Ducati ST3 2004

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General summary

12 ST3 - M.Y. 2004 - edizione/edition 00

Main Page

General Summary2
Description14
Manual Layout17
Symbols18
Abbreviations18
Text References18
Product Specifications21
General Safety Rules23
Carbon Oxide23
Fuel23
Hot Component Parts23
Used Engine Oil24
Brake Lining Debris24
Brake Fluid24
Coolant24
Model-Specific Information28
Identification Data29
Identification Data for ST330
Data Punched on Frame30
Data Punched on Engine31
Technical Specification32
Overall Dimensions (MM)48
Fuels and Lubricants49
Engine Oil49
Oil Viscosity49
Service Tools73
Engine Special Tools73
Frame Special Tools78
Use and Maintenance Operations80
Preliminary Checks82
Running-In Precautions82
Max. Rotation Speed82
Max. Rotation Speed up to 1000 Km82
Pre-Ride Checks83
Fuel Level in the Tank83
Engine Oil Level83
Brake and Clutch Fluid83
Key-Operated Locks84
Stand84
Starting the Engine85
Cold Ambient Temperature85
High Ambient Temperature86
Routine Maintenance Table89
Maintenance Operations91
Cancelling the "Service" Indicator on the Instrument Panel91
Checking the Engine Oil Level92
Changing the Engine Oil and Filter Cartridge93
Checking Valve Clearances95
Opening Rocker Arm95
Adjusting Valve Clearances96
Closing Rocker Arm96
Checking the Coolant Level97
Changing the Coolant98
Changing the Fuel Filter100
Changing the Air Filter101
Changing the Brake Fluid102
Changing the Fluid in the Front Brake Circuit102
Changing the Fluid in the Rear Brake Circuit103
Draining the Brake Circuits104
Filling the Brake Circuits105
Changing the Clutch Fluid107
Draining the Clutch Circuit108
Refilling the Clutch Circuit109
Steering Angle Adjustment111
Adjusting the Front Brake and Clutch Levers112
Adjusting Chain Tension113
Checking Brake Pad Wear. Changing Brake Pads114
Checking Front Brake Wear114
Changing Rear Brake Pads116
Adjusting the Throttle and Choke Cables117
Adjusting the Position of the Gear Change and Rear Brake Pedals119
Adjusting the Front Fork120
Adjusting the Rear Shock Absorber121
Adjusting Setup121
Diagnostic Instruments122
Description of the Diagnostic Tester123
Connecting the Tester to the Motorcycle124
Parts Delivered with the Diagnostic Tester124
The Mathesis Diagnostic Tester125
Checking and Adjusting Cam Belt Tension126
Belt Reading128
Adjusting the Throttle Body130
Positioning the Throttle Sensor131
Adjusting the Throttle Position Sensor131
Adjusting the Idling Mixture132
Adjusting the Throttle Set Screw (Vertical Cylinder)132
Balancing the Air Flows132
Adjusting the CO Rate133
Adjusting the Choke Control134
Checking Engine Oil Pressure135
Hot Engine136
Checking Cylinder Compression137
Checking Fuel Pressure139
Fairing140
Headlight Fairing - Rear-View Mirrors142
Removing the Rear View Mirrors and Dash Panels143
Disassembling the Headlight Fairing145
Refitting the Headlight Fairing147
Refitting the Rear View Mirrors and Dash Panels149
Removing Lower Side Fairings153
Reassembling Lower Side Fairings154
Removing the Complete Fairings155
Removing the Front Shield159
Reassembling the Front Shield159
Tail Guard160
Removing the Seat161
Removing the Side Panels162
Removing the Tool Compartments - Rear Splashguard163
Reassembling the Tool Compartments - Rear Splashguard163
Reassembling the Side Panels164
Refitting the Seat165
Removing the Front Mudguard166
Reassembling the Front Mudguard166
Controls - Devices168
Throttle - Choke Control170
Disassembling the Throttle Control172
Reassembling the Throttle Control173
Throttle Cable Routing174
Removing the Choke Control175
Refitting the Choke Control176
Choke Cable Routing178
Clutch Hydraulic Control179
