Ducati SUPERBIKE 848 MY 2008 User manual

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SUPERBIKE 848 MY
2008 Home Main
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A - General
0A - General
0B - Information about the model
0C - Technical data
0D - Use and maintenance
0E - Fairings
0F - Controls - Devices
0G - Wheels - Suspension - Brakes
0H - Frame
0L - Fuel/Exhaust System
0M - Fuel injection - ignition system
0N - Engine
0P - Electrical system
0GENERAL SUMMARY
Section A
0A - 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
Section B
0B - Information about the model
1 - Identification data 3
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A - General
Identification data for the Superbike 848 3
Section C
0C - Technical data
1.1 - Technical specifications 3
General 3
Colours 4
Transmission 4
Timing system/valves 4
Crankshaft 5
Cylinder/Piston 5
Gearbox 6
Cooling system 6
Front wheel 6
Front suspension 6
Rear wheel 6
Rear suspension 7
Hydraulic brakes 7
Charging system/alternator 7
Injection - ignition system 8
Fuel system 8
Lights/instrument panel 8
1.2 - Dimensions 9
2 - Fuel, lubricants and other fluids 10
3 - Torque settings 11
Frame torque settings 11
Engine torque settings 16
4 - Service tools 19
Specific tools for the engine 19
Specific tools for the frame 25
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A - General
Section D
0D - Use and maintenance
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 client 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
Changing the coolant 16
Changing and cleaning the air filters 17
Changing the brake fluid 19
Draining the brake circuit 22
Filling 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 39
Adjusting the clutch lever and front brake lever 41
Adjusting the position of the gearchange and rear brake pedals 42
Adjusting the front fork 43
Adjusting the rear shock absorber 44
5 - Diagnostic instruments 46
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A - General
Description of the Ducati Diagnostic System instrument 47
Tester power supply 49
DDS tester 52
Checking and adjusting timing belt tension 53
Resetting the throttle position sensor (TPS) 57
Adjusting the idle speed 61
Checking the engine oil pressure 66
Cylinder compression test 71
Fuel pressure test 74
Immobilizer override procedure 77
Guided diagnosis 81
Testing the battery charging system 84
Deactivating the service indication on the instrument panel 87
Icons table 90
Section E
0E - Fairings
1 - Headlight shell - rear-view mirrors 3
Removal of the rear-view mirrors 4
Refitting the rear-view mirrors 5
Removal of the air scoop covers 6
Refittingthe airscoop covers 8
Removal of the headlight shell 11
Refitting the headlight shell 13
2 - Fairing panels 16
Removal of the side fairings 17
Removal of the front shield 20
Refitting the front shield 20
Refitting the side fairings 21
3 - Seat seat cowling and side panels 24
Removal of the seats 25
Removal of the side panels and seat cowling 26
Refitting the side panels and seat cowling 30
Refitting the seats 34
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A - General
Refitting the pillion seat 35
4 - Front mudguard 36
Removal of the front mudguard 37
Refitting the front mudguard 38
Section F
0F - Controls - Devices
1 - Throttle twistgrip 3
Adjusting the throttle cable 4
Removal of the throttle twistgrip 4
Refitting the throttle twistgrip 5
2 - Hydraulic clutch control 7
Removal of the clutch master cylinder assembly 8
Refittingthe clutch master cylinder assembly 9
Removal of the clutch slave cylinder 10
Refitting the clutch slave cylinder 12
3 - Front brake control 15
Removal of the front brake master cylinder 16
Refitting the front brake master cylinder 17
4 - Rear brake control 18
Removal of the rear brake control 19
Disassembly of the rear brake control 20
Refitting the rear brake control 21
5 - Gearchange mechanism 22
Removal of the gearchange mechanism 23
Disassembly of the gearchange mechanism 24
Refitting the gearchange mechanism 25
Section G
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A - General
0G - Wheels - Suspension - Brakes
1 - Front wheel 3
Removal of the front wheel 4
Overhauling the front wheel 6
Refitting the front wheel 9
2 - Front fork 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
Refittingthe brake discs 26
Overhauling the front brake components 27
Refitting the front brake system 28
4 - Rear wheel 31
Removal of the rear wheel 32
Overhauling the rear wheel 33
Refitting the rear wheel 34
5 - Rear swingarm 35
Removal of the rear wheel eccentric hub and rear wheel axle 36
