User manual DUCATI 748 - 2002

Owner's manual E DUCATI998/748 1 E 2 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. We are steadily doing our best to improve our "Technical Assistance" service. For this reason, we recommend you to strictly follow the indications given in this manual, especially for motorcycle running-in. In this way, your Ducati motorbike will surely give you unforgettable emotions. For any servicing or suggestions you might need, please contact our authorized service centres. Enjoy your ride! Ducati Motor Holding S.p.A. declines any liability whatsoever for any mistakes incurred in drawing up this manual. The information contained herein is valid at the time of going to print. Ducati Motor Holding S.p.A. reserves the right to make any changes required by the future development of the above-mentioned products. E For your safety, as well as to preserve the warranty, reliability and worth of your motorcycle, use original Ducati spare parts only. Warning This manual forms an integral part of the motorcycle and - if a transfer of title occurs - must always be handed over to the new owner. 3 TABLE OF CONTENTS E General 6 Warranty 6 Symbols 6 Useful information for safe riding 7 Carrying the max load allowed 8 Identification data 9 Controls 10 Position of motorcycle controls 10 Instrument panel 11 Keys 12 Ignition switch and steering lock 12 Left switch 13 Clutch lever 14 Cold start button 15 Starter lever 15 Right switch 16 Throttle twistgrip 16 Front brake lever 16 Rear brake pedal 17 Gear change pedal 17 Setting the gear change and rear brake pedals 18 4 Main components and devices 19 Location 19 Tank filler plug 20 Seat catch and helmet hook 21 Side stand 23 Steering damper 24 Front fork adjusters 748/748S/998 24 Shock absorber adjusters (748/748S) 26 Shock absorber adjusters (998) 27 Changing motorcycle track alignement 28 Directions for use 29 Running-in recommendations 29 Pre-ride checks 31 Starting the engine 32 Moving off 34 Braking 34 Stopping the motorcycle 35 Parking 35 Refueling 35 Tool kit and accessories 36 Main maintenance operations 37 Removing the fairing 37 Cleaning and changing air filters 39 Checking the coolant level 40 Checking brake and clutch fluid level 41 Checking brake pads for wear 42 Lubricating cables and joints 43 Throttle cable adjustment 43 Charging the battery 44 Adjusting headstock angle 45 Chain tension inspection 46 Chain lubrication 46 Replacing bulbs 47 Beam setting 50 Rear view mirror adjustment 51 Tubeless tyres 51 Checking engine oil level 53 Cleaning and replacing the spark plugs 54 Cleaning the motorcycle 55 Storing the bike away 56 Important notes 56 Technical data 57 Overall dimensions 57 Weights 57 Top-ups 58 Engine (748/748S) 59 Timing system (748/748S) 59 Engine (998) 60 Timing system (998) 60 Performance data 61 Spark plugs 61 Brakes 61 Transmission 62 Frame 63 Wheels 64 Tyres 64 Suspensions 65 Available colours 65 Electric system 66 For United States of America version only 73 Routine maintenance record 82 E 5 GENERAL E Warranty In your own interest, and in order to guarantee product reliability, you are strongly advised to refer to a Ducati Dealer or Authorized Workshop for any servicing requiring particular technical expertise. Our highly skilled staff have access to the implements required to perform any servicing job at best, using Ducati original spare parts only as the best guarantee for full interchangeability, smooth running and long life. All Ducati motorcycles come with a "Warranty Card". However, warranty does not apply to the motorcycles used in competitions. No motorcycle part may be tampered with, altered, or replaced with parts other than original Ducati spare parts during the warranty period, or the warranty will be automatically invalidated. Symbols Ducati Motor Holding S.p.A. advises you to read this manual carefully so as to become familiar with your motorcycle. In case of any doubts, please call a Ducati Dealer or Authorized Workshop. The information contained herein will prove useful on your trips - and Ducati Motor Holding S.p.A. wishes you smooth, enjoyable riding - and will help you keep the performance of your motorcycle unchanged for a long time. Warning Failure to comply with these instructions may put you at risk and lead to severe injury or death. Important Possibility of damaging the motorcycle and/or its components. Note Additional information concerning the job being carried out. The terms right and left are referred to the motorcycle viewed from the riding position. 6 Useful information for safe riding Warning 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. Do not lend your motorcycle to inexperienced riders or who do not hold a valid licence. Both rider and pillion passenger must always wear a safety helmet. Wear proper clothing, with no loose items or accessories that may become tangled in the controls or limit your zone of vision. Never start or run the engine indoors. Exhaust gases are poisonous and may lead to loss of consciousness or even death within a short time. Both rider and pillion passenger should keep their feet on the footpegs when the motorcycle is in motion. Always hold the handlebars firmly with both hands so you will be ready for sudden changes of direction or in the road surface. The pillion passenger should always hold on to the