Ducati Multistrada 1200 Enduro (E4) - Service Manual - Repair Manual

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DUCATI MULTISTRADA 1200 ENDURO (E4) - SERVICE MANUAL / REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycle Ducati Multistrada 1200 Enduro (E4).


CONTENTS:

MTS(E4).01 - GENERAL
SYMBOLS - ABBREVIATIONS - REFERENCES
- Product specifications
DANGEROUS PRODUCTS - WARNINGS
- General maintenance instructions
- General safety rules
MTS(E4).02 - MODEL-SPECIFIC INFORMATION
MODEL IDENTIFICATION
- Identification data
MTS(E4).03 - TECHNICAL DATA
TECHNICAL SPECIFICATIONS
- Lights/instrument panel
- Injection system
- Fuel system
- Injection-ignition system
- Charging system/generator
- Hydraulic brakes
- Rear suspension
- Rear wheel
- Front suspension
- Front wheel
- Cooling system
- Gearbox
- Cylinder/piston
- Crankshaft
- Timing system/valves
- Transmission
- Colours
- General
OVERALL DIMENSIONS
- Dimensions
FUEL, LUBRICANTS AND OTHER FLUIDS
- Fuel, lubricants and other fluids
TIGHTENING TORQUE SETTINGS
- Engine tightening torque values
- Frame tightening torque values
SERVICE TOOLS
- Diagnosis special tools
- Frame special tools
- Engine special tools
MTS(E4).04 - MAINTENANCE OPERATIONS
VEHICLE PRE-DELIVERY
- Vehicle pre-delivery
SCHEDULED MAINTENANCE CHART
- Operations to be carried out by the customer
- Operations to be carried out by the dealer
MAINTENANCE OPERATIONS
- Filling the clutch hydraulic circuit
- Draining the clutch hydraulic circuit
- Changing the clutch fluid
- Adjusting the rear shock absorber
- Front fork adjustment
- Adjusting the position of the gearchange pedal and rear brake pedal
- Adjusting the front brake control lever
- Checking rear brake pad wear and replacing brake pads
- Checking front brake pad wear and replacing brake pads
- Adjusting the chain tension
- Adjusting the steering head bearing play
- Changing the fluid in the rear brake system
- Changing the fluid in the front brake system
- Changing the coolant
- Check coolant level
- Changing and cleaning the air filters
- Changing the spark plugs
- Change timing belts
- Checking valve clearance
- Changing the engine oil and filter cartridge
- Check engine oil level
MTS(E4).05 - FAIRINGS
PANEL - HEADLIGHT FAIRING
- Refitting the headlight fairing
- Removing the headlight fairing
- Refitting the panel
- Removing the panel
FAIRINGS
- Refitting the tank fairings
- Removing the tank fairings
- Refitting the front half-fairing
- Removing the front half-fairing
SEAT - TAIL GUARD AND SIDE BODY PANELS
- Refitting the seat
- Refitting side body panel and tail guard
- Removing the side body panels and the tail guard
- Removing the seat
FRONT MUDGUARD - BELLY PAN
- Refitting the belly pan
- Removing the belly pan
- Refitting the front mudguard
- Removing the front mudguard
REAR MUDGUARD - SPLASH GUARD
- Refitting the rear mudguard
- Removing the rear mudguard
MTS(E4).06 - ELECTRIC SYSTEM AND ENGINE MANAGEMENT
WIRING DIAGRAM
- Branch 10
- Branch 9
- Branch 8
- Branch 7
- Branch 6
- Branch 5
- Branch 4
- Branch 3
- Branch 2
- Branch 1
- Routing of wiring on frame
- Key to wiring diagram
- Technological Dictionary
- Acronyms and abbreviations used in the manual
CHARGE SYSTEM - BATTERY
- Rectifier-regulator
- Alternator / Generator
- Refitting the battery
- Removing the battery
- Topping up the electrolyte
- Recharging the battery
- Checking the battery charging system
ELECTRIC STARTER
- Solenoid starter
- Starter motor
- Electric starting system
LIGHTING
- Replacing the tail light bulbs
- Tail light
- Aligning the headlight
- Replacing the headlight bulbs
- Headlight
HANDLEBAR CONTROLS: CONTROLS
- Right-hand switch
- Left-hand switch
SAFETY AND PROTECTION SENSORS: CONTROLS
- Horn
- Checking the fuses
- Side stand switch
- Air temperature sensor
- Engine temperature sensor
- Clutch switch
- Oil pressure sensor
- Gear/neutral sensor
- Rear stop switch
- Front stop switch
ELECTRICAL COMPONENTS: CHECKS
- Exhaust valve motor
- Solenoid valves
- Coils
ELECTRONIC COMPONENTS: CHECKS
- Accelerometers
- Bluetooth
- Inertial Measurement Unit (IMU)
- Knock Sensor
- Accelerator Position System (APS)
- Lambda sensors
- Ducati Cornering Lights (DCL)
- Local Interconnect Network (LIN)
- VIN line
- Anti-lock Braking System (ABS)
