Ducati 1098 2007 Manual de usuario

Draft copy

General 0

Information about the model 0

Technical data 0

Use and maintenance 0

Fairings 0

Controls - Devices 0

Wheels - Suspension - Brakes 0

Frame 0

Fuel / Exhaust System 0

Injection - ignition system 0

Engine 0

Electric system 0

GENERAL SUMMARY 0

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21098/1098S - M.Y. 2007 - edition 00

General summary

Section A

General 0

1 - How to use this manual 3

Layout of the manual 4

2 - Symbols - Abbreviations - References 5

Product specifications 6

3 - Hazardous Products - Warnings 8

General safety rules 8

General maintenance indications 10

Section B

Information about the model 0

1 - Identification data 3

Identification data for the Superbike 1098 3

Section C

Technical data 0

1.1 - Technical specifications 3

General 3

Colours 4

Transmission 4

Timing system/valves 5

Crankshaft 5

Cylinder/Piston 5

Gearbox 6

Cooling system 6

Front wheel 6

Front suspension (1098) 6

Front suspension (1098S) 7

Rear wheel 7

Rear suspension (1098) 7

Rear suspension (1098S) 7

Hydraulic brakes 8

Charging system/alternator 8

Injection - ignition system 8

Fuel system 8

Lights/instrument panel 9

1.2 - Dimensions 10

2 - Fuel, lubricants and other fluids 11

3 - Torque settings 12

Frame torque settings 12

Engine torque settings 13

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31098/1098S - M.Y. 2007 - edition 00

General summary

4 - Service tools 16

Special tools for the engine 16

Special tools for the frame 22

Section D

Use and maintenance 0

1 - Preliminary checks 3

Running-in precautions 3

Pre-ride checks 4

2 - Starting - Engine warmup 5

Starting the engine 5

3 - Routine maintenance table 6

Programmed maintenance plan: operations to be carried out by the dealer 6

Programmed maintenance plan: operations to be carried out by the dealer 8

4 - Maintenance operations 9

Checking the engine oil level 9

Changing the engine oil and filter cartridge 10

Checking valve clearances 13

Adjusting the valve clearances 14

Checking the coolant level 15

Change the coolant 16

Changing and cleaning the air filters 17

Changing the brake fluid 19

Draining the braking circuit 22

Fill the brake system with fluid 24

Changing the clutch fluid 27

Draining the clutch hydraulic circuit 28

Filling the clutch circuit 30

Adjusting the steering head bearings 32

Adjusting the chain tension 33

Checking brake pad wear and changing brake pads 35

Adjusting the throttle cable 38

Adjusting the clutch lever and front brake lever 40

Adjusting the position of the gearchange and rear brake pedals 41

Adjusting the front fork 42

Adjusting the rear shock absorber 43

Adjusting the rear ride height 45

5 - Diagnostic instruments 47

Description of the Ducati Diagnostic System instrument 48

Tester power supply 50

DDS tester 53

Checking and adjusting timing belt tension 54

Resetting the throttle position sensor (TPS) 58

Adjusting the idle speed 62

Checking the engine oil pressure 66

Cylinder compression test 71

Fuel pressure test 74

Immobilizer override procedure 77

Guided diagnosis 81

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41098/1098S - M.Y. 2007 - edition 00

General summary

Testing the battery charging system 84

Deactivating the “maintenance” indication on the instrument panel 87

Icons table 90

Section E

Fairings 0

1 - Headlight shell - rear-view mirrors 3

Removal of the rear-view mirrors 4

Refitting the rear-view mirrors 5

Removal of the headlight shell 6

Refitting the headlight shell 8

2 - Fairing panels 11

Removal of the side fairings 12

Removal of the front shield 14

Refitting the front shield 14

Refitting the side fairings 15

3 - Seat - seat cowling and side panels 17

Removal of the seat 18

Removal of the side panels and seat cowling 19

Refitting the side panels and seat cowling 22

Refitting the seats 26

Refitting the pillion seat 27

4 - Front mudguard 28

Removal of the front mudguard 28

Refitting the front mudguard 29

Section F

Controls - Devices 0

1 - Throttle and choke controls 3

Adjusting the throttle cable 4

Removal of the throttle cable 4

Refitting the throttle twistgrip 5

2 - Hydraulic clutch control 7

Removal of the clutch master cylinder assembly 8

Refitting the clutch master cylinder assembly 9

Removal of the clutch slave cylinder 11

Refitting the clutch slave cylinder 13

3 - Front brake control 16

Removal of the front brake master cylinder 17

Refitting the front brake master cylinder 18

4 - Rear brake control 19

Removal of the complete rear brake control 20

Disassembly of the rear brake master control 21

Refitting the rear brake control 22

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51098/1098S - M.Y. 2007 - edition 00

