1 300 giri/ 1'.
Idle adjushnent.
The adjustme nt of th e idle mixture strength is one of the motor op eration pa r ame ters
controlled by almost all inte rn ational anti-pollution norms. Th erefore it is easy to
understand how
th is adjustment con be performed based on two di ff ere nt criteria,
al
way s in co ntr asteachother. Th e co mpl ia nce with th ese norms wi ll r esult in o "leon" mixture [abo ut 1, 5% of CO ) whi le the requir em e nt ofa be ller
drivi ng capa bi li ty will on the contrary need a "max. load" mixture, co rr esponding to a percentage of CO ranging from 3 to 6%.
If using t hi s lost criterion, the adjustm en ts to be performed ore the following:
a)Heat the motor usi ng it lor l 0 minutes at about 2/3 of t he max. power and loading co nditions;
b) Compensate the air capac ity on the corburettor ducts.
The check gouge is the vocuometer with mercury columns. Ass u re that the columns ore compensated. Th is operation is performed using only one
of the by·poss sc rews (A) (the other one must be completely closed). Therefore open the screw corresponding to the higher column;
c) Ad j ust th e mixture strengt h.
The check instrument is the exhaust ga sanalyzer. Through the mixture s tr e ngth screws (A) reach for both cylinders a CO percentage between 3
and 6
%. Th e absolute va lu e sha ll be quite equal f.or'both cylinders [in cluded within the above mentioned va l ues)
d) By means of the speed screw (B) se t th e rotation speed too value within 1200 and 13 00 r.p.m.
The exec
ut ion in se quence of the a.m. opera tions con change th e r es ult of th e previous ones, th erefore try to reach th e bes t co mpromise,
corr
es ponding in this case to the following: Mercury columns balanced; co ntent in CO from 3 to 6%; idle rpm of about 1200+ 1300 rpms.

•••
......
0.6
REGISTRAZIONI E REGOLAZIONI
SETTINGS AND ADJUSTMENTS
REGLAGES ET CALAGES
EJNSTELLUNGEN UNO REGULIERUNGEN
AJUSTES Y REGULACIONES
Regolazione cavi di comartdo del gas e dello starter.
Icovi di comondo delgase dellastarter devonoovere u no corsoo vuoto ol copocordo
di 1, 5+2 ,0 mm; se necessorioagi re sugli oppositi registri situoti in corrispondenza dei
comondi sui manubria. Allentore il con tr ododo ( 1) e operore sui regi stro (2) ottenendo
lo regolozione prescritto; bloccare il contrododo (1 ).
Regolozioni piu consistenti sui covi del gas si possono effettuore agenda su i registri (3)
posti in corrispondenzo del corburotore.
Ouo loro si riscontrosse un ind ebo limento
dell'ozione di ritorno de lla monopoledicomondo de l gasverificare lo stotodi elosticita
della molla di richiomo sui corburotore.
Throttle and starter control cables adjushnent.
The throllle and starter control cables must hove on idle stroke, of the cable terminal,
of
0.06+0.08 in.; ifnecessary, adjust it through theproperscrew ad ju sters pl aced n ear
the some controlson the handlebar. Loosen th e locknut ( 1) and octon the screwadjuster
(2)
thus reaching the required adjustment; th en fasten the lock nu l (1 ).
More substantial adjustments of the throttle cables con be performed by acting on the
screws adjuster {3) placed near
the carburetor. If the re t urn action of th e throttle control
grip gets weakened, check the springness stole of the re turn spring on the carburetor.
Reglage des cables commande gaz et starter.
Les cables de commande goz et starter doivent avoir un e course a vide aIa cosse de
1 ,5+2,0 mm; si necessoire, ogir sur le regleur oppropr ie sit ue pres de Ia meme
commonde. Desserrerlecontre-€crou (
1) et ogir sur leregleur(2) pourobtenir le r eg l oge
desire; bloquer le contre-€crou.
