Ducati MONSTER S4R - Repair Manual

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Index2
Description11
Description: Table of Contents12
Product Specifications18
General Safety Rules20
General Maintenance Indications22
General Advice on Repair Work23
Model-Specific Information24
Model-Specific Information: Table of Contents25
Identification Data26
Technical Specification28
Technical Specification: Table of Contents29
Overall Dimensions37
Use and Maintenance Operations53
Use and Maintenance Operations: Table of Contents54
Preliminary Checks55
Running-In Precautions55
Pre-Ride Checks56
Starting/Engine Warm-Up58
Starting the Engine58
Routine Maintenance Table62
Checking the Engine Oil Level64
Changing the Engine Oil and Filter Cartridge65
Checking Valve Clearances67
Adjusting Valve Clearances67
Checking the Coolant Level68
Changing the Coolant69
Changing the Fuel Filter70
Refitting the Fuel Filter71
Changing and Cleaning the Air Filter72
Changing the Brake Fluid73
Fitting the Front Braking System73
Fitting the Rear Braking System74
Draining the Brake Circuit75
Filling the Braking Circuit76
Changing the Clutch Fluid78
Draining the Clutch Circuit79
Filling the Clutch Circuit80
Adjusting Steering Bearings Play82
Adjusting the Clutch Lever and the Front Brake Lever83
Adjusting Chain Tension84
Checking Brake Pad Wear85
Changing Brake Pads85
Checking Rear Brake Wear86
Adjusting the Throttle and Choke Cables87
Adjusting the Position of the Gear Change and Rear Brake Pedals89
Adjusting the Rear Shock Absorber90
Adjusting the Front Fork91
Changing Motorcycle Track Alignment92
Testers93
Tester Description94
Connection to the Bike95
Mathesis Tester96
Checking and Adjusting Timing Belt Tension97
Adjusting the Throttle Body101
Positioning the Throttle Sensor102
Adjusting the Throttle Position Sensor102
Adjusting the Idling Mixture103
Adjusting the Throttle Set Screw103
Balancing the Air Flows103
Adjusting the CO Rate104
Adjusting the Choke Control104
Checking Engine Oil Pressure105
Checking Cylinder Compression107
Checking Fuel Pressure109
Fairing110
Fairing: Table of Contents111
Headlight Fairing - Rear-View Mirrors112
Removing the Rear View Mirrors113
Fitting the Rear-View Mirrors113
Removing the Headlight Fairing114
Disassembling the Headlight Fairing114
Reassembling the Headlight Fairing114
Fitting the Headlight Fairing114
Tail Guard115
Removing the Tail Guard116
Disassembling the Tail Guard116
Reassembling the Tail Guard117
Refitting the Tail Guard117
Fitting the under Seat118
Refitting the under Seat118
Removing the Side Panels119
Refitting the Side Panels119
Removing the Front Mudguard120
Controls - Devices121
Controls - Devices: Table of Contents122
Throttle - Choke Control123
Disassembling the Throttle Control125
Removing the Choke Control126
Refitting the Choke Control127
Throttle Cable Routing128
Choke Cable Routing129
Clutch Hydraulic Control130
Removing the Clutch Cylinder Assembly131
Removing the Clutch Transmission Unit132
Refitting the Clutch Transmission Unit133
Clutch Hose Routing134
Front Brake Control135
Removing the Front Brake Master Cylinder136
Refitting the Front Brake Master Cylinder136
Front Brake Line Routing137
Rear Brake Control139
Removing the Complete Rear Brake Master Cylinder140
Disassembling the Rear Brake Master Cylinder141
Refitting the Rear Brake Cylinder141
Rear Brake Line Routing143
Gear Change Control145
Removing the Gear Change Control146
Disassembling the Gear Change Control146
Refitting the Gear Change Control146
Releasing Mechanisms147
Removing the Seat Releasing Mechanism148
Refitting the Seat Releasing Mechanism148
Wheels - Suspensions - Brakes149
Wheels - Suspensions - Brakes: Table of Contents150
Front Wheel151
Removing the Front Wheel152
Overhauling the Front Wheel153
Overhauling the Front Wheel Bearings153
Overhauling the Front Wheel Shaft154
Overhauling the Front Wheel Rim154
Refitting the Front Wheel155
Adjustable Front Fork156
Removing the Front Fork157
Overhauling the Front Fork158
Disassembling the Front Fork158
Checking the Front Fork161
Reassembling the Front Fork162