suitable belt on the rear seat with both hands. Ride within the law and observe national and local rules. Always respect speed limits where these are posted. However, always adjust your speed to the visibility, road and traffic conditions you are riding in. Always signal your intention to turn or pull to the next lane in good time using the suitable turn indicators. Be sure you are clearly visible and do not ride within the blind spot of vehicles ahead. Be very careful when tackling road junctions, or when riding in the areas near exits from private grounds, car parks or on slip roads to access motorways. Always turn off the engine when refueling. Be extremely careful not to spill gasoline on the engine or on the exhaust pipe when refueling. Do not smoke when refueling. While refueling, you may inhale noxious gasoline vapors. Should any gasoline drops be spilled on your skin or clothing, immediately wash with soap and water and change your clothing. Always remove the key when you leave your motorcycle unattended. The engine, exhaust pipes, and mufflers stay hot for a long time. Park your motorcycle where no one is likely to hit it and use the side stand. Never park on uneven or soft ground or your motorcycle may fall over. E 7 Carrying the maximum load allowed Your motorcycle is designed for long-distance riding, carrying the maximum load allowed in full safety. Even weight distribution is critical to preserving safety features and avoiding trouble when performing sudden manoeuvres or riding on bumpy roads. Information about carrying capacity The total weight of the motorcycle in running order including rider, pillion passenger, luggage and additional accessories should not exceed 375 Kg. Arrange your luggage or heavy accessories in the lowest possible position and close to motorcycle centre. Be sure to secure the luggage to the supports provided on the motorcycle as firmly as possible. Improperly secured luggage may affect stability. Never fix bulky or heavy objects to the handlebar or to the front mud guard as this would affect stability and cause danger. Do not insert any objects you may need to carry into the gaps of the frame as these may foul moving parts. Make sure the tyres are inflated to the proper pressure indicated at page 51 and that they are in good condition. E 8 Identification data All Ducati motorcycles have two identification numbers, for frame (fig. 1.1) and engine (fig. 1.2). Frame number Engine number Note These numbers identify the motorcycle model and are required when ordering spare parts. fig. 1.1 E fig. 1.2 9 CONTROLS 1 5 8 4 6 E Warning 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. 3 7 2 Position of motorcycle controls (fig. 2) 1) Instrument panel. 2) Key-operated ignition switch and steering lock. 3) Left switch. 4) Clutch lever. 5) Cold start button. 6) Right switch. 7) Throttle twistgrip. 8) Front brake lever. 9) Gear change pedal. 10) Rear brake pedal. 10 9 fig. 2 10 Instrument panel (fig. 3) 1) Speedometer (km/h or mph). Gives road speed. a) Odometer (km or miles). Gives total distance covered. b) Trip meter (km or miles). Gives distance covered since last resetting. c) Trip meter resetting knob. Turn to reset trip meter to "0000". 2) Engine revolution meter (rpm) Indicates engine rpm. 3) Green light N. Comes on when gearbox is in neutral. 4) Yellow light . Comes on when there are about 4 liters fuel left in the tank. 5) Green light . Comes on and flashes when a turn indicator is on. 6) Red light . Comes on when engine oil pressure is too low. It comes on when the ignition is switched to ON and normally goes out a few seconds after engine starts. It may shortly come on when the engine is hot, however, it should go out as the engine revs up. Important If this light (6) stays on, stop the engine or it may suffer severe damage. 7) Blue light . Comes on when right high beam is on. 8) Water temperature indicator . Indicates engine coolant temperature. Important Stop riding if the temperature reaches the max. value, otherwise the engine might damage. When parking light is on, the instrument panel is lighted. E 1 c a 5 3 7 4 2 6 ATICORS UC D 8 b fig. 3 11 E Keys (fig. 4) Your Ducati was delivered with two universal keys for ignition, steering lock and seat catch and a key identification plate (1). Note Separate the two keys and keep the identification plate (1) in a safe place. Warning The 998 model is equipped with an energy-saving CPU. If the key stays ON for a long period but the ignition button is not pressed within 15 seconds, the CPU will stop operating to avoid current absorption. Move the key to OFF and then to ON again. Note To move the key to the last two positions, press it down before turning it. Switching to (B), (C) and (D), you will be able to take the key out. E Ignition switch and steering lock (fig. 5) It is located in front of the fuel tank and has four positions: A) ON: lights and engine enabled; B) OFF: lights and engine disabled; C) LOCK: steering locked; D) P: parking light and steering lock. B A 1 C D fig. 4 12 fig. 5 Left switch 1) Switch, light switch, 3 positions: Down = light off; Centre = front and rear parking light, number plate light and panel lights on; Up = headlamp, front and rear parking light, number plate light and panel lights on. Note This device is not fitted on the Australia and Japan versions. 