Instruction/ maintenance manual of the product 800 Sport (2003) Ducati
Go to page of 84
1 E Owner’ s manual DUC A TI M OTOR HOL DI N G SUPERSPOR T800 800Sport.
2 E.
3 E Hearty welcome among Ducati fans! Please accept our best compliments for choosing a Ducati motorcycle. We think you will ride your Ducati motorcycle for long journeys as well as short daily trips. Ducati Motor Holding S.p.A. wishes you smooth and enjoyable riding.
4 E T ABLE OF CONTENTS General 6 Warranty 6 Symbols 6 Useful information for safe riding 7 Carrying the maximum load allowed 8 Identification data 9 Controls 10 Position of motorcycle controls 10 Inst.
5 E Lubricating joints 49 Throttle cable adjustment 50 Charging the battery 51 Chain tensioning 52 Chain lubrication 53 Replacing bulbs 54 Beam setting 58 T yres 59 Checking engine oil level 61 Cleani.
6 E GENERAL W arranty In your own interest, and in order to guarantee product reliability , you are strongly advised to refer to a Ducati Dealer or Authorised Workshop for any servicing requiring particular technical expertise.
7 E Useful information for safe riding W arning Read this section before riding your motorcycle. Accidents are frequently due to inexperience. Always make sure you have your licence with you when riding; you need a valid licence to be entitled to ride your motorcycle.
8 E Carrying the maximum load allowed Y our motorcycle is designed for long-distance riding, carrying the maximum load allowed in full safety . Even weight distribution is critical to preserving these safety features and avoiding trouble when performing sudden manoeuvres or riding on bumpy roads.
9 E Identification data All Ducati motorcycles have two identification numbers, for frame (fig. 1) and engine (fig. 2). Frame number Engine number Note These numbers identify the motorcycle model and should always be indicated when ordering spare parts.
10 E CONTROLS W arning This section details the position and function of all the controls you need to drive your motorcycle. Be sure to read this information carefully before you use the controls. P osition of motorcycle contr ols (fig. 3) 1) Instrument panel.
Instrument panel (fig. 4) 1) High beam light (blue) . Comes on when high beam is on. 2) T urn indicator light (green) . Comes on and flashes when a turn indicator is on. 3) Fuel warning light (yellow) . Comes on when there are about 4 liters fuel left in the tank.
12 E LCD unit functions When the ignition key is turned to ON , the instrument panel carries out a Check of all instruments (pointers, display , lights) (see fig. 5 and 6). LCD (1) T urn the key to ON and press (B) (fig. 6) to display trip meter and odometer alternatively .
13 E Oil temperature When the oil temperature goes below 50 °C (122 °F), " LO " will be displayed. " HI " will be displayed when the temperature exceeds 170 °C (338 °F). Fuel light " FUEL" will be displayed when the fuel warning light comes on.
14 E The key A performs the same functions as the keys B, and is also used to wipe off and re-program other black keys, if needed. Note The three keys have a small plate (1) attached that reports their identification number . W arning Keep the keys in different places.
15 E Code card The keys come with a CODE CARD (fig. 8) that reports: A) (fig. 9) the electronic code to be used to be used in case of engine block, i.e. bike did not start after key-ON . B) (fig. 9) the mechanical code for the keys to be reported to the DUCA TI Service network when you are ordering any duplicate keys.
16 E Procedur e to disable immobilizer engine block through thr ottle twistgrip 1) T urn the key to ON and fully open throttle. Keep it open. The EOBD warning light turns off after 8 seconds. 2) Release the throttle as soon as the EOBD warning light turns off.
17 E Operation When the ignition key is turned to OFF , the immobilizer inhibits engine operation. When the ignition key is turned back to ON to start the engine, the following happens: 1) if the CPU recognised the code, the CODE light on the instrument panel will flash briefly .
18 E Ignition switch and steering lock (fig. 10) It is located in front of the fuel tank and has four positions: A) ON : lights and engine on; B) OFF : lights and engine off; C) LOCK : steering locked; D) P : parking light and steering lock. Note T o move the key to the last two positions, press it down before turning it.
19 E Left switch (fig. 11a-11b) 1) Dip switch, light dip switch, two positions: position = low beam on; position = high beam on. 2) Switch = 3-position turn indicator: centre position = OFF; position = left turn; position = right turn. T o reset turn indicators, push in when switch returns to central position.