Removing the Clutch Cylinder Assembly180
Fitting the Clutch Cylinder Assembly180
Removing the Clutch Slave Cylinder Assembly181
Refitting the Clutch Slave Cylinder Assembly182
Clutch Cable Routing183
Front Brake Control184
Removing the Front Brake Master Cylinder185
Refitting the Front Brake Master Cylinder186
Front Brake Hose Routing187
Rear Brake Control189
Removing the Rear Brake Master Cylinder190
Refitting the Rear Brake Control191
Disassembling the Rear Brake Control191
Rear Brake Hose Routing192
Gear Change Control194
Removing the Gear Change Control195
Disassembling the Gear Change Control195
Refitting the Gear Change Control195
Seat Lock196
Removing the Seat Opening Device197
Reassembling the Seat Opening Device197
Wheels - Suspensions - Brakes198
Front Wheel200
Removing the Front Wheel201
Overhauling the Front Wheel202
Overhauling the Front Wheel Bearings202
Overhauling the Front Wheel Shaft203
Refitting the Front Wheel204
Front Fork205
Removing the Front Fork206
Overhauling the Adjustable Front Fork207
Disassembling the Adjustable Front Fork207
Inspecting the Adjustable Front Fork210
Reassembling the Adjustable Front Fork211
Refitting the Front Fork214
Front Brake215
Braking System Maintenance216
Removing the Front Brake System217
Removing the Front Brake Caliper217
Overhauling the Front Brake Components218
Removing the Front Brake Discs218
Refitting the Front Brake System219
Refitting the Front Brake Discs219
Refitting the Front Brake Caliper219
Rear Wheel221
Removing the Rear Wheel222
Overhauling the Rear Wheel223
Overhauling the Rear Brake Disc223
Refitting the Rear Wheel224
Rear Swingarm225
Removing the Rear Swingarm226
Inspecting the Swingarm Shaft227
Checking Swingarm Axial Play227
Refitting the Rear Swingarm228
Rear Brake229
Removing the Rear Brake System230
Refitting the Rear Brake System232
Rear Suspension233
Rear Suspension Unit234
Removing the Rear Shock Absorber234
Overhauling the Rear Shock Absorber235
Disassembling the Rear Shock Absorber235
Reassembling the Rear Shock Absorber235
Removing the Rear Suspension Rocker Arm236
Overhauling the Rear Suspension Rocker Arm237
Disassembling the Rear Suspension Rocker Arm237
Reassembling the Rear Suspension Rocker Arm237
Overhauling the Monoshock Linkage238
Refitting the Rear Suspension239
Final Drive241
Inspecting the Final Drive242
Removing the Front Sprocket243
Refitting the Front Sprocket243
Removing the Rear Sprocket244
Refitting the Rear Sprocket244
Washing the Chain245
Lubricating the Chain245
Frame246
Handlebars248
Removing the Handlebars249
Removing the Grips249
Refitting the Handlebars250
Refitting the Grips250
Removing the Handlebar Mountings251
Refitting the Handlebar Mountings252
Adjusting the Handlebar Mountings Height252
Steering253
Adjusting Steering Bearing Play254
Adjusting the Steering254
Removing the Steering Head Bearings255
Refitting the Steering Bearings257
Footpeg Mounts260
Removing the Footpegs261
Refitting Footpegs263
Stands265
Removing the Side Stand266
Disassembling the Side Stand266
Inspecting the Side Stand266
Reassembling the Side Stand267
Removing the Center Stand268
Refitting the Center Stand268
Frame Inspection269
Frame and Related Components270
Removing Frame and Structural Parts270
Frame Overall Dimensions (MM)273
Checking the Frame274
Refitting Frame and Related Components274
Tail Light and Number Plate Holder275
Removing and Refitting the Rear Grab Rail276
Removing the Tail Light277
Refitting the Tail Light277
Removing the Number Plate Holder278
Refitting the Number Plate Holder278
Fuel System / Exhaust System280
Description of Fuel System282
Fuel Tank284
Raising the Fuel Tank286
