Ducati SCRAMBLER 800 Instruction manual

DUCATI SCRAMBLER 800 Workshop
Manual 2015
S.01 - General
Symbols - Abbreviations - References
Product specifications
Dangerous products - warnings
General maintenance instructions
General safety rules
S.02 - Model-specific information
Model identification
Identification data
S.03 - Technical data
Technical specifications
Lights/instrument panel
Injection system
Fuel system
Injection-ignition system
Charging system/generator
Hydraulic brakes
Rear suspension
Rear wheel
Front suspension
Front wheel
Cooling system
Gearbox
Cylinder/piston
Crankshaft
Timing system/valves
Transmission
Colours
General
Overall dimensions
Overall dimensions
Fuel, lubricants and other fluids
Fuel, lubricants and other fluids
Tightening torque settings
Engine tightening torque values
Frame tightening torque values
Service tools
Diagnosis special tools
Frame special tools
Engine special tools
S.04 - Maintenance operations
Vehicle pre-delivery
Vehicle pre-delivery
Scheduled maintenance chart
Operations to be carried out by the customer
Operations to be carried out by the dealer
Maintenance operations
Adjusting the rear shock absorber
Adjusting the position of the gearchange pedal and rear brake pedal
Adjusting the front brake control lever
Adjusting the throttle cable
Checking rear brake pad wear and replacing brake pads
Checking front brake pad wear and replacing brake pads
Adjusting the chain tension
Adjusting the steering head bearing play

Clutch control cable adjustment
Changing the fluid in the rear brake system
Changing the fluid in the front brake system
Changing and cleaning the air filters
Replacing the spark plugs
Changing the timing belts
Checking valve clearance
Changing the engine oil and filter cartridge
Check engine oil level
S.05 - Fairings
Rear-view mirrors
Refitting the rear-view mirrors
Removing the rear-view mirrors
Seat - tail guard - side body panels
Refitting the tail guard (CLASSIC)
Removing the tail guard (CLASSIC)
Refitting the seat release mechanism
Removing the seat release mechanism
Refitting the tail guard
Removing the tail guard
Refitting the rear side body panels
Removing the rear side body panels
Refitting the seat
Removing the seat
Mudguard
Refitting the front mudguard (URBAN ENDURO)
Removing the front mudguard (URBAN ENDURO)
Refitting the front mudguard
Removing the front mudguard
Belly pan
Refitting the belly pan (URBAN ENDURO)
Removing the belly pan (URBAN ENDURO)
S.06 - Electric system and engine management
Wiring diagram
Table Z
Table Y
Table X
Table W
Table V
Table U
Table T
Table S
Table R
Table Q
Table P
Table O
Table N
Table M
Table L
Table K
Table J
Table H
Table G
Table F
Table E
Table D
Table C
Table B
Table A
Routing of wiring on frame
Fuse box key
Wiring diagram cable colour codes
Key to wiring diagram

Charge system - Battery
Rectifier-regulator
Alternator
Battery
Topping up the electrolyte
Recharging the battery
Checking the battery charging system
Electric starter
Solenoid starter
Starter motor
Electric starting system
Lighting
Aligning the headlight
Changing bulbs
Instrument panel
Entering PIN CODE function for overriding purposes
Key duplication
Operation
Keys
Immobilizer system
Light control
Setting the units of measurement
Changing the PIN CODE
Pin Code
Clock setting function (CLOCK)
Instrument panel back-lighting setting (B.LIGHT)
Battery voltage
ABS control unit enabling/disabling
Setting menu
DESMO SERVICE indication
DESMO SERVICE countdown indication
OIL SERVICE zero warning
Service indication (SERVICE)
High engine temperature
Clock
Displayed errors description
Error warnings
Errors
Ambient air temperature (AIR)
Partial fuel reserve counter (TRIP FUEL)
Trip meter 2 (TRIP 2)
Trip meter 1 (TRIP 1)
Odometer (TOT)
Menu 1 functions
Engine rpm indication (RPM)
Motorcycle speed
Main functions
Parameter setting/displaying
Function buttons
Technological Dictionary
Acronyms and abbreviations used in the Manual
Instrument panel
System components
Diagnostic socket
Main relay and injection
Timing/rpm sensor
Throttle position potentiometer
Coil
Ignition spark plug
Temperature sensor
Air pressure sensor
Lambda sensor
Stepper motor
Electric injector
Electronic control unit