Des regloges p lu s importonls son! possibles en operant sur le regleurs (3) sit ue pres du
carburaleur.
Si on verifie un offoiblissement de l'oclion de retour de Ia poignee
commonde
goz, verifier l'etot d'elcisticite du ressort de rappel sur le carburoteur.
Einstellung der Gas· und Startersteuerungskabel.
Die Gas -und Stortersteuerungskobel mi.issen, bei dem Kobel schuh, einen Lee rlouf von
l
,5+2,0 mm haben; wenn notig, die entsprechenden Register, die sich au f der
L enks ton ge in der Nohe de r enlsprechenden Steuerungen befi nd en, regulieren. Die
Gegenmuller ( l) Ibsen und dos Register {2) bis zur vorgeschriebenen Regulierung
drehen, donn
die Gegenmutler { l) wiede r spannen.
Grossere Regulierungen des Goskobels konnen durch
dos R eg i ster (3) vorgenommen
werden, welches sich in der
Nohe des Vergosers befinder. Sollie die Ruckkehr des
Drehknopfes der Gassteuerung obschwochen,
donn muss die Elostizitat der Feder
nochgepruft werden.
Regulaci6n cables de mando del acelerador y del starter.
LoscablesdelocelerodorY.del starter de ben cumplir uno correro en vocio de l ,5+ 2, 0
mm.; si fuese necesorio, regular los r eg istrocion es siluodas en correspondencio de los
mondos en el manubria. Aflojor Ia contra-tuerca ( l) y maniobrar el registro {2)
ateniendose a Ia regulaci6n prescrita; bloqueor Ia contro-tuerco (l ).
Si se deben efecluar regulociones mas consistentes de l os cables de l ocelerodor,
pueden hocerse maniobrando los registros (3) situado en correspondencio con el
corburodor. Si se detectase un debilitomiento de Ia acci6n de relroceso de Iamanoplo
del ocelerodor, verificor el estodo de elosli cidad del resorle de retorno siluodo en el
corburodor.

Regolazion e forcella anteriore (900 S.S.) .
REGISTRAZIONI E REGOLAZIONI
SETTINGS AND ADJUSTMENTS
REGLAGES ET CALAGES
EINSTELLUNGEN UNO REGULIERUNGEN
AJUSTES Y REGULACIONES
II grodo di smorzomento idroulico della force ll o e regolobile sio in esten s ione che in
com pr essione.
La regolozipne
owi e ne per mezzo dei registri este rni a vile (A: per fr en o idraulico
estensione ; B: percompressione ).Ruotondo Ia vitedi regolozi one e po ss i bi le owert ire
deg li sco tli, ognuno de i quoli corrisponde ad uno po sizione di smorzomento.
Awit ondo co mpletome nt e Ia vile fi no a bl occ orlo si ottiene Ia po sizione "0", che
cor
ri sponde o li o mossimo frenoturo. A portire do questa posizione, ruotondo in sensa
ontiororio, si possono contore i vori
sc otti che corrisponderon no successivomente aile
posizio
ni 1, 2, ecc.
Le posizioni standard
son o le seguenti:
com
pr essione: 6 scotti
es ten si one: 4 sc otti
II volore mossimo e 14 scotti o cui corrisponde Ia posizione di mini ma fr enoturo.
Adjushnent of front fork (900 S.S.).
The hydraulic damping degree of the fork is ad justable both in rebound and com -
pression act io ns.
Th e ad justment is mode by means of external screwad ju st ers ( A: for hydraulic rebound
damping ; B: for c ompres sio ndamping ). Whe n you rot ate the adj u st ment screw yo u
con hear various clicks, each one
of them co rresponds too damping position. If you
fullyscrew
in th escrew to lo ck it, yo u'll reach the position "0", co rresponding to the max.
damping
ef fec t. Fr om thi s p os iti on you con rotate in counterclockwise dir ection and
co unt the various clic ks , wh ich corresponds to t he positio ns 1, 2 etc. respectively.
