Ducati Scrambler User manual

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Scrambler
Valve Measurement and Adjustment User Guide

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Contents
Introduction ..............................................................................................................................3
Operation .................................................................................................................................3
Checking Valve Clearances .................................................................................................4
Remove the Spark Plugs.........................................................................................................4
Opening Shim Clearance Measurement………………………………………………………6
Closing Shim Clearance Measurement………………………………………………...………6
Determine if valves are within specification........................................................................7
Opening Shim Removal, Measurement, Replacement.....................................................7
Measure ................................................................................................................................8
Record...................................................................................................................................8
Closing Shim Removal and Measurement...........................................................................8
Measure ................................................................................................................................9
Reassembly.........................................................................................................................10
Appendix 1 –Ducati Scrambler Valve Measurement Recording Sheet.......................11

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Introduction
The Scrambler engine is an updated version of
Ducati’s classic SOHC V-twin. It is an air-and-oil
cooled two-valve engine displacing 803cc. The
valve service intervals are more frequent with the
air/oil cooled engines; therefore the Scrambler
Valve Adjustment Intervals are 7500 miles.
The shims don’t wear as much as the valve seats
do. As the engine is run, the face of the valves
and seats wear as they bed into each other
(opener clearances get smaller and the closer
clearances get bigger). The result is opening and
closing clearances that change with use.
Bringing the valve clearances into factory specifications assures the best possible
performance of from your scrambler.
Operation
The Desmodromic (Desmo) engines use a positive valve control system to open and
close the valves at the same time in the combustion cycle regardless of RPM. The
Desmo valve system uses an opening rocker arm and a closing rocker arm that
press on shims attached to the valve stem to open and close the valve in a precisely
controlled manner: as the components wear, the gap (clearance) between the
rocker and the shim changes. To compensate for these naturally occurring changes,
the shims are replaced with thicker/thinner shims to bring the gap back into
specification.
1. Valve
2. Closing Shim
3. Closing Rocker Arm
4. Retaining Clip
5. Opening Rocker Arm
6. Opening Shim

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Checking Valve Clearances
Before the clearances can be checked there is some disassembly required. Try and
have as little fuel as possible in the gas tank before beginning this procedure. It is
easiest to measure all the clearances prior to disassembling the valve train to
replace the shims.
1. Place the motorcycle on a swing arm stand, transmission in neutral.
2. Remove the seat.
3. Remove the fuel tank.
4. Remove the blow-by (part of the air box)
5. Remove the following components from the electrical component box:
a. Battery
b. Starter Relay
c. Fuse box
6. Remove the cylinder head valve covers (1) ,be careful if not replacing the
gaskets with new ones
Vertical Cylinder Vertical Cylinder Horizontal Cylinder
Remove the Spark Plugs
Remove the spark plug boots (1) and the spark plugs (2) from the horizontal and
vertical cylinders.

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Working from vehicle left-hand side, loosen the two
screws (3) and remove plug (1) from generator
cover (2)
Once the
plug is
removed
from the
generator
cover, install
the engine
turning tool,
making sure the tangs on the tool engage the
indents on the crank shaft (4).
Tighten the retaining bolt snug with a 13 mm wrench.
With the sparkplugs removed rotate the engine turning tool counter clockwise (from
the left side of the engine) until the horizontal cylinder comes to the top if its stroke:
Top Dead Center (TDC).
TDC occurs at the top of the compression stroke. You can feel air rushing out of the
cylinder as the piston comes up on the compression stroke. The magnet gently
inserted into the cylinder will give a visual indication when the piston has reached
the top of the stroke. (The handle of the engine turning tool will be in line with the
horizontal cylinder)
IMPORTANT: With the horizontal cylinder at TDC, the engine is in the “HOME” position.
The HOME position is the condition where all of the timing marks will align (useful for
belt changes).
The horizontal cylinder is also in the “rest” position (no tension on the valves). The
“rest” position is the correct position to measure the valve clearances. Verify the rest
position by spinning the opening shim with your finger.
1