S.07 - Chassis
Front wheel
Overhauling the front wheel (URBAN ENDURO)
Overhauling the front wheel (CLASSIC)
Refitting the front wheel
Overhauling the front wheel
Removing the front wheel
Rear wheel
Overhauling the rear wheel (URBAN ENDURO)
Overhauling the rear wheel (CLASSIC)
Refitting the rear wheel
Overhauling the rear wheel
Removing the rear wheel
Front brake control
Refitting the front brake system
Refitting the brake disc
Overhauling the front brake components
Removing the brake disc
Removing the front brake system
Maintenance operations
Refitting the front brake master cylinder
Removing the front brake master cylinder
Rear brake
Refitting the rear brake disc
Removing the rear brake disc
Refitting the rear brake calliper
Removing the rear brake calliper
Refitting the rear brake control
Disassembling the rear brake control
Removing the rear brake control
ABS system information
ABS system deactivation
ABS system operation information
Operating principle
ABS system components
Routing wiring harnesses/hoses
Refitting the ABS control unit
Removing the ABS control unit
Changing the rear phonic wheel sensor
Changing the front phonic wheel sensor
ABS component maintenance
Bleeding of the ABS hydraulic system
Adjusting the AIR-GAP of phonic wheel sensor
Handlebar assembly: throttle control
Refitting the throttle control
Removing the throttle control
Adjusting the throttle cable
Refitting the handlebar
Removing the handlebar
Handlebar assembly: clutch control
Refitting the clutch assembly
Removing the clutch assembly
Handlebar assembly: ignition switch
Refitting the ignition switch
Removing the ignition switch
Gear selector control
Refitting the gear change control
Disassembling the gear change control
Removing the gear change control
Fork - steering head: front fork
Refitting the front fork
Overhauling the front fork
Removing the front fork
Fork - steering head: steering assembly

Refitting the steering tube components
Removing the steering tube components
Steering angle adjustment
Adjusting the steering head bearing clearance
Rear shock absorber assembly
Refitting the rear suspension
Overhauling the rear shock absorber
Removing the rear shock absorber
Rear suspension system
Swinging arm
Refitting the rear swinging arm
Overhauling the rear swinging arm
Inspecting the swinging arm shaft
Removing the swinging arm
Final drive
Lubricating the chain
Washing the chain
Refitting the rear sprocket
Removing the rear sprocket
Refitting the front sprocket
Removing the front sprocket
Inspection of the final drive
Footrest support
Refitting the rear footpegs
Removing the rear footpegs
Refitting the front footpeg support
Removing the front footpeg support
Refitting the front footpegs
Removing the front footpegs
Stands
Refitting the side stand
Removing the side stand
Inspecting the frame
Checking the frame
Refitting the structural parts and frame
Removing structural components and frame
Tail light - number plate holder
Rimontaggio fanale posteriore
Smontaggio fanale posteriore
Refitting the number plate holder
Removing the number plate holder
Electrical components compartment
Refitting the electric components compartment
Removing the electric components compartment
S.08 - Fuel/Exhaust system
Fuel tank
Refitting the fuel tank
Refitting the fuel tank flange
Removing the fuel tank flange
Refitting the tank filler plug
Removing the tank filler plug
Removing the fuel tank
Airbox – throttle body
Refitting the throttle body
Removing the throttle body
Refitting the airbox
Removing the airbox
Air intake
Refitting the secondary air system
Removing the secondary air system
Refitting the air filters
Removing the air filters
Exhaust system
Refitting the silencer (FULL THROTTLE)