Stan
da rd positions ore as follows:
compression: 6th posit
io n
rebo
un d: 4th position
The max. va lu e is of 14 click s, corresponding to the min. damping po sition.
Reglage fourch e AV (900 S.S .).
Le degre de l'effet d' omor1 isse me nt hydroulique de Ia fourche peut eire regie soil en
extension
qu' en comp re ssion.
Le reglogeeste ffe ct ue au moyendesregulote ur sexterieurs6 vi s, (A: pouramortissement
hydraulique en extension ; B: pour amortissement en compression ). En tournont Ia vis de n§gloge, on e nt en d des declics: chocun d'e ux
correspond6 une po sitiond'omorti sse me nt. En vi sso nt co mpleteme nt ce tte vis pour Ia bloq uer, on rejoindro lo po sition ·o·, qui co rr es po nd 6 1'effet
d'
omor tis semen tm ax imal. A partir de cette posit io n il est possi ble de Ia to urn er donsle sens co ntroire 6 ce l ui de soig ui ll es d' un e mont re: on pour ro
compter le s declics qu'on e nt end, qui co rr es pondent re spectivement oux positions 1, 2 etc. i
Les po si tions standa rd sont l es suivontes:
compression:
6e me po sit io n
extension: 4eme position
La vale
ur max. e st de 14 declics, qui correspond a la position d' omo rtissem ent m in i mo le.
Einstellung d er Vordergabel (900 S.S . ).
Die hydrouli sc he Dompfung der Gobel konn se i es in Kompression sei es in Ausdehnung ge regelt werden.
Die
Reg e lu ng erfolgt durch ousse re Schroubenregler (A: fi.ir die Ausdehnungsdampfung ; B: fi.ir die Kompressionsdampfung ). We nn man die
Regel
sc hroube dreht, hort man verschiedene Schn op pg erousche, welche je einer getrennten Dompfungswirkung e nt sprechen. W e nn man di e
Sc hroube va ll onziehtund blockie rt, erreic ht man die "0" St ellung, welche der max. D omp fungsw irkung e nt spricht. Von dieser Stellung konn man
die Sc hr oube in Gege nuhrzeigersinn drehen un d die Schnoppgerou sch e zohlen, wel che bzw . den Ste llun ge n 1, 2 u .s .w. en tsp rec hen .
Die Stondord·Stellungen sind
wie folgt:
Kompre
ss ion: 6 Sch n op pge rousche
Ausdehnung: 4 Schnoppgerousche
Der max. W ert ist
14 Sc hn oppgerouschen, welcher der minimolen Dompfungswirkung entspricht.
Regulaci6n horquilla delante ra (900 S.S.).
El grodo de omortiguocion hidroulico de Ia ho rquillo se regula bien sea en e xt e nsi on c omo en compres io n.
Lo regulocion se hoce por media de tornillos exteriores ( A: freno hidr .e xte ns ion ;B:por co m presion ). Girondo el tornillo de reg ul ocion se pueden
oi r coda un o de los soltoscorrespon di en tes o uno posicionde omorti guo cion. Atornillo ndo co mp letomente el tor nilloho st o bloqueorlo se ob tiene
Ia posicion " 0" correspondie nte a Ia maximo omortiguocion. A partir de esto posicion, g irondo en se ntido o nt ihororio, se pueden can tor los
diversos soltos que corresponder6n sucesivomente a los posiciones l - 2, etc.
Los posiciones estandor son los siguient es:
compr es io n: 6 soltos
\. extension: 4 so ltos
El val
or maximo es de 14 so lt os y corresponde a Ia posi cio n de minima frenodo.