Refitting the rear wheel eccentric hub and rear wheel axle 38
Removal of the swingarm 41
Inspecting the swingarm pivot shaft 43
Overhauling the rear swingarm 44
Refitting the swingarm 49
6 - Hydraulic rear brake 51
Removal of the rear brake caliper 52
Removal of the rear brake disc 53
Refitting the rear brake caliper 54
7 - Rear suspension 55
Rear suspension system 56
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A - General
Removal of the rear shock absorber 56
Overhauling the rear shock absorber 57
Removal of the rear suspension rocker arm 58
Overhauling the rear suspension rocker arm 59
Disassembly of the shock absorber tie-rod 60
Refitting the rear suspension 60
8 - Final drive 63
Inspecting the final drive 64
Removal of the front sprocket 65
Refitting the front sprocket 67
Renewal of the rear sprocket 69
Refitting the rear sprocket 70
Washing the chain 71
Lubricating the chain 71
Section H
0H - Frame
1 - Handlebars 3
Removal of the handlebars 4
Refitting the handlebars 6
2 - Steering 7
Adjusting the steering head bearings 8
Steering angle adjustment 9
Removal of the steering head components 10
Refitting the steering head components 12
4 - Footrest brackets 15
Removal of the front footrests 16
Refitting the front footrests 17
Removal of the rear footrests 18
Refitting the rear footrests 19
5 - Sidestands 21
Removal of the sidestand 22
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A - General
Refitting the sidestand 24
6 - Frame inspection 25
Disassembly of structural components and the frame 26
Checking the frame 30
Reassembly of structuralcomponents and the frame 32
7 - Number plate holder 34
Removal of the number plate holder 35
Refitting the number plate holder 36
Section L
0L - Fuel/Exhaust System
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
6 - Airbox Throttle Body 15
Refitting the airbox and throttle body 16
Refitting the airbox and throttle body 25
7 - Air intake 31
Removal of the air filters 32
Refitting the air filters 33
8 - Exhaust system 34
Removal of the exhaust system 35
Refitting the exhaust system 40
Section M
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A - General
0M - Fuel injection - ignition system
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
Fuel injectors 13
Stepper motor 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
0N - Engine
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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A - General
3.1 - Cooling system: coolant expansion tank 21
Removal of the expansion tank 22
Refittingthe expansion tank 24
3.2 - Cooling system: radiator 27
Removal of the radiator 28
Renewal of the cooling fan 30
Refitting the radiator 31
Removal of the cooling system hosesand unions 33
Refitting the cooling system hoses and unions 36
3.3 - Cooling system: water pump 41
Removal of the water pump 42
Refitting the water pump 45
4.1 - Cylinder head assemblies: checks and adjustments 50
Checking and adjusting the valve clearances 51
Checking valve lift 53
Checking the engine timing 54
4.2 - Cylinder head assemblies: timing 57
Removal of the timing belt covers 58
Removal of the tensioner pulley/timing belt 59
Removal of the camshaft pulleys/idler pulley 59
Removal of the tensioner and idler pulley mounting studs 60
Disassembly ofthe camshaft pulleys 60
Removal of the timing belt driveshaft pulleys 61
Refitting the timing belt driveshaft pulley 63
Refitting the idler and tensioner pulley mounting studs 65
Reassembly of the timing pulleys 66
Refitting the camshaft pulleys/idler pulleys 67
Refitting the timing belts 70
Refitting the timing belt covers 72
4.4 - Cylinder head assemblies: camshafts 73
Removal of the camshafts 74
Checking the camshafts and supports 76
Refitting the camshafts 77
Removal of the intake manifold and coolant union 83
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A - General
Refitting the intake manifold and coolant union 84
4.5 - Cylinder head assemblies: valves - rocker arms 85
Removal of the cylinder heads 86
Removal of the valves 87
Removing the valve rocker arms 88
Overhaul of cylinder head components 91
Reassembly of the cylinder head 98
Refitting the cylinder head assemblies 105
5 - Cylinder/piston assemblies 107
Removal of the cylinder/piston assembly 108
Overhaul of the cylinder barrel/piston components 111
Refitting the cylinder/piston assembly 116
6.1 - Clutch assembly: clutch 120
Description of the clutch assembly 121
Removal of the clutch 122
Checking and overhauling the components 125
Reassembly of the clutch 127
6.2 - Clutch assembly: clutch-side crankcase cover 132
Removal of the clutch-side crankcase cover 133
