User manual DUCATI MONSTER S4 - 2002

Owner's manual E DUCATIMONSTERS4 1 E 2 Hearty welcome among Ducati fans! Please accept out 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 are 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. 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 the motorcycle is resold - must always be handed over to the new owner. 3 TABLE OF CONTENTS Setting the gear change and rear brake pedals 22 Main components and devices Location 23 Tank filler plug 24 Seat catch and helmet pin 25 Side stand 26 Shock absorber adjusters 27 Front fork adjusters 28 Directions for use 30 Running-in recommendations 30 Pre-ride checks 31 Starting the engine 32 Moving off 34 Braking 34 Stopping the motorcycle 35 Refueling 35 Parking 36 Tool kit and accessories 37 Main maintenance operations 38 Lifting the fuel tank 38 Changing air filter 39 Checking the coolant level 40 Checking brake and clutch fluid level 41 Checking brake pads for wear 42 Throttle cable adjustment 42 Lubricating cables and joints 43 Charging the battery 44 Chain tensioning 45 23 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 The immobilizer system 14 Keys 14 Code Card 15 Duplicate keys 16 Ignition switch and steering lock 17 Left switch 18 Clutch lever 18 Cold start lever 19 Right switch 19 Throttle twistgrip 20 Front brake lever 20 Rear brake pedal 21 Gear change pedal 21 4 Chain lubrication 46 Replacing bulbs 46 Headlamp alignment 48 Tyres 49 Checking engine oil level 51 Cleaning and replacing the spark plugs 52 Cleaning the motorcycle 53 Storing the bike away 53 Important notes 53 Technical data 54 Overall dimensions 54 Weights 54 Top-ups 55 Engine 56 Timing system 56 Performance data 57 Spark plugs 57 Brakes 57 Transmission 58 Frame 59 Wheels 59 Tyres 59 Suspensions 60 Electric system 60 Monster S4 versions 64 Monster S4 64 For United States of America version only 65 Routine maintenance record 74 E 5 GENERAL E Warranty In your own interest, and in order to guarantee product reliability, you are strongly advised to refer to our authorized Dealers and workshops for any servicing requiring particular technical expertise. Our highly skilled staff have access to the implements required to perform any servicing job at best, and use 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 or competitive trials. 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 right will be automatically invalidated. Symbols Ducati Motor Holding S.p.A. advises you to read this booklet 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. The text is supplemented with schematic illustrations for quick reference and better understanding of the subjects concerned. This manual contains some special remarks: 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 handles under the 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 vapours. 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 these 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 390 Kg. Try to 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 (see page 49) 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 should always be indicated when ordering spare parts. fig. 1.1 E fig. 1.2 9 CONTROLS 1 4 8 7 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. E 3 6 5 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) Fast-idle lever. 6) Right switch. 7) Throttle twistgrip. 8) Front brake lever. 9) Gear change pedal. 10) Rear brake pedal. 9 10 fig. 2 10 Instrument panel (fig. 3) 1) Blue light . Comes on when high beam is on. 2) Green light . Comes on and flashes when a turn indicator is on. 3) Yellow light . Comes on when there are about 3.5 liters fuel left in the tank. 4) Green light N. Comes on when in neutral position. 5) Red light . Comes on when engine oil pressure is too low. It briefly 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 stays on, stop the engine or it may suffer severe damage. 6) Orange light Comes on and flashes when the motorcycle is parked (Immobilizer on). Note When the Immobilizer is on, this light flashes for 48 hours and then goes out. The Immobilizer is still operating. 7) Orange light When on, engine operation is inhibited. It goes out after a few seconds (usually 1.8 - 2 sec.). 8) Speedometer (km/h). Gives road speed. a) LCD (1): - Odometer (km). Gives total distance covered. - Trip meter (km). Gives distance covered since last resetting. 9) Revolution counter (rpm). Shows the engine rotation speed/minute. b) LCD (2): - Clock - Oil temperature E 1 8 4 2 5 3 9 7 6 a b fig. 3 11 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. 3.1 and 3.2). LCD (1) Turn the key to ON and press (A) (fig. 3.2) to display trip meter and odometer alternatively. E Resetting the trip meter Keep (A) pressed (fig. 3.2) for more than 2 seconds. When the TRIP function is enabled (trip meter), display (LCD 1) will reset. LCD (2) Turn the key to ON and press (B) (fig. 3.2) to display clock and water temperature. Setting the clock Press (A) for at least 2 seconds. Press (B) to set AM/PM. Press (A) to set hours; press (B) repeatedly to set correct hour. Press (A) to set minutes. Press (B) to increase the value. Keep the button pressed for more than 5 seconds to proceed faster. Press (A) to quit this function. fig. 3.1 1 12 A B 2 fig. 3.2 Water temperature When the water temperature goes below 40°, "LO" will be displayed. "HI" will be displayed when the temperature exceeds 120°. Fuel light "FUEL" will be displayed when the fuel warning light comes on. E Maintenance indicator After the first 1,000 Km (621 miles) and then every 10,000 Km (6210 miles), "MAInt" will be displayed for 5 seconds when turning the key to ON. It reminds you of the routine maintenance servicing to be done. Instrument panel lighting Turn the key to ON and press (B) (fig. 3.2) within 5 seconds to change instrument panel lighting power. 