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OPENING SHIM CLEARANCE MEASUREMENT
With the valve in the “rest”
position, slide the feeler gauge
between the opening rocker
arm and the opening shim.
Begin measuring using a thin
gauge, ~ .05mm; proceed using
thicker/thinner gauges until the
gap can be determined. The
correct feeling is one of slight
resistance, similar to the feeling
of inserting the gauge into a
large book and moving it
between the pages.
Measure the valve clearances
for both the intake valve (middle
of the “vee,) and the exhaust
side (where the exhaust exits the
cylinder head).
Record measurements in APPENDIX 1.
CLOSING SHIM CLEARANCE MEASUREMENT
Once the opening clearances
have been measured, measure
and record the closing
clearances.
Slide a feeler gauge between
the closing rocker arm and the
closing shim to measure the
clearance.
Record your measurements in
APPENDIX 1.
The clearances for the horizontal
cylinder have been measured.
Repeat the measurements for the vertical cylinder:
Slowly rotate the engine turning tool counter clockwise 270 degrees to bring the
vertical cylinder to top dead center. When the vertical cylinder is on the
compression stroke, the air will rush out of the cylinder; a thumb or finger lightly
covering the spark plug hole is a good way to feel the air rushing out. Using the
magnet and slight adjustments with the engine turning tool, you will quickly locate
the TDC of the vertical cylinder. Repeat the measurements for the opening and
closing clearances and record those readings in APPENDIX 1.

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Determine if valves are within specification.
Determine if the clearances are within specification by comparing the
measurements you recorded to the Factory Specification. Any measurement that
exceeds Factory Specified Clearance will require changing a shim to bring the
clearance back into Factory Specification. The basic sequence is:
1. Look at the values you measured and recorded in (Column A) APPENDIX 1.
Note which measured clearances exceed the Factory Specified Clearance
(Column B).
2. Subtract the lowest Factory Specification (.1 for intake, .0 for exhaust) from
your measurement and record that number in Column C.
3. Measure the existing shim and record this number in Column D.
4. Add Columns C and D in order to determine the size of the new shim to bring
the clearances back into specification. Note, it is not always possible to get
the exact shim size. A larger shim can be made to the correct size using
emery paper or 400 grit wet/dry sandpaper to adjust the size of the shim.
Refer to the following sections for shim removal, measurement, and replacement.
Remember to place the cylinder being worked on at TDC for ease of shim removal
(no tension on the valve/shims).
Refer to Appendix 1.
Opening Shim Removal, Measurement, Replacement
If either the opening
or the closing shims
require replacement
to bring the gap(s)
into specification
follow this procedure.
Pry off the spring clip
(4) from the rocker
shaft.
WARNING, this clip will
fly into your eye or to
parts unknown if it
isn’t restrained.
Note: be sure to
segregate and mark all pieces/parts removed so there is no question on reassembly.
Once the clip is removed the opening rocker (5) will need to be slid out of the way
to access the opening shim. This will take some wiggling/working the cams back and
forth to get the opening rocker to slide. If the cam belts are removed, wiggle the
cam gear to get the rocker to slide off. If the cam belts are still in place, use the
engine turning tool to wiggle the shaft and release the opening rocker to slide to the
side (arrow).

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Remove the Opening shim (6) from the valve stem.
Measure
NOTE: The Opening Shim has a Flat side and a recessed side. Using light pressure,
close the dial caliper all the way and “zero” the unit: hold the On/Off/Set button
until all Zeros appear in the display.
Open the Caliper sufficiently to allow the Opening
Shim to fit between the jaws of the micrometer.
The flat side of the Opening Shim should rest
against the stationary jaw of the micrometer. The
moveable portion of the micrometer will fit inside
the recessed portion of the opening shim.
Record
Record the measurements in Appendix 1.
Closing Shim Removal and Measurement
If the closing shim needs replacement, remove the opening shim as described in the
previous section. The valve stem is exposed with the opening rocker slid to the side.
Place a clamp on the valve. In addition to having the
cylinder at TDC, this is a little extra insurance to keep the
valve from dropping into the cylinder.
Press down on the Closing rocker to expose the retaining
rings. Slight engine rotation may be required to get the
rocker to move far enough to expose the retaining rings. The
retaining rings are in two halves.