Fitting the Front Fork165
Front Brake166
Braking System Maintenance167
Removing the Front Brake System167
Removing the Brake Discs168
Overhauling the Front Brake Components168
Refitting the Front Brake System169
Rear Wheel171
Removing the Rear Wheel172
Overhauling the Rear Wheel173
Overhauling the Wheel Rim173
Refitting the Rear Wheel174
Rear Swingarm175
Removing the Rear Eccentric Hub176
Refitting the Rear Eccentric Hub178
Removing the Rear Swingarm179
Inspecting the Swingarm Shaft182
Checking Swingarm Axial Play182
Refitting the Rear Swingarm183
Rear Brake185
Removing the Rear Brake Caliper186
Removing the Rear Brake Disc187
Refitting the Rear Brake Caliper188
Rear Suspension189
Rear Suspension Unit190
Removing the Monoshock Absorber190
Overhauling the Monoshock Absorber191
Removing the Rear Suspension Rocker Arm192
Overhauling the Rear Suspension Rocker Arm193
Disassembling the Rear Suspension Rocker Arm193
Reassembling the Rear Suspension Rocker Arm193
Removing and Overhauling the Shock Absorber Linkage194
Refitting the Rear Suspension195
Final Drive197
Inspecting the Final Drive198
Removing the Front Sprocket199
Refitting the Front Sprocket200
Changing the Rear Sprocket201
Refitting the Rear Sprocket201
Washing the Chain202
Lubricating the Chain202
Frame203
Frame: Table of Contents204
Handlebar205
Removing the Handlebar206
Fitting the Handlebar207
Steering208
Adjusting Steering Bearing Play209
Adjusting the Steering Angle209
Disassembling the Headstock Parts210
Reassembling the Headstock Parts211
Footpeg Supports214
Removing the Footpegs215
Removing the Rear Footpegs217
Refitting the Front Footpegs218
Refitting the Rear Footpegs220
Stands221
Removing the Side Stand222
Disassembling/Assembling the Side Stand222
Checking the Side Stand222
Fitting the Side Stand222
Checking the Frame223
Removing Frame and Structural Parts224
Refitting Frame and Structural Parts224
Overhaul Dimensions - Frame227
Tail Light and Number Plate Holder228
Removing the Tail Light and the Number Plate Holder229
Fitting the Tail Light and the Number Plate Holder229
Fuel System/Exhaust System230
Fuel System/Exhaust System: Table of Contents231
Description of Fuel System232
Fuel Tank234
Removing the Fuel Tank236
Removing and Changing the Filler Plug Unit237
Reassembling the Filler Plug Unit238
Refitting the Fuel Tank239
Fuel Tank Drain and Breather Pipes Routing240
Fuel Pump241
Removing the Fuel Pump242
Replacing the Fuel Sensor243
Refitting the Fuel Pump244
Fuel Filter245
Removing the Fuel Filter/Refitting the Fuel Filter246
Pressure Regulator247
Changing the Pressure Regulator248
Throttle Body249
Removing the Throttle Body250
Removing the Injectors250
Refitting the Injectors250
Refitting the Throttle Body251
Air Intake252
Removing the Air Box253
Refitting the Air Box255
Air Box Drain Hose Routing257
Exhaust System258
Catalytic Converter Operating Principle (EU Only)260
Removing the Exhaust System262
Refitting the Exhaust System265
Canister Filter267
Canister Filter (USA Versions Only)268
Removing the Canister Filter269
Refitting the Canister Filter270
Routing of Hoses, Clamps and Canister Filter Position271
Ignition - Injection System275
Ignition - Injection System: Table of Contents276
Description of the Fuel Injection - Ignition System277
General Information on the Fuel Injection - Ignition System277
Importance of the Air-Fuel Mixture and of the Ignition Advance277
Marelli Injection-Ignition System278
Legend to Sensor Position Diagram279
Fuel Circuit281
Intake Air Circuit282
Operating Stages283
Normal Operation283
Starting283
Acceleration/Deceleration283
Fuel Injection-Ignition System Diagram284
Electronic Control Unit286
Removing the Electronic Control Unit287
Refitting the Electronic Control Unit287
Electric Injector289
Water Temperature Sensor290
Removing Water Temperature Sensor290
Refitting the Water Temperature Sensor290
Air Temperature/Presssure Sensor291
Removing the Air Temperature/Pressure Sensor291
Refitting the Air Pressure/Temperature Sensor291
Ignition Coils292
Checking the Spark Plugs292
Checking the Coils293