13 E The immobilizer system For improved anti-theft protection, the motorcycle is equipped with an IMMOBILIZER, an electronic system that inhibits engine operation whenever the ignition switch is turned off. Accommodated in the handgrip of each ignition key is an electronic device that modulates an output signal. This signal is generated by a special antenna incorporated in the switch when the ignition is turned on and changes every time. The modulated signal acts as a "password" and tells the CPU that an "authorised" ignition key is being used to start up the engine. When the CPU recognises the signal, it enables engine start-up. Note The three keys have a small plate (1) attached that reports their identification number. Important Keep the keys in different places. Store the plate (1) and the key A in a safe place. Keys (fig. 4.1) The Owner receives a set of keys comprising: - 1 RED key A - 2 BLACK keys B The keys B are regular ignition keys and are used to: - start up the engine - open the lock of the fuel tank filler plug - open the seat lock. 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. B A 1 14 fig. 4.1 Code card The keys come with a CODE CARD that reports: A) (fig. 4.3) the electronic code to be used to start the engine in the event of an emergency; B) (fig. 4.3) the part no. code for the keys to be reported to the DUCATI Service network when you are ordering any duplicate keys. Important Keep the CODE CARD in a safe place. However, it is advisable to keep the electronic code printed on the CODE CARD handy when you ride your motorcycle, so you will be able to start the engine in the event of an emergency. E fig. 4.2 A B fig. 4.3 15 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. This means that the immobilizer system has recognised the key code and enabled engine ignition. When you press the START button, the engine will start up. 2) If the CODE light stays on, it means that the code has not been recognised. When this is the case, turn the ignition key back to OFF and then to ON again. If the engine still does not start, try with another key. If the other key does not work out either, contact the DUCATI Service network. Warning The keys accommodate electronic components inside. If dropped or hit, they might damage. Duplicate keys If you need any duplicate keys, contact the DUCATI Service network with all the keys you have left and your CODE CARD. DUCATI Service will program up to 8 new keys and reprogram your original keys. You may be asked to identify yourself as the legitimate owner of the motorcycle. Be sure have any documents you might need to this end ready. The codes of any keys not submitted will be wiped off from the memory to make those keys unserviceable in case they have been lost. Note If you sell your motorcycle, do not forget to give all keys and the CODE CARD to the new owner. 16 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 on; B) OFF: lights and engine off; C) LOCK: steering lock; D) P: parking lights and steering lock. Warning This vehicle 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. fig. 5 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 17 Left switch (fig. 6) 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. To cancel turn indicators, return switch to central position and push in. 3) Button 4) Button = warning horn. = high-beam flasher. 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. Warning Set clutch lever when motorcycle is stopped. Important Using the clutch properly will avoid damage to transmission parts and spare the engine. fig. 6 18 Cold start lever (fig. 7) Use this device (3) to start the engine from cold. It will increase the engine idling speed after starting. Lever positions: A) (vertical) = closed B) = fully open. The lever can be opened and closed gradually to adjust speed until engine is fully warm (see page 32). Important Never use the cold start lever when the engine is warm or leave it open when riding. Right switch (fig. 8) 1) Switch, light switch, 3 positions: Right = light off; Centre = front and rear parking light, number plate light and panel lights on; Left = headlamp, front and rear parking light, number plate light and panel lights on. 2) 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 Riding with the lights on, stopping the engine using switch (2) and leaving the ignition key in the ON position, may run the battery flat as the lights will remain on. 3) Button = engine start. E fig. 7 19 Throttle twistgrip (fig. 8) The twistgrip (4) on the right handlebar opens throttles. When released, it will spring back to the initial position (idling speed). Front brake lever (fig. 9) Pull in the lever (1) towards the twistgrip to operate the front brake. The system is hydraulically operated and you just need to pull the lever gently. The control lever is provided with a dial adjuster (2) for lever distance adjustment from twistgrip on handlebar (see clutch lever adjustment page 16). Warning Please read the instructions on page 34 before using these controls. E fig. 8 20 fig. 9