20 E Clutch lever (fig. 12a - 12b) Lever (1) disengages the clutch. It features a dial adjuster (2) for lever distance from the twistgrip on handlebar (this adjuster is not fitted on the 800Sport version). T o set lever distance from twistgrip, push lever (1) fully forward and turn the dial adjuster (2) to one of its four positions.
21 E Cold start lever (fig. 13a-13b) Use this device to start the engine from cold. It will increase the engine idling speed after starting. Lever positions: A) = closed B) = fully open. The lever can be opened and closed gradually to adjust speed until engine is fully warm (see pages 35-36).
22 E Right switch (fig. 14a-14b) 1) Switch, light switch, three positions: right position = light off; centre position = front and rear parking lights, number plate and instrument panel lights on; left position = headlight, front and rear parking lights, number plate and instrument panel lights on.
23 E Throttle twistgrip (fig. 15a-15b) The twistgrip (1) on the right handlebar opens the throttles. When released, it will spring back to the initial position (idling speed). Front brake lever (fig. 15a-15b) Pull in the lever (2) towards the twistgrip to operate the front brake.
24 E Rear brake pedal (fig. 16) Push down on the pedal (1) to apply the rear brake. The system is hydraulically operated. Gear change pedal (fig. 17) The gear change pedal is at rest when in the central position N , is moved up and down to change gears and then returns to the central position.
25 E 5 4 6 7 fig. 19 Setting the gear change and rear brake pedals The gear change and rear brake pedals can be adjusted to suit the preferred riding position of each rider . T o set the gear change pedal, lock linkage (1) and loosen the check nuts (2) and (3).
26 E MAIN COMPONENTS AND DEVICES fig. 20 1 3 6 2 4 5 5 7 Location (fig. 20) 1) T ank filler plug. 2) Seat catch and helmet hooks. 3) Side stand. 4) Rear view mirrors.
27 E T ank filler plug (fig. 21) Opening Lift the protection lid (1) and fit the ignition key into the lock. T urn the key clockwise 1/4 turn to unlock. Lift the plug. Closing Refit the plug with the key in it and push it down into its seat. T urn the key anticlockwise to its initial position and take it out.
28 E 3 1 0 1 O P E N Seat catch and helmet hooks Opening (fig. 22) Fit the ignition key into the lock (1) and turn the key clockwise until the rear end of the seat lifts up. Pull the seat backward to slide it off its front holders (3). At the front end of the compartment underneath the seat, there are the helmet hooks (2, fig.
29 E Side stand (fig. 24) Important Before lowering the side stand, make sure that the bearing surface is hard and flat. Do not park on soft or pebbled ground or on asphalt melt by the sun heat and similar or the motorcycle may fall over . When parking in downhill road tracts, always park the motorcycle with its rear wheel facing downhill.
30 E Front fork adjusters (fig. 25) The front fork used on the SUPERSPORT800 model has rebound and compression damping adjusters. This adjustment is done using the outer adjusters: 1) to adjust rebound damping; 2) to adjust inner springs preload; 3) to adjust compression damping.
31 E Shock absorber adjusters Rear shock absorbers feature spring preload, rebound and compression damping adjusters. The adjuster (1, fig. 27) on the shock absorber expansion reservoir - LH side of the frame - controls compression damping. The adjuster (2, fig.
32 E W arning The shock absorber is filled with gas under pressure and may cause severe damage if taken apart by unskilled persons. Shock absorber (SS800) On the SS800 model, hydraulic damping changes with shock absorber travel (in other words, wheel travel) for improved comfort.
33 E DIRECTIONS FOR USE Running-in recommendations Max. rotation speed (fig. 30) Rotation speed for running-in period and during standard use (rpm): 1) up to 1000 km; 2) from 1000 to 2500 km; 3) after 2500 km. Up to 1000 km During the first 1000 km, keep an eye on the revolution meter .
34 E Important During the whole running-in period, the maintenance and service rules recommended in this manual should be observed carefully . Have the service inspections performed as recommended in the Warranty Card. Failure to comply with these rules will release Ducati Motor Holding S.
35 E Starting the engine Note Follow the “High ambient temperature” procedure to start the engine when it is warm. W arning Before starting the engine, become familiar with the controls you will need to use when riding. Regular ambient temperature (10 °C/50 °F to 35 °C/95 °F): 1) Move the ignition key to ON (fig.
36 E 4) Move the cold start lever to the vertical position (A) to let engine idle at about 1400-1500 rpm. Important Do not rev up the engine when it is cold. Allow some time for oil to reach all points that need lubricating. 5) As the engine warms up, move the cold start lever gradually towards the vertical position (A).