Removing the silencer (FULL THROTTLE)
Refitting the exhaust system
Removing the exhaust system
Refitting the silencer
Removing the silencer
Canister filter
Refitting the Canister filter
Removing the canister filter
Canister filter system
S.09 - Engine
Removing - refitting the complete engine
Refitting the engine
Removing the engine
Lubrication system: oil pump
Refitting the oil pump
Reassembling the oil pump
Disassembling the oil pump gear
Removing the oil pump
Lubrication system: oil cooler
Refitting the lubrication system
Inspecting the oil cooler
Removing the lubrication system
Cylinder head assembly: checks and adjustments
Checking the engine timing
Checking valve lift
Checking and adjusting the valve clearance
Cylinder head assembly: timing system
Refitting the timing outer covers
Refitting the timing belts
Refitting the cylinder heads pulleys/idler pulleys
Reassembling the timing pulleys
Refitting the timing layshaft pulley
Removing the timing layshaft pulleys
Disassembling the camshaft pulleys
Removing the cylinder head pulley/fixed tensioner
Removing the mobile tensioner/timing belt
Removing the timing belt covers
Cylinder head assembly: camshafts
Refitting the intake manifold
Removing the intake manifold
Refitting the camshafts
Check of the camshafts and supports
Removing the camshafts
Cylinder head assembly: valves - rocker arms
Refitting the cylinder heads
Refitting the valves and rocker arms
Overhauling the cylinder head components
Removing the valves and rocker arms
Removing the cylinder heads
Cylinder/piston assembly
Refitting the cylinder/piston assembly
Overhauling the cylinder/piston components
Removing the cylinder/piston assembly
Clutch assembly: clutch
Refitting the clutch
Checking and overhauling the components
Removing the clutch
Description of the clutch assembly
Clutch assembly: clutch cover
Refitting the clutch cover
Reassembling the clutch cover
Disassembling the clutch cover
Removing the clutch cover
Clutch assembly: primary drive gears

Refitting the primary drive gears and checking backlash
Removing the primary drive gears
Gearbox assembly: linkages
Refitting the gearchange mechanism
Refitting the gear interlock plunger and ratchet
Disassembling gear interlock plunger and ratchet
Removing the gearchange mechanism
Gearbox assembly: gearbox shafts
Reassembling the gearbox assembly
Reassembling the gearbox shafts
Inspecting the fork selector drum
Inspecting the gear selector forks
Overhauling the gearbox
Disassembling the gearbox shafts
Removing the gearbox assembly
Flywheel - generator
Refitting the flywheel/generator assembly
Overhauling the flywheel/generator assembly
Removing the flywheel/generator assembly
Refitting the generator cover
Reassembling the generator cover
Disassembling the generator cover
Removing the generator cover
Crankcase: external components
Refitting the starter motor
Removing the starter motor
Refitting the starter motor idler gear
Removing the starter motor idler gear
Refitting the timing gears
Removing the timing gears
Refitting the external components
Removing outer components
Crankcase: casings
Closing the crankcase
Shimming the shafts
Reassembling the crankcase halves
Main bearings
Overhauling the crankcase halves
Separating the crankcase halves
Crankcase: connecting rod assembly
Reassembling the connecting rod assembly
Overhauling the connecting rod assembly
Disassembling the connecting rod assembly
Removing the connecting rod assembly

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 real "reminders". Please refer to this page whenever in doubt as to
their meaning.
The terms right-hand and left-hand refer to the motorcycle viewed from the riding position.
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.
Note
This symbol indicates additional useful information for the current operation.
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 characteristics see Fuel, lubricants and other fluids).
SHELL Advance 4T
Ultra
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% + 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 or SHELL
Gadius S2 V220
AD 2
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
Grease PANKL - PLB 05
GREASE
F
Grease OPTIMOL - PASTE
WHITE T
GREASE
G
Grease PANKL - PLB07
GREASE
H
Grease KLÜBER
STABURAGS NBU
30 PTM
GREASE
I
Copper grease CUPRUM 320
LOCK 1 Low-strength threadlocker. Loctite 222
LOCK 2 Medium-strength threadlocker, compatible with oil. Loctite 243 (or
THREE BOND
TB1324)
LOCK 3 High-strength threadlocker for threaded parts. Loctite 270
LOCK 4 Surface sealant resistant to high mechanical stress and solvents. Resists
high temperatures (up to 200 °C) and pressures up to 350 bar; fills
gaps up to 0.4 mm.
Loctite 510
LOCK 5 Permanent adhesive for freely sliding cylindrical couplings or threaded
couplings on mechanical parts. High resistance to mechanical stress and
solvents. Temperature range: 55 to 175 °C.
Loctite 128455
(former 648 BV)
LOCK 6 Pipe sealant for pipes and medium to large fittings. For water and gases
(except oxygen). Maximum filling capacity: 0.40 mm (diameter
clearance).
Loctite 577
LOCK 7 Instant adhesive for rubber and plastics with elastomer charged ethylic
base.
Loctite 480
LOCK 8 High-strength retaining compound for threaded parts, bearings, bushes,
splines and keys. Operating temperature range: 55 to 150 °C.
Loctite 601 (As an
alternative THREE
BOND TB1378B)