0.7

REGISTRAZIONI E REGOLAZIONI
SffiiNGS AND ADJUSTMENTS
REGLAGES ET CALAGES
EINSTEUUNGEN UNO REGUUERUNGEN
AJUSTES Y REGULACIONES
==================================~: - ~
0 .8
Per m od ificore il precorico della mollo inferno ad ogni stela e necessaria ruotore il
regislro superiore
{C) con uno chiove esogonole di 22 mm. II volore de l preco ri co { 1)
puo variore Ir a 25 e 10 mm. La toraturo or iginole corr is ponde a 18 mm .
.,.. E' importante che i registri di e ntrombi gli steli vengono regola ti su lle
t.1J medesime posizioni .
In order to modify the spring preload of each leg, turn the upper adjusting sc rew {C)
with a 22 mm allen wrench. The preload value {1) con very between 0.98 and 0. 39
in. The factory presetting corresponds to 0.7 1 in.
mImportant - Set the adjustmentsof both legs at the some positions.
Afin de modifier le prechorge du res sort interieur 6 cheque t ige , tourner Ia vis de
regloge superieure {C) avec une de 6 6 pons de 22 mm. La valeur de prechorge { 1)
peul varier ent re 25 et 10 mm . La valeur porometree 6 l'usine correspond 6 18 mm.
~ Important - Le s regloges d es deux tiges doivent se trou ver sur l es m emes
t.1J positions . . ( .\
Um die Vors ponnung der Fed er jed er Stonge zu ondern, mus s der obere Reg i er {C) ·, 1
milein em Sechskonlschliisselvon 22 mm . DerVorsponnungswert{l )konn zwischen 25
und 10 mm. li ege n. Die Fobri k-V ore instellung dovo n isl 18 mm .
.,.. Wichtig - Die Regier beider Stongen mi.i sse n auf den se lben Pos i tionen
t.1J e ing este llt se in .
Para mod ificor Ia pre -c argo del resorte interior en coda varillo es necesorio gir or el
tornillo
de reguloci6n {C) conuno llove hexagonal de 22 mm. El val or de precorgo { 11
puede vorior ent re 25 y 10 mm. Ellorodo original corresponde a 18 mm .
mEs importante regular ambos vorillos en las mismos posicion es.
Regolozione l ev a c omondo freno e frizione.
La cor so a vuoto de lle !eve di comondo del frenoonteriore e della frizionedeveessere
di 1
, 0+ 1 ,5 mm . Per ope rare Ia regi sl r oz ionerimuovereIaprolezione di gommo eogire
sui gro no {AI con un cocciovile; ow itondo si diminuisce il gioco, svitondo si ournento.
Broke and clutch control levers adjustm e nt . {
The idle stroke of the front broke and clutch control levers mu st be of 0.04+0.06 in.
To adjust, remove th e ru bb er pr otection and oc t on the dowe l {A) by means of a
screwdriver;
by fas tening if the clearance wi ll decrease, whi le by loosen in g il, it wi ll
increase.
Regloge du levier commonde frein et embroyoge.
La course 6 vide des l ev iers de commonde du frein avant et de l'embroyoge doit eire
de 1 ,0+ 1,5 mm . Pour effectuer le regloge, enlever Ia protection en caoutchouc et ogir
sur le groin {AI avecun lournevis; en vissont on redu itle jeu, ed devissont on l'ougme nt e.
Ei nstellung des Brems - und Kupplungssteuershebels.
Der le erlouf de rHebelzur Steuerung der Vorderbremseund d er Kuppung muB 1• Q-;. 1•5
mm betrogen. Um diese zuregeln, d en Gummi sc hutzentfe rn en un d de nDiibel {A) du rch
einen
Sc hroubenzieher dre hen; beim Einschrouben wird dos Spiel vermindert, beim
losschrouben
wird es erhoh t.
Reguloci6n polanco del freno y embrogue.
La carrero en voci6 de los poloncos que occionon el frena delonte ro y el embrogue
debe ser 1 ,0+ 1 ,5 mm.
Para efectuorIa reguloci6n quitor Ia pratecci6n de gomoy accionor el posodor{AI con
un destornillodor; olornill ondo disminuye el j uego , desotornillando, oumento.