- CAN line
- Ducati Wheelie Control (DWC)
- Ducati Traction Control (DTC)
- Rpm sensor (pick-up)
- Throttle Position System (TPS)
- Electronic Throttle Valve (ETV)
- Black Box System (BBS)
- Map sensor
- Engine control unit (ECU)
INSTRUMENTATION: DASHBOARD
- Restoring motorcycle operation via the PIN CODE
- Key duplication
- Error warnings
- Warnings/Alarms
- Main functions
- Parameter setting/displaying
- Function buttons
- Instrument panel
MTS(E4).07 - CHASSIS
FRONT WHEEL
- Refitting the front wheel
- Overhauling the front wheel
- Removing the front wheel
REAR WHEEL
- Refitting the rear wheel
- Overhauling the rear wheel
- Removing the rear wheel
FRONT BRAKE CONTROL
- Refitting the front brake system
- Refitting the brake discs
- Overhauling the front brake components
- Removing the brake discs
- Removing the front brake system
- Maintenance operations
- Refitting the front brake master cylinder
- Removing the front brake master cylinder
REAR BRAKE
- Refitting the rear brake calliper
- Refitting the rear brake disc
- Removing the rear brake disc
- Removing the rear brake calliper
- Refitting the rear brake control
- Disassembling the rear brake control
- Removing the rear brake control
ABS SYSTEM INFORMATION
- ABS system deactivation
- ABS system operation information
- Operating principle
ABS SYSTEM COMPONENTS
- Routing wiring harnesses/hoses
- Refitting the ABS control unit
- Removing the ABS control unit
- Changing the rear phonic wheel sensor
- Changing the front phonic wheel sensor
ABS COMPONENT MAINTENANCE
- Bleeding of the ABS hydraulic system
- Adjusting the AIR-GAP of phonic wheel sensor
HANDLEBAR UNIT: HAND GUARD - REAR.VIEW MIRRORS - THROTTLE CONTROL
- Refitting the handlebar
- Removing the handlebar
- Reassembling the hand guards
- Removing the hand guards
- Refitting the rear-view mirrors
- Removing the rear-view mirrors
HANDLEBAR ASSEMBLY: THROTTLE TWISTGRIP
- Refitting the throttle control
- Removing the throttle control
HANDLEBAR ASSEMBLY: HYDRAULIC CLUTCH CONTROL
- Refitting the clutch slave cylinder
- Removing the clutch slave cylinder
- Refitting the clutch master cylinder assembly
- Removing the clutch master cylinder assembly
HANDLEBAR ASSEMBLY: HANDS FREE
- Refitting the Hands Free
- Removing Hands Free
STEERING DAMPER
- Refitting the steering damper
- Removing the steering damper
GEAR SELECTOR CONTROL
- Refitting the gear change control
- Disassembling the gear change control
- Removing the gear change control
FORK - STEERING HEAD: FRONT FORK
- Refitting the front fork
- Overhauling the front fork
- Removing the front fork
FORK - STEERING HEAD: STEERING ASSEMBLY
- Refitting the steering tube components
- Removing the steering tube components
- Steering angle adjustment
- Adjusting the steering head bearing clearance
REAR SHOCK ABSORBER ASSEMBLY
- Refitting the rear suspension
- Overhauling the rear shock absorber
- Removing the rear shock absorber
- Rear suspension system
SWINGING ARM
- Refitting the rear swinging arm
- Overhauling the rear swinging arm
- Inspecting the swinging arm shaft
- Removing the swinging arm
FINAL DRIVE
- Lubricating the chain
- Washing the chain
- Refitting the rear sprocket
- Replacing the rear sprocket
- Refitting the front sprocket
- Removing the front sprocket
- Inspection of the final drive
FOOTREST SUPPORT
- Refitting the footpegs
- Removing the footpegs
STANDS
- Refitting the centre stand
- Removing the centre stand
- Refitting the side stand
- Removing the side stand
INSPECTING THE FRAME
- Refitting the light assembly
- Refitting the side plates
- Refitting the structural parts and frame
- Removing the side panels
- Removing the light assembly
- Removing structural components and frame
TAIL LIGHT - NUMBER PLATE HOLDER
- Refitting the number plate holder
- Removing the number plate holder
ELECTRICAL COMPONENTS COMPARTMENT
- Refitting the electric components compartment
- Removing the electric components compartment
MTS(E4).08 - FUEL/EXHAUST SYSTEM
FUEL TANK
- Refitting the fuel tank
- Refitting the fuel tank flange
- Removing the fuel tank flange
- Refitting the tank filler plug
- Removing the tank filler plug
- Removing the fuel tank
AIRBOX – THROTTLE BODY
- Refitting the airbox and throttle body
- Removing the airbox and throttle body