Removing the Fuel Tank287
Changing the Fuel Filler Cap Assembly288
Changing the Fuel Sensor288
Refitting the Fuel Tank289
Fuel Tank Breather and Drain Hose Routing290
Fuel Pump291
Removing the Fuel Pump292
Refitting the Fuel Pump292
Fuel Filter293
Pressure Regulator295
Changing the Pressure Regulator295
Throttle Body296
Removing the Complete Throttle Body297
Refitting the Complete Throttle Body298
Hose Routing299
Air Filter301
Removing the Filter Box302
Refitting the Filter Box304
Filter Box Drain Hose Routing306
Exhaust System307
Catalytic Converter Operating Principle308
Removing the Exhaust System309
Reassembling the Exhaust System310
Canister Filter311
Removing the Canister Filter313
Refitting the Canister Filter313
Canister Hose Routing314
Ignition - Injection System316
Description of the Fuel Injection-Ignition System318
General Information on the Fuel Injection-Ignition System318
Marelli Injection-Ignition System319
Injection - Ignition System Sensor/Actuator Location Diagram320
Fuel Circuit322
Air Circuit323
Operating Stages324
Normal Running324
Starting324
Acceleration/Deceleration324
System Diagram325
Fuel Injection System Diagram325
Injection - Ignition System Diagram Legend327
System Components328
Electronic Control Unit328
Removing the Electronic Control Unit330
Refitting the Control Unit330
Electric Injector332
Air Temperature Sensor333
Air Pressure Sensor333
Coolant Temperature Sensor334
Removing the Coolant Temperature Sensor334
Refitting the Coolant Temperature Sensor334
Spark Plug335
Coil336
Throttle Position Sensor337
Rpm/Timing Sensor337
Injection Relay338
The CAN Line339
The Instrument Panel System340
The LCD Display341
Clock341
Display Functions343
Clock Display Functions343
Time Display - Setting the Clock343
Coolant Temperature Display343
Main Display Functions344
Speed Display344
Routine Maintenance Display344
Vertical Headlight Angle Adjustment345
Electronic Injection/Ignition System Diagnostics346
Special Settings349
Fuel Display Function351
Fuel Level Display351
Auxiliary Display Functions352
Display Function Scrolling352
Odometer352
Trip Counter352
Instantaneous Fuel Consumption Display353
Average Fuel Consumption Display353
Fuel Consumed Display353
Remaining Autonomy Display354
The Fuel Reserve Warning Light354
Instrument Panel Functions355
Headlight Switching Logic355
Switching the Headlights Back on355
Automatic LCD Display and Rev Counter Backlighting and Automatic Function Indicator Brightness Control355
Connector Pin-Out357
Engine358
Removing - Reassembling the Complete Engine362
Removing the Engine363
Disassembling the Engine365
Reassembling the Engine366
Lubrication System: Oil Pump367
Lubrication System Diagram368
Description of the Lubrication System369
Lubrication System Operation369
Removing the Oil Filters370
Crankcase Vapor Breather Circuit370
Removing the Oil Pump371
Oil Pump Disassembly371
Overhauling the Oil Pump372
Reassembling the Oil Pump372
Refitting the Oil Pump373
Lubrication System/Oil Cooler374
Removing the Lubrication System375
Removing the Cylinder Head Oil Delivery Line376
Refitting the Cylinder Head Oil Delivery Line376
Overhauling the Oil Cooler377
Fitting the Nipple and Oil Lines to the Oil Cooler378
Refitting the Lubrication System379
Oil Cooler Pipes Routing380
Lubrication System: Oil Breather Tank383
Removing the Oil Breather Reservoir384
Refitting the Oil Breather Reservoir384
Oil Breather Pipe Routing385
Cooling System/Tank387
Cooling System388
Cooling System Legend388
Circuit Total Capacity388
Removing the Water Reservoir389
Refitting the Water Reservoir390
Cooling System: Water Radiator391
Removing the Radiator392
Replacing the Electric Fan394
