Ducati Multistrada 1200 S ABS - Service Repair Manual - Manuel de Reparation Atelier

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DUCATI MULTISTRADA 1200 ABS, 1200 S ABS - SERVICE MANUAL - MANUEL DE REPARATION

- English and French Service Manual for motorcycle Ducati Multistrada 1200 S ABS.
- Manuel de réparation en français pour motocyclette Ducati Multistrada 1200 S ABS.


CONTENTS:

1 - GENERAL
- 1 - How to use this manual
- How to use this manual
- Layout of the manual
- 2 - Symbols - Abbreviations - References
- Product specifications
- 3 - Hazardous Products - Warnings
- General safety rules
- General maintenance indications

2 - MODEL-SPECIFIC INFORMATION
- 1 - Identification data
- Multistrada 1200 ABS identification data

3 - TECHNICAL DATA
- 1.1 - Technical specifications
- General
- Colours
- Transmission
- Timing system/valves
- Crankshaft
- Cylinder/Piston
- Gearbox
- Cooling system
- Front wheel
- Front suspension (1200 ASB)
- Front suspension (1200 S ASB)
- Rear wheel
- Rear suspension (1200 ASB)
- Rear suspension (1200 S ASB)
- Hydraulic brakes
- Charging system/alternator
- Injection-ignition system
- Fuel system
- Injection system
- Lights/instrument panel
- 1.2 - Dimensions
- 2 - Fuel, lubricants and other fluids
- 3 - Torque settings
- Frame torque settings
- Engine torque settings
- 4 - Service tools
- Specific tools for the engine
- Specific tools for the frame

4 - MAINTENANCE OPERATIONS
- 1 - Vehicle pre-delivery
- 2 - Scheduled maintenance chart
- Operations to be carried out by the dealer
- List of operations to be performed at 1000 km
- Operations to be carried out by the dealer
- List of operations to be performed every 12000 km / year (first limit reached)
- Operations to be carried out by the customer
- List of operations to be performed every 1000 km
- 3 - Maintenance operations
- Reading of the error memory with DDS on the engine control units, vehicle and ABS
- Checking the engine oil level
- Changing the engine oil and filter cartridge
- Checking valve clearances
- Renew the timing belts
- Spark plugs replacement
- Changing and cleaning the air filters
- Checking the coolant level
- Change the coolant
- Changing the brake fluid
- Draining the brake circuit
- Filling the brake system with fluid
- Changing the clutch fluid
- Draining the clutch hydraulic circuit
- Filling the clutch circuit
- Adjusting the steering head bearings
- Adjusting the chain tension
- Checking brake pad wear and changing brake pads
- Adjusting the throttle cable
- Adjusting the clutch lever and front brake lever
- Adjusting the position of the gear change and rear brake pedals
- Front fork adjustment (MTS 1200 ABS)
- Rear shock absorber adjustment (MTS 1200 ABS)
- Adjusting the rear ride set-up

5 - FAIRINGS
- 1 - Rear-view mirrors
- Removing the panel
- Refitting the panel
- Removing the headlight fairing
- Refit the headlight fairing
- 2 - Fairings
- Removing the front half-fairing
- Refitting the front half-fairing
- Removal of the fuel tank fairings
- Refitting the fuel tank fairings
- 3 - Seat - seat cowling and side panels
- Removal of the seat
- Removal of the side panels and seat cowling
- Refitting the side panels and seat cowling
- Refitting the seat
- 4 - Front mudguard
- Removal of the front mudguard
- Refitting the front mudguard
- Fitting the front semi mudguard
- Removing the oil sump guard
- 5 - Rear mudguard - Splash guard
- Removing the rear mudguard
- Refitting the rear mudguard
- Fitting the long rear mudguard
- Removing the splash guard
- Refitting the splash guard