AIR INTAKE
- Refitting the secondary air system
- Removing the secondary air system
- Refitting the air filters
- Removing the air filters
EXHAUST SYSTEM
- Refitting the exhaust system
- Removing the exhaust system
- Refitting the silencer
- Removing the silencer
CANISTER FILTER
- Refitting the Canister filter
- Removing the canister filter
- Canister filter system
MTS(E4).09 - ENGINE
REMOVING - REFITTING THE COMPLETE ENGINE
- Refitting the engine
- Removing the engine
LUBRICATION SYSTEM: OIL PUMP
- Refitting the oil pump
- Reassembling the oil pump
- Disassembling the oil pump gear
- Removing the oil pump
LUBRICATION SYSTEM: OIL COOLER
- Refitting the lubrication system
- Inspecting the oil cooler
- Removing the lubrication system
LUBRICATION SYSTEM: OIL BREATHER RESERVOIR
- Refitting the oil breather reservoir
- Refitting the oil breather reservoir
- Removing the oil breather reservoir
- Removing the oil breather reservoir
COOLING SYSTEM: WATER TANK
- Refitting the water tank
- Removing the water tank
COOLING SYSTEM: WATER RADIATOR
- Refitting the cooling system hoses and unions
- Removing the cooling system hoses and unions
- Fitting the radiator
- Replacing the electric fan
- Removing the radiator
COOLING SYSTEM: WATER PUMP
- Refitting the water pump
- Removing the water pump
CYLINDER HEAD ASSEMBLY: CHECKS AND ADJUSTMENTS
- Checking the engine timing
- Checking valve lift
- Checking and adjusting the valve clearance
CYLINDER HEAD ASSEMBLY: TIMING SYSTEM
- Refitting the timing outer covers
- Refitting the timing belts
- Refitting the cylinder heads pulleys/idler pulleys
- Refitting the tensioner pins
- Refitting the timing layshaft pulley
- Removing the timing layshaft pulleys
- Removing the tensioner pins
- Removing the cylinder head pulley/fixed tensioner
- Removing the mobile tensioner/timing belt
- Removing the timing belt covers
CYLINDER HEAD ASSEMBLY: CAMSHAFTS
- Refitting the camshafts
- Check of the camshafts and supports
- Removing the camshafts
CYLINDER HEAD ASSEMBLY: VALVES - ROCKER ARMS
- Refitting the cylinder heads
- Overhauling the cylinder head components
- Refitting the valve rocker arms
- Removing the valve rocker arms
- Refitting the valves
- Removing the valves
- Removing the cylinder heads
CYLINDER/PISTON ASSEMBLY
- Refitting the cylinder/piston assembly
- Overhauling the cylinder/piston components
- Removing the cylinder/piston assembly
CLUTCH ASSEMBLY: CLUTCH
- Refitting the clutch
- Checking and overhauling the components
- Removing the clutch
- Description of the clutch assembly
CLUTCH ASSEMBLY: CLUTCH COVER
- Refitting the clutch cover
- Reassembling the clutch cover
- Disassembling the clutch cover
- Removing the clutch cover
CLUTCH ASSEMBLY: PRIMARY DRIVE GEAR
- Refitting the primary drive gears and checking backlash
- Removing the primary drive gears
GEARBOX ASSEMBLY: LINKAGES
- Refitting the gearchange mechanism
- Refitting the gear interlock plunger and ratchet
- Disassembling gear interlock plunger and ratchet
- Removing the gearchange mechanism
GEARBOX ASSEMBLY: GEARBOX SHAFTS
- Reassembling the gearbox assembly
- Reassembling the gearbox shafts
- Inspecting the fork selector drum
- Inspecting the gear selector forks
- Overhauling the gearbox
- Disassembling the gearbox shafts
- Removing the gearbox assembly
FLYWHEEL - GENERATOR
- Refitting the flywheel/generator assembly
- Overhauling the flywheel/generator assembly
- Removing the flywheel/generator assembly
- Refitting the generator cover
- Reassembling the generator cover
- Disassembling the generator cover
- Removing the generator cover
CRANKCASE: OUTER COMPONENTS
- Refitting the starter motor
- Removing the starter motor
- Removing the starter motor idler gear
- Refitting the timing gears
- Removing the timing gears
- Refitting the external components
- Removing outer components
CRANKCASE: CASINGS
- Closing the crankcase
- Shimming the shafts
- Reassembling the crankcase halves
- Main bearings
- Overhauling the crankcase halves
- Separating the crankcase halves
CRANKCASE: CONNECTING ROD ASSEMBLY
- Refitting the connecting rod assembly
- Reassembling the connecting rod assembly
- Overhauling the connecting rod assembly
- Disassembling the connecting rod assembly
Removing the connecting rod assembly