37 E 2 1 fig. 33b 1 2 fig. 33a SUPERSPORT800 800Sport Moving off 1) Disengage the clutch squeezing the control lever . 2) Push down on gear change lever sharply with the tip of your foot to engage the first gear . 3) Speed up engine, by turning the throttle twistgrip and slightly releasing the clutch lever at the same time.
38 E Stopping the motorcycle If you let go of the throttle twistgrip, the motorcycle will slow down gradually and smoothly . Then, shift down releasing the clutch, and finally change from first to neutral. Apply brakes and you will bring the motorcycle to a complete stop.
39 E Refuelling Never overfill the tank when refuelling. Fuel should never be touching the rim of filler recess (fig. 34). W arning Use low-lead fuel having at least 95 fuel octane rating. Be sure there is no fuel trapped in the filler recess. Max level fig.
40 E T ool kit and accessories (fig. 35) Accommodated in the compartment under the seat is a bag (1) holding: an Owner’ s manual; a helmet fastening cable; a tool kit for usual maintenance and checks stored in the top pocket. T o access this compartment, lift the seat by opening the catch (page 28).
41 E Removing the fairing Some servicing operations need the motorcycle fairing to be removed. W arning Firmly secure all removed parts when refitting them, otherwise some of them might suddenly come off when riding and you may lose control of your motorcycle.
42 E 3 Half-faired version (fig. 39) Unscrew the screw (3) that holds each body panel to the lower support bracket. Disconnect the indicator connectors and remove the body panels. Fully-faired version (fig. 40) Unscrew the screw (4) that holds the left body panel to the side stand fixing plate.
43 E Headlamp fairing Unscrew the two nuts (1, fig. 41) that hold the rear view mirrors to the headlamp fairing and remove the rear view mirrors. Unscrew the three screws (2, fig. 42) that hold each body panel to the headlamp fairing. Move the body panels slightly apart and unscrew the four screws (3, fig.
44 E Lifting the fuel tank (fig. 44 and 45) Remove the seat (see page 28). Pull the clip (1, fig. 44) upwards to disengage it from the tank catch. Lift the tank and unhook the service rod (2, fig. 45) from its retainer (3). Place the tank onto the rod (2) fitting rod end into the hole in frame cross-member .
45 E Changing the air filter (fig. 46 and 47) Replace air filter at the required intervals shown in the routine maintenance chart (see Warranty Card). The air box is accessible after lifting the fuel tank. Undo the clips (1) of the cover on both sides of the air box, then remove cover (2).
46 E Checking brake and clutch fluid level Fluid level should never fall below the MIN mark on each reservoir (fig. 48 to 50). If level drops below the limit, air might get into the circuit and affect the operation of the system involved.
47 E Clutch system If the control lever has exceeding play and the transmission snatches or jams as you try to engage a gear , it means that there is air in the circuit. Contact your Ducati Dealer or Authorised Workshop to have the system inspected and air drained out.
48 E Checking brake pads for wear (fig. 51) Front brake T o facilitate inspection without removing the pads from the calipers, brake pads have a wear mark. If the grooves in the friction material are still visible, the pad is still in good condition. Rear brake The friction material on each pad should be at least 1 mm thick.
49 E 3 1 2 Lubricating joints The condition of the outer sheaths of the throttle and cold start cables should be checked at regular intervals. The sheaths should show no signs of squeezing or cracking.
50 E 1 1,5 ÷ 2 mm ➤ ➤ - + fig. 54b Throttle cable adjustment The throttle twistgrip must have a free play of 1.5 - 2 mm measured at the edge of the twistgrip, at all positions of the handlebars. If it needs adjusting, use the suitable adjuster (1, fig.
51 E 1 – + Charging the battery (fig. 55) Before charging the battery , it is best to remove it from the motorcycle. Always disconnect the black negative terminal ( - ) first, and then the red positive terminal ( + ). Undo the straps (1) and remove the battery .
52 E . 25 ÷ 30 mm = = fig. 56 Chain tensioning T urn the rear wheel slowly until you find the position where chain tension is tightest. Put motorcycle on the side stand and push the chain up pressing with a finger at mid-length of swingarm. The lower stretch of chain must have a slack of 25-30 mm .
53 E Chain lubrication The chain fitted on your motorcycle has O-rings that keep dirt out of and lubricant inside the sliding parts. The seals might be irreparably damaged if the chain is cleaned using any solvent other than those specific for O-ring chains or washed using steam or water jets.