Inspecting the Coolant Radiator394
Removing the Electric Fan394
Refitting the Electric Fan394
Refitting the Water Radiator395
Removing the Cooling System Pipes and Unions397
Refitting the Cooling System Pipes and Unions399
Engine Cooling System Pipe Routing401
Cooling System/Coolant Pump402
Removing the Coolant Pump403
Reassembling the Coolant Pump405
Head Unit / Checks and Adjustments409
Checking and Adjusting Valve Clearance410
Checking and Adjusting Opening Clearance (Sa)411
Checking and Adjusting Closing Clearance (Sc)412
Checking Valve Lift413
Checking Engine Timing414
Heads/Timing System Assembly416
Removing the Timing System Parts417
Removing Timing Outer Covers417
Timing System Disassembly418
Disassembling the Mobile Tensioner420
Removing the Camshaft Pulleys420
Reassembling the Timing System421
Reassembling the Timing Belt Rollers on Camshafts421
Reassembling Timing Belt Rollers on Layshaft423
Reassembling the Timing Belt Tensioners424
Refitting the Timing Side Covers428
Heads/Side Covers Assembly429
Removing the Intake Manifolds430
Refitting the Intake Manifolds430
Camshafts Disassembly431
Removing the Valve Covers433
Refitting the Valve Covers433
Removing the Camshafts434
Checking Camshafts435
Refitting the Camshaft436
Refitting the Cam Covers437
Head Unit: Valves - Rocker Arms439
Removing the Complete Head440
Removing the Head440
Removing the Valves441
Removing the Valve Rocker Arms445
Head Parts Overhaul447
Heads447
Overhauling the Valve448
Changing Valve Seats449
Valve-To-Valve Seat Clearance449
Overhauling the Valve Guide450
Valve-To-Valve Guide Clearance450
Changing Valve Guides450
Overhauling the Rocker Arms451
Reassembling the Head452
Reassembling the Valve Rocker Arms453
Refitting the Valves456
Reassembling the Heads459
Cylinders/Pistons Assembly460
Removing Cylinder / Piston Assy461
Overhauling the Cylinder463
Overhauling the Piston464
Piston-Cylinder Clearance464
Overhauling the Gudgeon Pins465
Overhauling the Piston Rings465
Piston Ring-Piston Groove Clearance465
Gudgeon Pin-Piston Clearance466
Piston Rings-Cylinder Clearance467
Refitting Cylinder / Piston Assy468
Clutch Assembly / Clutch471
Clutch Unit Description472
Disassembling the Clutch474
Checking and Overhauling the Components477
Clearance between Clutch Housing and Drive Plate477
Overhauling the Clutch Plates477
Overhauling the Pressure Plate477
Reassembling the Clutch478
Clutch/Clutch Cover Assembly481
Removing the Clutch Cover482
Clutch Cover Disassembly482
Reassembling the Clutch Cover483
Fitting the Clutch Cover484
Clutch/Primary Drive Gear Assembly485
Disassembling the Primary Drive Gears486
Reassembling Primary Drive Gear and Checking Meshing Clearance488
Gearbox/Gear Selector Lever Assembly490
Removing the Gear Selector Levers491
Removing the Gear Stopper and Ratchet492
Reassembling Gear Stopper and Ratchet492
Reassembling the Gear Selector Lever493
Gearbox/Gearbox Shafts Assembly494
Removing the Gearbox496
Disassembling the Gearbox Shafts497
Secondary Shaft497
Gearbox Primary Shaft499
Overhauling the Gearbox501
Overhauling the Gear Selector Forks503
Fork Selector Drum503
Reassembling the Gearbox Shafts504
Reassembling the Gearbox506
Flywheel - Generator507
Removing the Generator Cover509
Disassembling the Generator Cover510
Removing the Flywheel - Generator Assembly511
Checking the Flywheel - Generator Assembly512
Disassembling the Flywheel - Generator Assembly512
Reassembling the Flywheel - Generator Assembly513
Refitting Flywheel / Generator Assembly514
Reassembling the Generator Cover515
Checking the Air Gap of Engine Sensor517
Casing Unit518
Removing Outer Components519
Reassembling the Outer Parts521