LOCK 9
Medium-strength threadlocker.
Loctite 406
LOCK
10
Product for metal parts to seal and lock freely sliding cylindrical
couplings or threaded couplings. Resistant to high mechanical stress and
high temperature, excellent resistance to solvents and chemical attack.
Loctite 128443
(former 648 AV)
LOCK
11
Medium-strength threadlocker. Loctite 401
LOCK
12
Instant adhesive gel offering tensile/shear strength. Loctite 454 gel
DUCATI sealing compound. THREE BOND
1215
Sealing compound THREE BOND
1207B
Exhaust pipe sealing compound. Self-sealing paste hardens when
heated and resists temperatures exceeding 1000 °C.
Holts Firegum
Spray used to protect electric systems. Eliminates moisture and
condensation and provides excellent corrosion resistance. Water
repellent.
SHELL Advance
Contact Cleaner
Dry lubricant, polymerising on contact with air. Molykote D321R
Molykote M55 Plus
Emulsion for lubrication of rubber. P 80
Protection lubricant emulsion. KLUBERPLUS S
06/100
Lubricant for mechanical elements Castor oil

General maintenance instructions
Useful tips
Ducati recommends you to follow the instructions below in order to prevent problems and obtain the best
result:
-when diagnosing faults, primary consideration should always be given to what the customer reports
about motorcycle operation since this information can highlight faults; your questions to the customer
concerning symptoms of the fault should be aimed at clarifying the problem;
-diagnose the problem systematically and accurately before proceeding further. This manual provides
the theoretical background for troubleshooting; this basis must be combined with personal experience
and attendance at periodic training courses held by Ducati;
-repair work should be planned carefully in advance to prevent any unnecessary downtime, for example
obtaining the required spare parts or preparing the necessary tools, etc.;
-limit the number of operations needed to access the part to be repaired. Note that the disassembly
procedures in this manual describe the most efficient way to reach the part to be repaired.
General advice on repair work
-Always use top quality tools. When lifting the motorcycle, only use devices that fully comply with the
relevant European directives.
-When working on the motorcycle, always keep the tools within reach, ideally in the order required, and
never put them on the motorcycle or in hard-to-reach or inaccessible places.
-The workplace must be kept clean and tidy at all times.
-Always replace gaskets, sealing rings and split pins with new parts.
-When loosening or tightening nuts or screws, always start with the largest or start from the centre;
tighten nuts and screws to the specified torque working in a cross pattern.
-Always mark any parts and positions which might easily be confused upon reassembly.
-Use exclusively Ducati original spare parts and the recommended brands of lubricants.
-Use special tools where specified.
-Ducati Technical Bulletins often contain updated versions of the service procedures described in this
manual. Check the latest Bulletins for details.

General safety rules
Carbon monoxide
When a maintenance operation must be performed with the engine running, make sure that the working
area is well-ventilated. Never run the engine indoors.
Warning
Exhaust gases 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 gas 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 working area and fuel storage area.
Warning
Fuel 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; pay particular attention not to touch
exhaust system with any body part 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, we recommend washing your hands thoroughly with soap immediately afterwards. Keep away
from children.
Brake dust
Never clean the brake assembly using compressed air or a dry brush.
Brake fluid
Warning
Spilling brake fluid onto plastic, rubber or painted parts of the motorcycle may cause damages. Protect
these parts with a clean shop cloth before proceeding to service the system. Keep away from children.
Battery
Warning
The battery gives off explosive gases; never cause sparks or allow naked flames and cigarettes near the
battery. When charging the battery, ensure that the working area is properly ventilated.