54 E 2 fig. 59 1 A Replacing bulbs Before replacing a burnt-out bulb, make sure that the new bulb complies with voltage and wattage as specified on page 72, “Electric System”, for that lighting device. Always test the new lamp before refitting the parts you have removed.
55 E 3 fig. 60 Reassembly Insert the locating pegs of the bulb base into their seats to obtain correct alignment. Hook the clip (2) to the headlamp holders; reconnect the connector (1) you have detached previously and refit the rubber cover . The parking light bulb is fitted on the top section of the headlamp body .
56 E A fig. 62 T urn indicators (fig. 61) Remove the screw (1) and detach the glass (2) from the indicator body holder . The bulb has a bayonet-type fitting: press and rotate anti- clockwise to remove; fit the spare bulb by pressing and turning clockwise until it clicks.
57 E 1 fig. 63 Stop light T o replace the stop and parking light bulb, unscrew the two screws (1, fig. 63) that secure the glass and remove glass. The bulb has a bayonet-type fitting: press and rotate anti-clockwise to remove; fit the spare bulb by pressing and turning clockwise until it clicks (fig.
58 E Beam setting (fig. 65) When checking beam setting, put the motorcycle upright. T yres should be inflated at the correct pressure and one person should be sitting astride the motorcycle, keeping it at right angles to its longitudinal axis.
59 E The height of the light beam can be corrected using the screw (1, fig. 66) on the left side of the headlamp. T urn the screw clockwise to lower the beam, anticlockwise to raise it. The side position of the headlamp is adjusted using the adjusting screw (2, fig.
60 E Minimum tread depth Measure tread depth (S, fig. 67) at the point where tread is most worn. It should not be less than 2 mm and anyway not below the legal limit. Important Visually inspect the tyres at regular intervals for cracks and cuts, especially on the side walls, bulges or large spots that are indicative of internal damage.
61 E 1 2 –10 Unigrade Multigrade 01 0 2 0 3 0 4 0 ° C 40 20W–40 20W–50 15W–40 15W–50 10W–40 10W–30 10W 20W 20 30 fig. 68 Checking engine oil level (fig. 68) Engine oil level can be checked through the sight glass (1) provided on the clutch cover .
62 E Refit spark plug into cylinder head. T ighten until thread is fully into the head. T ighten the spark plug to 20 Nm. If you do not have a torque wrench, you can use the wrench supplied with the tool kit to tighten the spark plug an additional 1/2 turn.
63 E Cleaning the motorcycle T o preserve the finish of metal parts and paintwork, wash and clean your motorcycle at regular intervals, anyway according to the road conditions you ride in. Use specific products only . Prefer biodegradable products. A void aggressive detergents or solvents.
64 E Storing the bike away If the motorcycle is to be left unridden over long periods, it is advisable to carry out the following operations before storing it away: clean the motorcycle; drain all fue.
65 E TECHNICAL DA T A Overall dimensions (mm) (fig. 70) W eights Dry weight: 183 Kg. SS800(half-faired) 182.3 Kg. 800Sport (half-faired) Carrying full load: 385 Kg W arning Failure to observe weight limits could result in poor handling and impair the performance of your motorcycle, and you may lose control of the motorcycle.
66 E T op-ups T ype of fluid cu dm (litres) Fuel tank, including a reserve Unleaded fuel 16 of 4 cu dm (liters) 95 fuel octane rating (at least) Oil sump and oil filter SHELL Advance Ultra 4 3.
67 E Engine T win cylinder , four-stroke, 90° “L” type, longitudinal. Bore: 88 mm. Stroke: 66 mm. T otal displacement: 802 cu. cm. Compression ratio: 10.3±0.5:1. Max. power at crankshaft (95/1/EC): 54.8 kW – 74.5 HP at 8250 rpm. Max torque at crankshaft (95/1/EC): 70 Nm-7.
68 E Rear brake With fixed drilled disc. Braking surface material: stainless steel. Disc diameter: 245 mm. Hydraulically operated by a pedal on RH side. Braking surface: 32 sq cm. Make: BREMBO T ype: P 34 C. Friction material: FERIT I/D 450 FF Master cylinder type: PS 11.
69 E T ransmission Clutch: multi-plate wet clutch. Clutch is operated by a control lever on left handlebar . Drive is transmitted from engine to gearbox main shaft via spur gears. Gear ratio: 33/61 . Gearbox: 6-speed. Gearbox with constant mesh gears, gear change pedal on left side of motorcycle.