6 - ELECTRIC SYSTEM AND ENGINE CONTROL SYSTEM
- 1 - Wiring diagram
- Wiring diagram 1200 S ABS - Key
- Wiring diagram 1200 S ABS - Key
- Wiring diagram colour codes
- Key of front fuse box
- Key of rear fuse box
- Routing of wiring on frame
- Table A
- Table B
- Table C
- Table D
- Table E -1
- Table E-2
- Table F
- Table G
- Table H
- Table I
- Table J
- Table K
- Table L
- Table M
- Table N
- Table O
- Table P
- Table Q
- Table R
- Table S
- Table T
- 2 - Battery charging system
- Checking the battery charging system
- Recharging the battery
- Topping up the electrolyte
- Battery
- Alternator
- Rectifier-regulator
- 3 - Electric starting system
- Electric starting system
- Starter motor
- Solenoid starter
- 4 - Lights and indicating devices
- Replacing bulbs
- Headlight aim
- 5 - Indicating devices
- Checking the indicating system components
- Water temperature sensor
- Checking operation of the fan relay
- Changing light bulbs
- 6 - Protection and safety devices
- Checking protection and safety device components
- Checking the fuses
- 7 - Instruments
- Instrument panel
- Instrument panel system (DASHBOARD)
- Display settings and functions
- 8 - “Hands free” system
- Hands free system Key-On and Key-Off
- Key-On/Key-Off using the red key on the handlebar with the active key
- Key-On/Key-Off using the key on the Hands free lock with the active key
- Key-On/Key-Off using the red key on the handlebar with the passive key
- Key-On/Key-Off using the key on the Hands free lock with the passive key
- Key-On/Key-Off using the pin code (immobilizer release)
- Entering PIN CODE function for vehicle release
- 9 - immobilizer and transponder
- 10 - Description of the system
- Injection and ignition
- 11 - Fuel injection-ignition system
- 12 - System components
- Positioning of the control system components on the vehicle
- Control unit support removing
- Refitting the control unit support
- Fuel injectors
- Air pressure sensor
- Engine temperature sensor
- Air temperature sensor
- Removing the coils
- Throttle valve operation engine
- Rpm/timing sensor
- Injection relay
- CAN Line
- 13 - Diagnostic instruments
- Using a multimeter to check the electrical systems
- Description of the diagnosis instrument (DDS)
- Tester power supply
- DDS diagnosis instrument
- Checking and adjusting timing belt tension
- Check the engine oil pressure
- Cylinder compression test
- Fuel pressure test
- immobilizer override procedure
- Guided diagnosis
- Testing the battery charging system
- Deactivating the “service” indication on the instrument panel
- Icons table