Disassembly of the clutch-side crankcase cover 134
Reassembly of the clutch-side crankcase cover 135
Refittingthe clutch-side crankcase cover 136
6.3 - Clutch assembly: primary drive gears 138
Removal of the primary drive gears 139
Refitting the primary drive gears and checking backlash 142
7.1 - Gearbox assembly: gearchange mechanism 145
Removal of the gearchange mechanism 146
Disassembly ofgear interlock plunger andpawl assembly 148
Refitting the gear interlock plunger and pawl assembly 149
Refitting the gearchange mechanism 150
7.2 - Gearbox assembly: gearbox shafts 152
Removal of the gearbox assembly 153
Disassembly of the gearbox shafts 155
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A - General
Overhaul of the gearbox 160
Inspection of the gear selector forks 161
Inspection of the gear selector drum 162
Reassembly of the gearbox shafts 163
Reassembly of the gearbox 167
8 - Flywheel-alternator 168
Removal of the alternator-side crankcase cover 169
Disassembly of the alternator-side crankcase cover 171
Removal of the flywheel/alternator assembly 172
Overhaul of the flywheel/alternator assembly 174
Refitting the flywheel/alternator assembly 182
Refitting the alternator-side crankcase cover 184
9.1 - Crankcase assembly: external components 187
Removal of external components 188
Refitting the external components 191
Removal of the timing gears 195
Refitting the timing gears 196
Removal of the starter motor idler gear 197
Refitting the starter motor idler gear 198
9.2 - Crankcase assembly: crankcase halves 199
Separation ofthe crankcase halves 200
Overhaul of the crankcase halves 203
Main bearings 207
Reassembly of the crankcase halves 208
Shimming the shafts 211
Reassembly of the crankcase halves 216
9.3 - Crankcase assembly: crankshaft/connecting rods assembly 222
Removal of the crankshaft/connecting rods assembly 223
Disassembly of the crankshaft/connecting rods assembly 224
Overhaul of the connecting rods 225
Reassembly of the connecting rods 230
Refitting the crankshaft/connecting rod assembly 233
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A - General
Section P
0P - Electrical system
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 25
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
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A - General
Plate 31 34
Plate 32 35
Plate 33 36
Plate 34 37
Plate 35 37
Plate 36 38
Plate 37 39
Plate 38 40
Plate 39 41
Plate 40 42
Plate 41 43
Plate 42 44
Plate 43 45
2 - Battery charging system 46
Checking the battery charging system 46
Recharging the battery 47
Topping up the electrolyte 48
Battery 51
Alternator 53
Regulator/rectifier 56
3 - Electric starting system 59
Electric starting system 59
Starter motor 60
Starter contactor 63
4 - Lights and indicating devices 66
Changing light bulbs 66
High beam headlights relay 69
Headlight aim 71
5 - Indicating devices 72
Checking the indicating system components 72
Coolant temperature sensor 79
Fan relay 80
Checking operation of the fan relay 80
Changing light bulbs 81
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A - General
6 - Protection and safety devices 85
Checking protection and safety device components 85
Checking the fuses 87
7 - Instruments 88
Instrument panel 88
Instrument panel system 89
Display settings and functions 91
8 - Immobilizer and transponder 118
9 - Diagnostic instruments 122
Using a multimeter to check the electrical systems 122
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A - General
0A - 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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How to use this manual
1 - How to use this manual
This manual has been prepared for technical personnel at Ducati Authorized Service Centres with the
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, as we believe that all specialized technicians 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
Layout of the manual
This manual is divided into sections (1), each identified by a letter.
Each section (1) is made up of several chapters (2), which are numbered consecutively.
The chapters (2) may be further subdivided into paragraphs (3).
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How to use this manual
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 consultation of the manual, the table of contents is identical for all motorcycle models.
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Symbols - Abbreviations - References
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.
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
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