General summary

5 - Gearchange control 23

Removal of the complete gearchange control 24

Disassembly of the gearchange control 25

Refitting the gearchange control 26

Section G

Wheels - Suspension - Brakes 0

1 - Front wheel 3

Removal of the front wheel 4

Overhauling the front wheel 6

Refitting the front wheel 9

2 - Front fork (1098) 11

Removal of the front forks 12

Overhauling the front forks 13

Refitting the front forks 20

3 - Hydraulic front brake 22

Maintenance operations 23

Removal of the front brake system 24

Refitting the brake discs 26

Overhauling the front brake components 27

Refitting the front brake system 28

4 - Rear wheel 30

Removal of the rear wheel 31

Overhauling the rear wheel 32

Refitting the rear wheel 33

5 - Rear swingarm 34

Removal of the rear eccentric hub 35

Removal of the rear eccentric hub 37

Removal of the swingarm 39

Inspecting the swingarm pivot shaft 41

Overhauling the rear swingarm 42

Refitting the swingarm 46

6 - Hydraulic rear brake 48

Removal of the rear brake caliper 49

Removal of the rear brake disc 50

Refitting the rear brake caliper 51

7 - Rear suspension 52

Rear suspension system 53

Removal of the rear shock absorber 54

Overhauling the rear shock absorber 55

Removal of the rear suspension rocker arm 56

Overhauling the rear suspension rocker arm 57

Disassembly and overhaul of the shock absorber tie-rod 58

Refitting the rear suspension 59

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61098/1098S - M.Y. 2007 - edition 00

General summary

8 - Final drive 61

Inspecting the final drive 62

Removal of the front sprocket 63

Refitting the front sprocket 65

Renewal of the rear sprocket 67

Refitting the rear sprocket 68

Washing the chain 69

Lubricating the chain 69

Section H

Frame 0

1 - Handlebars 3

Removal of the handlebars 4

Refitting the handlebars 5

2 - Steering 6

Adjusting the steering head bearings 7

Steering angle adjustment 8

Removal of the steering head components 9

Refitting the steering head components 11

3 - Steering damper (1098) 14

Removal of the steering damper 15

Refitting the steering damper 16

4 - Footrest brackets 17

Removal of the footrests 18

Refitting the footrests 19

5 - Stands 20

Removal of the sidestand. 21

Refitting the sidestand 23

6 - Frame inspection 24

Disassembly of structural components and the frame 25

Checking the frame 29

Reassembly of structural components and the frame 31

7 - Number plate holder 33

Removal of the number plate holder 34

Section L

Fuel / Exhaust System 0

2 - Fuel tank 3

Removal of the fuel tank 4

Removal of the fuel filler cap assembly 6

Refitting the fuel filler cap assembly 7

Renewal of the fuel tank flange 8

Refitting the fuel tank flange 9

Refitting the fuel tank 10

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71098/1098S - M.Y. 2007 - edition 00

General summary

6 - Airbox - Throttle Body 14

Removal of the throttle body 15

Refitting the airbox and throttle body 23

7 - Air intake 29

Removal of the air filters 30

Refitting the air filters 31

8 - Exhaust system 32

Removal of the exhaust system 33

Refitting the exhaust system 37

Section M

Injection - ignition system 0

2 - Fuel injection-ignition system 3

3 - System components 4

Electronic Control Unit (ECU) 4

Removal of the battery support 6

Refitting the battery support 9

Electric injector 14

Air pressure sensor 15

Coolant temperature sensor 16

Air temperature sensor 17

Ignition coils 18

Throttle Position Sensor (TPS) 21

Rpm/timing sensor 22

Injection relay 23

CAN Line 24

Section N

Engine 0

1 - Removal–refitting of the engine assembly 5

Removal of the engine 6

Refitting the engine 9

2.1 - Lubrication system: oil pump 10

Removal of the oil pump 11

Disassembly of the oil pump 12

Reassembly of the oil pump 13

Refitting the oil pump 14

2.2 - Lubrication system: oil cooler 15

Removal of the lubrication system 16

Oil cooler inspection 18

Refitting the lubrication system 18

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81098/1098S - M.Y. 2007 - edition 00