7 - CHASSIS
- 1 - Front wheel
- Removal of the front wheel
- Overhauling the front wheel
- Refitting the front wheel
- 2 - Rear wheel
- Removing of the rear wheel
- Overhauling the rear wheel
- Refitting the rear wheel
- 3 - Front brake control
- Removal of the front brake master cylinder
- Refitting the front brake master cylinder
- Maintenance operations
- Removal of the front brake system
- Removal of the brake disks
- Overhauling the front brake components
- Refitting the brake disks
- Refitting the front brake system
- 4 - Rear brake
- Removing of the rear brake control
- Disassembly of the rear brake control
- Refitting the rear brake control
- Removal of the rear brake calliper
- Removal of the rear brake disc
- Refitting the rear brake calliper
- 5 - ABS system information
- Operating principle
- ABS system operating information
- ABS system deactivation
- 6 - System components
- Replacing the front phonic wheel sensor
- Replacing the rear phonic wheel sensor
- Removing of the ABS control unit
- Refitting the ABS control unit
- Flexible wiring/hoses positioning
- Table A
- Table B
- Table C
- 7 - ABS components maintenance
- Adjusting of the AIR-GAP phonic wheel sensor
- Bleeding of the ABS hydraulic system
- 8.1 - Handlebar assembly - Hand guards - Rear-view mirrors - Throttle grip
- Removal of the rear-view mirrors
- Refitting the rear-view mirrors
- Removing of the hand guards
- Refitting the hand guards
- Removal of the handlebar
- Refitting the handlebar
- Adjusting the throttle cable
- Removal of the throttle twistgrip
- Refitting the throttle twistgrip
- 8.2 - Handlebar unit: clutch hydraulic control
- Removal of the clutch master cylinder assembly
- Refitting the clutch master cylinder assembly
- Removal of the clutch transmission unit
- Refitting the clutch transmission unit
- 9 - Gearchange mechanism
- Removal of the gearchange control
- Disassembly of the gearchange mechanism
- Refitting the gearchange mechanism
- 10.1 - Fork - Steering head: front fork (1200 ABS)
- Refitting the front fork (1200 ABS)
- Overhauling the front fork (1200 ABS)
- Refit the front fork (1200 ABS)
- 10.2 - Front fork - Steering head: front fork (1200 S ABS)
- Removal of the front fork (1200 S ABS)
- Overhauling the fork
- Refit the fork (1200 S ABS)
- 10.3 - Fork - Steering head: yoke
- Adjusting the steering head bearings
- Steering angle adjustment
- Removal of the steering head components
- Refitting the steering head components
- 12 - Rear shock absorber assembly
- Rear suspension system
- Removal of the rear shock absorber
- Overhauling the rear shock absorber
- Refitting the rear suspension
- 13 - Swingarm
- Removal of the rear wheel eccentric hub and rear wheel axle
- Refitting the rear wheel eccentric hub and rear wheel axle
- Removal of the swingarm
- Inspecting the swingarm pivot shaft
- Overhauling the rear swingarm
- Refitting the swingarm
- 14 - Final drive
- Inspecting the final drive
- Removing of the front sprocket
- Refitting the front sprocket
- Replacing of the rear sprocket
- Refitting the rear sprocket
- Washing the chain
- Lubricating the chain
- 15 - Footrest brackets
- Removal of the front footrests
- Refitting the front footrests
- Removing of the rear footrests
- Refitting the rear footrests
- 16 - Stands
- Removing of the sidestand
- Refitting the sidestand
- 17 - Frame inspection
- Disassembly of structural components and the frame
- Removing of the headlight assembly
- Refitting the headlight assembly
- Checking the frame
- Reassembly of structural components and the frame
- 18 - Licence plate holder
- Removal of the licence plate holder
- Refitting the licence plate holder

8 - FUEL SYSTEM / EXHAUST SYSTEM
- 2 - Fuel tank
- Removal of the fuel tank
- Removing the filler plug unit
- Refitting the filler plug unit
- Renewal of the fuel tank flange
- Refitting the fuel tank flange
- Refitting the fuel tank
- 6 - Airbox - Throttle Body
- Removal the airbox and throttle body
- Refitting the airbox and throttle body
- 7 - Air intake
- Removal of the air filters
- Refitting the air filters
- 8 - Exhaust system
- Removal of the exhaust system
- Refitting the exhaust system
- 10 - Evaporative emissions canister
- Evaporative emissions canister system (USA versions only)
- Removal of the evaporative emissions canister
- Refitting the evaporative emissions canister