Throttle Position Sensor294
Rpm/Timing Sensor294
Main and Injection Relays295
Engine296
Engine: Table of Contents297
Removing - Refitting the Complete Engine300
Removing the Engine301
Disassembling the Engine303
Reassembling the Engine304
Lubrication System: Oil Cooler305
Lubrication System Diagram306
Description of the Lubrication System307
Lubrication System Operation307
Crankcase Vapor Breather Circuit308
Removing the Oil Filters308
Removing the Oil Cooler and Pipes309
Checking the Oil Cooler310
Removing the Oil Delivery Pipes to Heads311
Reassembling the Oil Cooler and Pipes312
Oil Cooler Pipes Routing313
Lubrication System: Oil Pump315
Removing the Oil Pump316
Disassembling the Oil Pump316
Overhauling the Oil Pump317
Reassembling the Oil Pump317
Refitting the Oil Pump318
Lubrication System: Oil Breather Reservoir319
Removing the Oil Breather Reservoir320
Refitting the Oil Breather Reservoir320
Oil Breather Pipe Routing321
Cooling System: Tank323
Cooling System Description324
Cooling System Components Key325
Removing Water Reservoir326
Refitting Water Reservoir327
Cooling System: Radiator328
Removing the Radiator329
Checking the Water Radiator330
Removing the Cooling Fan330
Refitting the Coolant Radiator331
Removing the Engine Cooling System Pipes and Unions332
Refitting the Cooling System Pipes and Unions333
Engine Cooling System Hose Routing334
Cooling System: Coolant Pump336
Removing the Coolant Pump337
Refitting the Coolant Pump338
Head Unit: Check and Adjustments340
Checking and Adjusting Valve Clearance341
Checking and Adjusting Opening Clearance (Sa)342
Checking and Adjusting Closing Clearance (Sc)343
Checking Valve Lift344
Checking Engine Timing345
Head Unit: Side Covers/Timing System347
Removing the Timing System Parts349
Removing Timing Outer Covers349
Removing the Mobile Tensioner/Timing Belt350
Removing Head Belt Rollers351
Removing the Tensioner Pins and Inner Covers351
Removing the Timing Layshaft Belt Rollers352
Disassembling Belt Tensioners353
Disassembling Timing Belt Rollers353
Refitting the Timing System Parts354
Timing Layshaft Belt Rollers354
Refitting Inner Covers and Tensioner Pins355
Refitting the Timing Belts356
Refitting Timing Outer Covers359
Head Unit: Covers/Camshafts360
Removing the Intake Manifolds362
Refitting the Intake Manifolds362
Removing Head Covers363
Refitting Head Covers364
Removing Side Covers and Camshafts365
Disassembling the Timing-Side Head Side Covers366
Disassembling the Generator-Side Head Side Covers366
Reassembling the Generator-Side Head Side Covers366
Reassembling the Timing-Side Head Side Covers366
Checking Camshafts367
Checking Camshaft Covers367
Checking Circlips368
Checking Oil Seals368
Checking Bearings368
Refitting Camshafts and Side Covers369
Head Unit: Head370
Removing the Complete Head371
Removing Opening Rocker Arms372
Removing the Valves373
Removing the Closing Rocker Arms374
Overhauling Head Parts375
Valve Seals375
Valve Seat376
Valve Guides377
Valve378
Checking Valve Sealing Surface378
Rocker Arms379
Opening and Closing Shims379
Reassembling Head Parts380
Reassembling Closing Rocker Arms380
Reassembling Valves and Valve Shims381
Refitting Opening Rocker Arms382
Refitting the Complete Heads383
Cylinder/Piston Assembly384
Removing Cylinder/Piston Assy385
Overhauling and Checking the Components387
Cylinder387
Piston387
Piston Rings388
Piston Ring-Piston Groove Clearance388
Piston Rings-Cylinder Clearance389
Gudgeon Pins389
Con-Rod Small End Bush-Gugeon Pin Clearance389
Refitting Cylinder/Piston Assy390
Clutch Assembly: Clutch393
Clutch Unit394
Disassembling the Clutch396
Clearance between Clutch Housing and Drive Plate399
Overhauling the Clutch Plates399
Overhauling the Pressure Plate399
Overhauling the Clutch Springs399
Reassembling the Clutch400
Clutch Assembly: Clutch Cover403
Removing the Clutch Cover404
Disassembling the Clutch Cover404
Reassembling the Clutch Cover405
Refitting the Clutch Cover406
Clutch Assembly: Primary Drive Gears407
Disassembling the Primary Drive Gears408
Refitting the Primary Drive Gear and Checking Meshing Play410