General summary

3.2 - Cooling system: radiator 20

Removal of the radiator 21

Renewal of the cooling fan 23

Refitting the radiator 24

Removal of the cooling system hoses and unions 26

Refitting the cooling system hoses and unions 29

3.3 - Cooling system: water pump 32

Removal of the water pump 33

Refitting the water pump 36

4.1 - Cylinder head assemblies: checks and adjustments 41

Checking and adjusting the valve clearances 42

Checking valve lift 44

Checking the engine timing 46

4.2 - Cylinder head assemblies: timing 49

Removal of the timing belt covers 50

Removal of the tensioner pulley/timing belt 51

Removal of the camshaft pulleys/idler pulley 51

Removal of the tensioner and idler pulley mounting studs 52

Disassembly of the camshaft pulleys 53

Removal of the timing belt driveshaft pulleys 54

Refitting the timing belt driveshaft pulleys 56

Refitting the idler and tensioner pulley mounting studs 58

Reassembly of the timing pulleys 59

Refitting the camshaft pulley/idler pulley 60

Refitting the timing belts 63

Refitting the timing covers 65

4.4 - Cylinder head assemblies: camshafts 66

Removal of the camshafts 67

Checking the camshafts and supports 69

Refitting the camshafts 70

Removal of the intake manifold and coolant union 76

Refitting the intake manifold and coolant union 77

4.5 - Cylinder head assemblies: valves–rocker arms 78

Removal of the cylinder heads 79

Removal of the valves 80

Removal of the valve rocker arms 81

Overhaul of cylinder head components 84

Reassembly of the cylinder head 91

Fitting the cylinder head assemblies 98

5 - Cylinder/piston assemblies 100

Disassembly of the cylinder/piston 101

Overhaul of the cylinder barrel/piston components 104

Refitting the cylinder/piston assembly 109

6.1 - Clutch assembly: clutch 113

Description 114

Disassembly of the clutch 115

Inspection and overhaul of the clutch components 120

Reassembly of the clutch 122

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91098/1098S - M.Y. 2007 - edition 00

General summary

6.2 - Clutch assembly: right-hand side crankcase cover 126

Removal of the right-hand side crankcase cover 127

Disassembly of the right-hand side crankcase cover 128

Reassembly of the right-hand crankcase cover 129

Refitting the right-hand side crankcase cover 131

6.3 - Clutch assembly: primary drive gears 133

Removal of the primary drive gears 134

Refitting the primary drive gears and checking backlash 137

7.1 - Gearbox assembly: gearchange mechanism 140

Removal of the gearchange mechanism 141

Disassembly of gear interlock plunger and pawl assembly 143

Refitting the gear interlock plunger and pawl assembly 144

Refitting the gearchange mechanism 145

7.2 - Gearbox assembly: gearbox shafts 147

Removal of the gearbox assembly 148

Disassembly of the gearbox shafts 150

Overhaul of the gearbox 155

Inspection of the gear selector forks 156

Inspection of the gear selector drum 157

Reassembly of the gearbox shafts 158

Reassembly of the gearbox 162

8 - Flywheel/alternator 163

Removal of the left-hand side crankcase cover 164

Disassembly of the left-hand crankcase cover 166

Removal of the flywheel/alternator assembly 167

Overhaul of the flywheel/alternator assembly 169

Refitting the flywheel/alternator assembly 177

Refitting the left-hand crankcase cover 179

9.1 - Crankcase assembly: external components 182

Removal of external components 183

Refitting the external components 186

Removal of the timing gears 190

Refitting the timing gears 191

Removal of the starter motor idler gear 192

Refitting the starter motor idler gear 193

Checking the engine sensor air gap 194

9.2 - Crankcase assembly: crankcase halves 195

Separation of the crankcase halves 196

Overhaul of the crankcase halves 199

Main bearings 203

Reassembly of the crankcase halves 204

Shimming the shafts 207

Reassembly of the crankcase halves 212

9.3 - Crankcase assembly: connecting rods 218

Removal of the connecting rods assembly 219

Disassembly of the connecting rods 220

Overhaul of the connecting rods 221

Reassembly of the connecting rods 226

Refitting the connecting rods. 228

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10 1098/1098S - M.Y. 2007 - edition 00

General summary

Section P

Electric system 0

1 - Wiring diagram 4

Key to wiring diagram 5

Wiring colour codes 6

Key to fusebox 6

Routing of wiring on frame 7

Plate 1 9

Plate 2 9

Plate 3 10

Plate 4 10

Plate 5 11

Plate 6 11

Plate 7 12

Plate 8 13

Plate 9 14

Plate 10 14

Plate 11 15

Plate 12 15

Plate 13 16

Plate 14 17

Plate 15 18

Plate 16 19

Plate 17 20

Plate 18 21

Plate 19 22

Plate 20 23

Plate 21 24

Plate 22 24

Plate 23 25

Plate 24 26

Plate 25 27

Plate 26 28

Plate 27 29

Plate 28 30

Plate 28 31

Plate 29 32

Plate 30 33

Plate 31 34

Plate 32 35

Plate 33 36

Plate 34 37

Plate 35 38

2 - Battery charging system 39

Checking the battery charging system 39

Recharging the battery 40

Topping up the electrolyte 41

Battery 44

Alternator 46

Regulator/rectifier 49

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