9 - ENGINE
- 1 - Removal-refitting of the engine assembly
- Removal of the engine
- Refitting the engine
- 2.1 - Lubrication system: oil pump
- Removal of the oil pump
- Disassembly of the oil pump
- Reassembly of the oil pump
- Refitting the oil pump
- 2.2 - Lubrication system: oil cooler
- Removal of the lubrication system
- Oil cooler inspection
- Refitting the lubrication system
- 2.3 - Lubrication system: oil breather tank
- Refitting the oil breather tank
- Refitting the oil breather tank
- 3.1 - Cooling system: coolant expansion tank
- Removal of the expansion tank
- Refitting the expansion tank
- 3.2 - Cooling system: radiator
- Removal of the radiator
- Renewal of the cooling fan
- Refitting the radiator
- Removal of the cooling system hoses and unions
- Refitting the cooling system hoses and unions
- 3.3 - Cooling system: water pump
- Removal of the water pump
- Refitting the water pump
- 4.1 - Cylinder head assemblies: checks and adjustments
- Checking and adjusting the valve clearances
- Checking valve lift
- Checking the engine timing
- 4.2 - Cylinder head assemblies: timing system
- Removal of the timing belt covers
- Removal of the movable tensioner/timing belt
- Removing of the cylinder head pulley/fixed tensioner
- Removal of the tensioner and idler pulley mounting studs
- Disassembly of the camshaft pulleys
- Removing the timing belt driveshaft pulleys
- Refitting the timing belt driveshaft pulleys
- Refitting the idler and tensioner pulley mounting studs
- Reassembly of the timing pulleys
- Refitting the cylinder heads pulleys/fixed tensioners
- Refitting the timing belts
- Refitting the timing covers
- 4.4 - Cylinder head assemblies: camshafts
- Removal of the camshafts
- Checking the camshafts and supports
- Refitting the camshafts
- Removal of the intake manifold and coolant union
- Refitting the intake manifold and coolant union
- 4.5 - Cylinder head assemblies: valves - rocker arms
- Removal of the cylinder heads
- Removing the valves
- Removing the valve rocker arms
- Overhaul of cylinder head components
- Reassembly of the cylinder head
- Refitting the cylinder head assemblies
- 5 - Cylinder/piston assemblies
- Removal of the cylinder/piston assembly
- Overhaul of the cylinder barrel/piston components
- Refitting the cylinder/piston assembly
- 6.1 - Clutch assembly: clutch
- Description of the clutch assembly
- Removal of the clutch
- Checking and overhauling the components
- Reassembling the clutch
- 6.2 - Clutch assembly: clutch-side crankcase cover
- Removal of the clutch-side crankcase cover
- Disassembly of the clutch-side crankcase cover
- Reassembly of the clutch-side crankcase cover
- Refitting the clutch-side crankcase cover
- 6.3 - Clutch assembly: primary drive gears
- Removal of the primary drive gear
- Refitting the primary drive gears and checking backlash
- 7.1 - Gearbox assembly: gearchange mechanism
- Removal of the gear selector lever
- Disassembly of gear interlock plunger and pawl assembly
- Refitting the gear interlock plunger and pawl assembly
- Refitting the gear selector lever
- 7.2 - Gearbox assembly: gearbox shafts
- Removal of the gearbox assembly
- Disassembly of the gearbox shafts
- Overhaul of the gearbox
- Inspection of the gear selector forks
- Inspection of the gear selector drum
- Reassembly of the gearbox shafts
- Reassembly of the gearbox
- 8 - Flywheel - alternator
- Removal of the alternator-side crankcase cover
- Disassembly of the alternator-side crankcase cover
- Removing the flywheel - generator assembly
- Overhaul of the flywheel-alternator assembly
- Refitting the flywheel-alternator assembly
- Refitting the alternator-side crankcase cover
- 9.1 - Crankcase assembly: external components
- Removing outer components
- Refitting the external components
- Removal of the timing gears
- Refitting the timing gears
- Removal of the starter motor idler gear
- Refitting the starter motor gear
- 9.2 - Crankcase assembly: crankcase halves
- Separation of the crankcase halves
- Overhaul of the crankcase halves
- Main bearings
- Reassembly of the crankcase halves
- Shimming the shafts
- Reassembly of the crankcase halves
- 9.3 - Crankcase assembly: crankshaft/connecting rods assembly
- Removal of the crankshaft/connecting rods assembly
- Disassembly of the crankshaft/connecting rods assembly
- Overhaul of the connecting rods
- Reassembly of the connecting rods
- Refitting the crankshaft/connecting rod assembly