70 E Frame T ubular trestle frame with upper section made of high- strength steel. Steering angle (on each side): 28° Headstock angle: 24° T rail: 96 mm. Wheels Three-spoke, light-alloy rims (800Sport). Five-spoke rims for SS800. Front wheel Make: BREMBO Dimensions: 3.
71 E Exhaust system Catalyzed in compliance with emission regulations. Available colors SUPERSPORT800 Ducati Anniversary red 473.101 (PPG) Ducati yellow 473.201 (PPG) Metal-color rims and frame. Dark grey *0017 (PPG) FLUO red rims and metal color frame.
72 E Electric system Basic electric items are: Headlamp with double filament 12V -55/60 W iodine bulb. 12V -5W parking light. Electrical controls on handlebar . T urn indicators, 12V -10W bulbs. Horn. Stop light switches. Battery 12V -10 Ah. Generator 12V -520W.
73 E 4 4 IN GOOD CONDITION BLOWN 3 2 1 fig. 72 fig. 73 Injection /electric system diagram key 1) RH switch. 2) T ransponder Aerial. 3) Key-operated switch. 4) Main relay . 5) Fuse box. 6) Horn. 7) Starter motor . 8) Starter contactor . 9) Battery . 10) Regulator fuse.
74 E 31) T iming/rpm sensor . 32) Oil temperature sensor (control unit). 33) 5.9 M E.C.U. 34) Neutral switch. 35) Oil pressure switch. 36) Front stop light switch. 37) Clutch switch. 38) Oil temperature sensor (instrument panel). 39) LH switch. 40) Air temperature/pressure sensor .
75 E USA FOR UNITED ST A TES OF AMERICA VERSION ONL Y Reporting of safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway T raffic Safety Administration (NHTSA) in addition to notifying Ducati North America.
76 E USA made except idle speed adjustments with the throttle stop screw . The Exhaust Emission Control System is separate from the crankcase emission control system. Crankcase Emission Control System The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
77 E USA Riding safety The points given below are applicable for every day motorcycle use and shoud be carefully observed for safe and effective vehicle operation. A motorcycle does not provide the impact protection of an automobile, so defensive riding in addition to wearing protective apparel is extremely important.
78 E USA The exhaust system becomes very hot during operation, never touch the exhaust system. Wear clothing that fully covers your legs. Do not wear loose clothing which could catch on the control levers, footrests, wheels, or chain. Any amount of alcohol will significantly interfere with your ability to safely operate your motorcycle.
79 E USA Label location (fig. B) 3 6 5 10 2 4 8• 1 7• 7 9• 11 fig. B ● only for California.
80 E USA TO HORIZONTAL MANIFOLD VEHICLE EMISSION CONTROL LABEL ENGINE DISPLACEMENT : 904 cc. ENGINE FAMILY : THIS VEHICLE CONFORMS TO U.S. EPA AND CALIFORNIA REGULATIONS APPLICABLE TO 1998 MODEL YEAR NEW MOTORCYCLES. EVAP FAMILY : TO VERTICAL MANIFOLD WARM AIR INLET Via A.
81 E USA Ducati limited warranty on emission control system Ducati North America, Inc., 237 West Parkway , Pompton Plains, New Jersey 07444-1028 warrants that each new 1998 and later Ducati motorcycle.
82 E USA parts replaced and labor charges based on Ducati ’ s recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate. The owner may be required to keep receipts and failed parts in order to receive compensation.
83 E USA transportation of the motorcycle to or from the Ducati dealer . Ducati shall not be liable for any other expenses, loss or damage, whether direct, incidental, consequential or exemplary arising in connection with the sale or use of or inability to use the Ducati motorcycle for any purpose.
84 E ROUTINE MAINTENANCE RECORD km Ducati Mileage Date Service Name 1000 10000 20000 30000 40000 50000.
An important point after buying a device Ducati 800 Sport (2003) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Ducati 800 Sport (2003) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Ducati 800 Sport (2003) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Ducati 800 Sport (2003) you will learn all the available features of the product, as well as information on its operation. The information that you get Ducati 800 Sport (2003) will certainly help you make a decision on the purchase.
If you already are a holder of Ducati 800 Sport (2003), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Ducati 800 Sport (2003).
However, one of the most important roles played by the user manual is to help in solving problems with Ducati 800 Sport (2003). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Ducati 800 Sport (2003) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