Gearbox Assembly: Lever Assembly412
Removing the Gear Selector Levers413
Removing the Gear Stopper and Ratchet414
Reassembling Gear Stopper and Ratchet414
Reassembling the Gear Selector Lever415
Gearbox Assembly: Gearbox Shafts416
Removing the Gearbox418
Disassembling the Gearbox Shafts419
Secondary Shaft419
Gearbox Primary Shaft421
Overhauling the Gearbox423
Overhauling the Gear Selector Forks425
Fork Selector Drum425
Reassembling the Gearbox Shafts426
Reassembling the Gearbox428
Flywheel - Generator429
Removing the Generator Cover431
Disassembling the Generator Cover432
Removing the Flywheel - Generator Assembly433
Checking the Flywheel - Generator Assembly434
Disassembling the Flywheel - Generator Assembly434
Reassembling the Flywheel - Generator Assembly435
Refitting Flywheel/Generator Assembly436
Reassembling the Generator Cover437
Checking the Air Gap of Engine Sensor439
Casing Unit: Outer Components440
Removing Outer Components441
Reassembling the Outer Parts443
Removing the Timing Lay Gear444
Reassembling the Timing Lay Gear444
Removing the Starter Motor Driven Gear445
Reassembling the Starter Motor Driven Gear445
Casing Unit: Crankcases446
Opening the Casings447
Overhauling the Casings449
Main Bearings450
Reassembling the Casings451
Overhauling the Clutch-Side Casing451
Overhauling the Generator-Side Casing452
Shimming the Shafts453
Shimming the Crankshaft453
Shimming the Gearbox Shafts455
Shimming the Gearbox Drum456
Closing the Casings456
Casing Unit: Connecting Rods460
Removing the Connecting Rods461
Disassembling the Connecting Rod461
Overhauling the Connecting Rods462
Changing the Connecting Rod Small End Bush462
Checking the Connecting Rod Big End Bearings463
Checking the Crankshaft464
Checking Big End Bearings-Crank Pin Clearance465
Reassembling the Connecting Rods466
Refitting the Connecting Rod Unit467
Electric System468
Wiring Diagram469
Key to Fuse Box473
Arrangement of Wiring on Frame473
Charging System Battery - Checking the Charging System489
Charging Methods489
Normal Charge (with Constant Voltage)490
Charging the Battery under Critical Conditions490
Battery - Safety Rules491
Instructions for Use of the Battery491
Removing the Battery491
Refitting the Battery491
Battery Mount492
Generator493
Removing the Generator493
Refitting the Generator493
Rectifier - Regulator494
Removing the Regulator494
Refitting the Regulator494
Removing the Regulator Fuse495
Electric Starting496
Electric Starting System497
Safety Devices Function Table498
Starter Motor499
Removing the Starter Motor499
Refitting the Starter Motor500
Starter Contactor501
Starter Contactor Operational Check501
Lighting Devices502
Changing Light Bulbs502
Changing the Headlight Bulbs502
Changing the Number Plate Lights503
Replacing the Headlight504
Removing the Turn Indicators and Headlight Support504
Beam Setting505
Indicators and Lighting System506
Checking the Indicators and Lighting System Components506
Checking the Left Switch506
Turn Indicator Switch507
Checking the Right Switch508
Checking Front and Rear Stop Switches, Neutral Switch, Oil Pressure Switch and Clutch Switch509
Changing Bulbs511
Changing the Turn Indicator Bulbs511
Changing the Stop Light Bulbs511
Protection and Safety Devices512
Checking Protection and Safety Devices Components512
Checking the Key-Operated Switch512
Checking the Side Stand Switch513
Checking the Fuses514
Instrument Panel515
Immobilizer and Transponder518
Keys with Transponder518
Immobilizer Aerial519
Operating Principle of the Immobilizer519
Immobilizer Warning Lights and Indicators520
Programming the Immobilizer521
Checking Immobilizer Programming523
Emergency Procedure to Override the Immobilizer System524
Removing the Immobilizer526
Reassembling the Immobilizer526
Disassembling the Red Key with Transporter527
Multimeter528
How to Use Multimeter to Check Electric Systems528
How to Measure Voltage528
How to Measure Current529
How to Measure Resistance and Electric Coninuity530
Protections and Precautions531
Subject Index532

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