2) Dip switch, light dip switch, two positions: position = low beam on; position = high beam on. 3) Switch = 3-position turn indicator: centre position = off; position = left turn; position = right turn. To cancel turn indicators, return switch to central position and push in. 4) Button 5) Button = warning horn. = high-beam flasher. 748/748S 5 2 3 4 1 fig. 6 998 E 5 2 3 1 4 fig. 6.1 13 E Clutch lever (fig. 7) Lever (1) disengages the clutch. It features a dial adjuster (2) for lever distance from the twistgrip on handlebar. To set lever distance from twistgrip, push lever (1) fully forward and turn the dial adjuster (2) to one of its four positions. Remember that position no. 1 gives maximum distance between lever and twistgrip, whereas lever and twistgrip are closest when adjuster is set to position no. 4. When you pull in the lever (1), you will disengage the engine from the gearbox and therefore from the driving wheel. Using the clutch properly is essential to smooth riding, especially when moving off. Important Using the clutch properly will avoid damage to transmission parts and spare the engine. 2 1 fig. 7 14 Cold start button (fig. 8) This device is on throttle control. Push the button (3) to enable control. In this way, the throttle control (4) will lightly turn, thus increasing the engine rotation speed. Use this device to start the engine from cold (page 32). Important Move the button (3) back to rest position once the engine is warm. Turn the throttle twistgrip (4) clockwise (slow down). Never use this device when the engine is warm. 748/748S 4 3 E fig. 8 Starter lever (fig. 8.1) The starter lever (1) is used to start the engine from cold and to increase the engine idle rotation speed after starting. Control positions: A - (vertical) Control not activated B - Control fully activated The lever may also be placed on intermediate positions to match the progressive engine warming up (see page 32). Important Never use this device when the engine is warm. Do not run with the starter control on. A B 998 1 fig. 8.1 15 Right switch (fig. 9) 1) Switch for ENGINE STOP, two positions: position (RUN) = run. position (OFF) = stop. Warning This switch is mainly intended for use in emergency cases when you need to stop the engine quickly. After stopping the engine, return the switch to the position to enable starting. Important Stopping the engine using switch (1) after riding with the lights on and leaving the ignition key in the ON position, may run the battery flat as the lights will remain on. 2) Button = engine start Front brake lever (fig. 9) Pull in the lever (4) towards the twistgrip to operate the front brake. The system is hydraulically operated and you just need to pull the lever gently. The brake lever is provided with a dial adjuster (5) for lever distance adjustment from twistgrip on handlebar. Warning Please read the instructions on page 34 before using these controls. E 1 5 4 Throttle twistgrip (fig. 9) The twistgrip (3) on the right handlebar opens the throttles. When released, it will spring back to the initial position (idling speed). 2 3 16 fig. 9 Rear brake pedal (fig. 10) Push down on the pedal (1) with your foot to operate the rear brake. The system is hydraulically operated. Gear change pedal (fig. 11) 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. down = push down on the pedal to engage 1st gear and to shift down. The N light will go out. up = lift the pedal to engage the 2nd gear and then the 3rd, 4th, 5th and 6th gear. Each time you move the pedal you will engage the next gear. E ;;;;;;; ;;;;;;; ;;;;;;; ;;;;;;; ;;;;;;; ;;;;;;; 6 5 4 3 2 N 1 1 fig. 10 fig. 11 17 Setting the gear change and rear brake pedals (fig. 11.2 and 11.3) The gear change and rear brake pedals can be adjusted to suit the preferred riding position of each rider. To set the gear change pedal, lock linkage (1) and loosen the check nuts (2) and (3). Note Nut (2) has a left-hand thread. E Fit an open-end wrench to the hexagon portion of linkage (1). Rotate linkage until setting pedal in the desired position. Tighten both check nuts onto linkage. To set the rear brake pedal, loosen check nut (4). Turn pedal travel adjusting screw (5) until pedal is in the desired position. Tighten check nut (4). Work pedal by hand to make sure it has 1.5 - 2 mm free play before brake begins to bite. If not so, set the length of cylinder linkage as follows. Loosen the check nut (6) on cylinder linkage. Tighten linkage into fork (7) to increase play, or unscrew linkage to reduce it. Tighten check nut (6) and check pedal free play again. fig. 11.2 fig. 11.3 18 MAIN COMPONENTS AND DEVICES Location (fig. 12) 1) Tank filler plug. 2) Seat catch. 3) Side stand. 4) Hook for helmet fastening cable. 5) Steering damper. 6) Rear view mirrors. 7) Front fork adjusters. 8) Rear shock absorber adjusters. 9) Motorcycle track alignment linkage. E fig. 12 19 Tank filler plug (fig. 13) Opening Lift the protection lid (1) and fit the ignition key into the lock. Turn 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. Turn the key anticlockwise to its initial position and take it out. Close the lock protection lid (1). Note The plug can only be closed with the key in. Warning Always make sure you have properly refitted (see page 35) and closed the plug after each refueling. 1 E 1/4 OPEN 0 fig. 13 20