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Use the magnet or magnet end of the screwdriver to extract
both halves of the retaining rings and set aside in a very safe
place (a zip lock bag properly labelled with the valve the
rings belong to).
With the retaining rings removed, you can now slide the
closing shim up and off the valve stem. If the shim gets
“stuck” at the top of the valve stem, it is an indication the
valve stem has mushroomed a bit. Some emery
cloth/sandpaper is needed to remove the wide part at the
top of the valve stem to provide clearance for the shim to
slide off.
Measure
The valve shim measuring tool and the electronic caliper will
be used to take the measurement. The tool sets inside of the
closing shim and gives a standard 10mm addition to your
measurement.
Turn the caliper on. Close the jaws using light pressure. Select
the unit of measure: either inch or mm. The shims are
designated by Ducati in millimeters and using mm as the unit
of measure simplifies new shim size selection. Press ZERO to
set the base line for the caliper.
Place the Shim Measuring Tool inside the closing shim
(narrow end in) and measure the overall length.
REMEMBER- The TOOL adds 10mm to the measurement:
subtract 10mm from the measurement and record your
number in Appendix 1.
In this example, the closing shim size would be 6.57mm.

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Reassembly
Obtain the correct shim(s) and reassemble the valve
train. Slide the closing shim onto the valve stem. The
wider side slides onto the valve stem first.
Depress the closing rocker and install the half rings
(retaining rings). Do this with your finger or dip the end
of the screwdriver in a little oil and use the screwdriver
to install the half rings.
While depressing the closing rocker, set a half ring in
place on the valve stem. Rotate this ring around to the
back side of the valve stem to leave room for the other
half ring. Install the other half ring and slowly release the
pressure from the closing rocker, making sure the half-
rings sit onto the valve stem correctly.
Put Opening shim onto valve stem
Once installed, slide the
opening rocker over the
opening shim.
REMEMBER, you will have to
wiggle the cam (belts
removed) or the motor using
the Engine rotating tool(belts
installed) to get the cams in
position to slide the rocker
over the valve.
Once the rocker is in place, press the spring clip into place. Some firm pressure will
be required.
Once the valve is reassembled, re-check the clearances to verify the valve train is
within specification. With the cam belts installed, rotate the engine to verify smooth
operation. Reassemble as required.

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Appendix 1 –Ducati Scrambler Valve Measurement Recording
Sheet
HORIZONTAL CYLINDER
INTAKE
A
B
C
D
E
MEASURED
CLEARANCE
DUCATI
SPECIFIED
CLEARANCE
NUMBER TO BE
ADDED TO SHIM
SHIM
MEASUREMENT
NEW SHIM SIZE
OPENER
-
.10 - .15mm
=
+
=
CLOSER
-
.00 - .05mm
=
+
=
EXHAUST
OPENER
-
.10 - .15mm
=
+
=
CLOSER
-
.00 - .05mm
=
+
=
VERTICAL CYLINDER
INTAKE
MEASURED
CLEARANCE
DUCATI
SPECIFIED
CLEARANCE
NUMBER TO BE
ADDED TO SHIM
SHIM
MEASUREMENT
NEW SHIM SIZE
OPENER
-
.10 - .15mm
=
+
=
CLOSER
-
.00 - .05mm
=
+
=
EXHAUST
OPENER
-
.10 - .15mm
=
+
=
CLOSER
-
.00 - .05mm
=
+
=
INTAKE
HORIZONTAL
CYLINDER
EXHAUST
INTAKE
VERTICAL CYLINDER
EXHAUST
Opener
0.10mm
0.15mm
Closer
0.0mm
0.05mm
Closer
0.0mm
0.05mm
Closer
0.0mm
0.05mm
Closer
0.0mm
0.05mm
Opener
0.10mm
0.15mm
Opener
0.10mm
0.15mm
Opener
0.10mm
0.15mm
If there is a clearance out of specification, that is the gap is larger
than the Ducati Specified Clearance there is a little calculation to
figure out the new shim size to bring the gap back into spec.
- Record the measured clearance in the column A.
- Subtract the Ducati Specified clearance, column B, (use .10mm for
Openers and .00 for Closers). Record the result in column C.
- Remove the existing shim and measure. Record this number in
column D.
-Add columns C and D together and you will have the new shim size.
- Shims come in .05mm increments. If the new shim size you calculate
is between shims available in the kit, you may have to use 400 grit
wet/dry sandpaper and sand a larger shim into the perfect size.