Removing the Timing Lay Gear522
Reassembling the Timing Lay Gear522
Removing the Starter Motor Driven Gear523
Reassembling the Starter Motor Driven Gear523
Opening the Casings525
Overhauling the Casings527
Main Bearings528
Reassembling the Casings529
Overhauling the Clutch-Side Casing529
Overhauling the Generator-Side Casing530
Shimming the Shafts531
Shimming the Crankshaft531
Shimming the Gearbox Drum533
Practical Shimming Procedure for the Selector Drum and Gearbox Shafts534
Checking Gearbox Position537
Closing the Casings539
Casing Unit: Connecting Rods542
Removing the Connecting Rods543
Disassembling the Connecting Rod543
Overhauling the Connecting Rods544
Changing the Connecting Rod Small End Bush545
Changing the Connecting Rod Big End Bearings546
Checking the Crankshaft547
Checking Big End Bearings Crank Pin Clearance548
Reassembling the Connecting Rods549
Refitting the Connecting Rod Unit550
Electric System552
Wiring Diagram554
Key to Wiring Diagram556
Electrical System Fuse Box Legend558
Arrangement of Wiring on Frame558
Diagram a561
Diagram B562
Diagram C563
Diagram D564
Diagram E565
Diagram F566
Diagram H567
Diagram J568
Diagram K569
Diagram L570
Diagram M571
Diagram N572
Diagram P573
Diagram Q574
Diagram R575
Diagram S576
Diagram T577
Diagram U578
Charging System - Battery579
Checking the Charging System579
Charging Methods579
Normal Charge580
Charging the Battery under Critical Conditions580
Battery581
Safety Rules581
Removing the Battery581
Refitting the Battery581
Battery Mount582
Generator583
Removing the Alternator583
Refitting the Alternator583
Rectifier - Regulator584
Removing the Regulator584
Refitting the Regulator584
Regulator Fuse585
Electric Starting586
Electric Starting System587
Safety Devices Function Table588
Starter Motor589
Starter Motor Removal589
Reassembling the Starter Motor590
Contactor591
Starter Contactor Operational Check591
Lighting Devices592
Removing the Instrument Panel592
Replacing Bulbs593
Replacing Headlight Bulbs593
Main Beam (HI) Bulb594
Parking Light (A)594
Refitting Bulbs594
Replacing the Number Plate Bulb594
Headlight Switching Relay595
Checking Headlight Relay Functioning595
Aligning Dipped (LO) Beam596
Checking the Indicators and Lighting System Components597
Left Switch597
HORN Button597
Turn Indicator Switch (TURN)598
Low and High Beam (DIMMER)598
Flasher (PASSING)598
Right Switch599
ENGINE STOP Button599
STARTER Button599
Hazard599
STOP Switches600
Neutral Light600
Oil Pressure Sensor601
Clutch Switch601
Cooling Fan Relay602
Checking High Beam and Electric Fan Relay Correct Operation602
Changing Light Bulbs603
Turn Indicators603
Front Turn Indicators603
Rear Turn Indicators603
Replacing the Stop Light Bulb604
Protection and Safety Devices605
Checking Components605
Checking the Ignition Key Switch605
Side Stand Switch605
Fuses Check606
Immobilizer and Transformer607
Transponder Keys607
Immobilizer Antenna608
Principle of Immobilizer Functioning608
Function Indicator and Immobilizer Signals609
Programming the Immobilizer610
Checking that the Immobilizer System Is Correctly Programmed612
First Signal: One Flash the Shows612
Second Signal: a Series of Brief612
Fourth Signal612
Emergency Immobilizer Unlocking Procedure613
Removing the Immobilizer Antenna615
Refitting the Immobilizer Antenna615
Disassembling the Red Transponder Key615
Using a Multi-Meter to Test Electrical Systems616
How to Measure Voltage616
How to Measure Current617
How to Measure Resistance and Electric Continuity617
Protections and Precautions618
Power Socket619
Subject Index620
Indice Generale621

Ducati ST3 2004 - Page 13

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