Identification data
Each Ducati motorcycle has two identification numbers - the frame number and the engine number - and an
EC nameplate (A) not present on the U.S.A. version.
Note
Please quote these numbers, which identify the motorcycle model, when ordering spare parts.
DATA STAMPED ON THE FRAME
Example: ZDM K 100AA # B ?????
Following is the table with the frame part numbers.
EC Plant Borgo Panigale
VERSION 1 2 3 4 5 6
EC version frame ZDM K 100AA # B ?????
JAPAN version frame ZDM K 101JA # B ?????
EC 35 kW version frame ZDM K 102AA # B ?????
EC 25 kW version frame ZDM K 103AA # B ?????
EC Plant THAI version
EC version frame ML0 K 100AA # T ?????
JAPAN version frame ML0 K 101JA # T ?????
1 = Manufacturer: Ducati Motor Holding
2 = Type - identical for all models
3 = Variant
4 = Model Year, E for 2014 models, F for 2015 models, G for 2016 models etc.
5 = Manufacturing facility
6 = Progressive serial no.
DATA STAMPED ON ENGINE

Example: ZDM 800A2C ?????
Following is the table with the engine part numbers.
EC Plant Borgo Panigale
VERSION 1 2 3
Engine ZDM 800A2C ?????
Engine ML0 800A2C ?????
EC Plant THAI version
Engine ML0 800A2D ?????
Engine ZDM 800A2D ?????
1 = Manufacturer
2 = Engine type
3 = Progressive serial no.

Lights/Instrument panel
Reference Technical specifications
Headlight
Headlight low beam/high beam lamp type H4 (12V-60/55W)
Parking light LED No. 1 LED (3.1W — 13.5V)
Tail light
Parking light LED No. 2 LEDs (3.24W-12V)
Stop light LED No. 6 LEDs (7.9W-12V)
Number plate light
- lamp No. 3 LEDs (0.67W-13.5V)
Turn indicators
Front lamp 12V RY10W
Rear lamp 12 VRY10W
Fuses
1 Key-on 10A
2 El. loads 15A
3 Instrument panel 10A
4 Control unit 5A
5 Injection 20A
6 ABS motor 25A
7 ABS 10A

Fuel system
Important
Do not use any additives in fuel or lubricants. Using them could result in severe damage of the engine and
motorcycle components.
Warning
The motorcycle is only compatible with fuel having a maximum content of ethanol of 10% (E10). Using fuel
with ethanol content over 10% is forbidden. Using it could result in severe damage to the engine and
motorcycle components. Using fuel with ethanol content over 10% will make the warranty null and void.
Make Type
Unleaded fuel
Fuel specifications for the US market.
95-98 RON
Unleaded fuel with a minimum octane rating of 90 (RON+MON)/2
Throttle body Ø 45 mm
Injectors per cylinder 1
Firing points per injector 8

Ignition system
Reference Technical specifications
Starting Type Electric starter motor 12 V - 0.7 kW
Spark plugs Make and type NGK DCPR8E
Electrode gap 0.7÷0.8 mm
Injection system
Make Type
Control unit – –

Charging system/generator
Reference Technical specifications
Battery Voltage 12 V
Charge 10 A/h
Type Sealed-type, maintenance-free
Generator Capacity 490 W - 14 V - 34.8 A

Hydraulic brakes
Reference Standard value Service limit
FRONT
Brake disc Type Drilled disc
Thickness 5 mm
Flange material Steel
Braking surface material Stainless steel
Diameter 330 mm
Brake calliper Make Brembo
Type M 4.3
Calliper cylinder diameter 32 mm
Pad friction material FERIT I/D 450-FF
Master cylinder Type PS 13/22
REAR
Brake disc Type Fixed drilled disc
Thickness 4mm
Material Stainless steel
Diameter 245 mm
Brake calliper Make Brembo
Type PF 32
Pad friction material FERIT I/D 450-FF
Master cylinder Type PS 11
Master cylinder diameter 11 mm