Ducati SCRAMBLER 800 Gebrauchsanweisung

DUCATI SCRAMBLER 800 Workshop

Manual 2015

S.01 - General

Symbols - Abbreviations - References

Product specifications

Dangerous products - warnings

General maintenance instructions

General safety rules

S.02 - Model-specific information

Model identification

Identification data

S.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

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

S.04 - Maintenance operations

Vehicle pre-delivery

Scheduled maintenance chart

Operations to be carried out by the customer

Operations to be carried out by the dealer

Maintenance operations

Adjusting the rear shock absorber

Adjusting the position of the gearchange pedal and rear brake pedal

Adjusting the front brake control lever

Adjusting the throttle cable

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

Clutch control cable adjustment

Changing the fluid in the rear brake system

Changing the fluid in the front brake system

Changing and cleaning the air filters

Replacing the spark plugs

Changing the timing belts

Checking valve clearance

Changing the engine oil and filter cartridge

Check engine oil level

S.05 - Fairings

Rear-view mirrors

Refitting the rear-view mirrors

Removing the rear-view mirrors

Seat - tail guard - side body panels

Refitting the tail guard (CLASSIC)

Removing the tail guard (CLASSIC)

Refitting the seat release mechanism

Removing the seat release mechanism

Refitting the tail guard

Removing the tail guard

Refitting the rear side body panels

Removing the rear side body panels

Refitting the seat

Removing the seat

Mudguard

Refitting the front mudguard (URBAN ENDURO)

Removing the front mudguard (URBAN ENDURO)

Refitting the front mudguard

Removing the front mudguard

Belly pan

Refitting the belly pan (URBAN ENDURO)

Removing the belly pan (URBAN ENDURO)

S.06 - Electric system and engine management

Wiring diagram

Table Z

Table Y

Table X

Table W

Table V

Table U

Table T

Table S

Table R

Table Q

Table P

Table O

Table N

Table M

Table L

Table K

Table J

Table H

Table G

Table F

Table E

Table D

Table C

Table B

Table A

Routing of wiring on frame

Fuse box key

Wiring diagram cable colour codes

Key to wiring diagram

Charge system - Battery

Rectifier-regulator

Alternator

Battery

Topping up the electrolyte

Recharging the battery

Checking the battery charging system

Electric starter

Solenoid starter

Starter motor

Electric starting system

Lighting

Aligning the headlight

Changing bulbs

Instrument panel

Entering PIN CODE function for overriding purposes

Key duplication

Operation

Keys

Immobilizer system

Light control

Setting the units of measurement

Changing the PIN CODE

Pin Code

Clock setting function (CLOCK)

Instrument panel back-lighting setting (B.LIGHT)

Battery voltage

ABS control unit enabling/disabling

Setting menu

DESMO SERVICE indication

DESMO SERVICE countdown indication

OIL SERVICE zero warning

Service indication (SERVICE)

High engine temperature

Clock

Displayed errors description

Error warnings

Errors

Ambient air temperature (AIR)

Partial fuel reserve counter (TRIP FUEL)

Trip meter 2 (TRIP 2)

Trip meter 1 (TRIP 1)

Odometer (TOT)

Menu 1 functions

Engine rpm indication (RPM)

Motorcycle speed

Main functions

Parameter setting/displaying

Function buttons

Technological Dictionary

Acronyms and abbreviations used in the Manual

Instrument panel

System components

Diagnostic socket

Main relay and injection

Timing/rpm sensor

Throttle position potentiometer

Coil

Ignition spark plug

Temperature sensor

Air pressure sensor

Lambda sensor

Stepper motor

Electric injector

Electronic control unit

S.07 - Chassis

Front wheel

Overhauling the front wheel (URBAN ENDURO)

Overhauling the front wheel (CLASSIC)

Refitting the front wheel

Overhauling the front wheel

Removing the front wheel

Rear wheel

Overhauling the rear wheel (URBAN ENDURO)

Overhauling the rear wheel (CLASSIC)

Refitting the rear wheel

Overhauling the rear wheel

Removing the rear wheel

Front brake control

Refitting the front brake system

Refitting the brake disc

Overhauling the front brake components

Removing the brake disc

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 disc

Removing the rear brake disc

Refitting the rear brake calliper

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 assembly: throttle control

Refitting the throttle control

Removing the throttle control

Adjusting the throttle cable

Refitting the handlebar

Removing the handlebar

Handlebar assembly: clutch control

Refitting the clutch assembly

Removing the clutch assembly

Handlebar assembly: ignition switch

Refitting the ignition switch

Removing the ignition switch

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

Removing the rear sprocket

Refitting the front sprocket

Removing the front sprocket

Inspection of the final drive

Footrest support

Refitting the rear footpegs

Removing the rear footpegs

Refitting the front footpeg support

Removing the front footpeg support

Refitting the front footpegs

Removing the front footpegs

Stands

Refitting the side stand

Removing the side stand

Inspecting the frame

Checking the frame

Refitting the structural parts and frame

Removing structural components and frame

Tail light - number plate holder

Rimontaggio fanale posteriore

Smontaggio fanale posteriore

Refitting the number plate holder

Removing the number plate holder

Electrical components compartment

Refitting the electric components compartment

Removing the electric components compartment

S.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 throttle body

Removing the throttle body

Refitting the airbox

Removing the airbox

Air intake

Refitting the secondary air system

Removing the secondary air system

Refitting the air filters

Removing the air filters

Exhaust system

Refitting the silencer (FULL THROTTLE)

Removing the silencer (FULL THROTTLE)

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

S.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

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

Reassembling the timing pulleys

Refitting the timing layshaft pulley

Removing the timing layshaft pulleys

Disassembling the camshaft pulleys

Removing the cylinder head pulley/fixed tensioner

Removing the mobile tensioner/timing belt

Removing the timing belt covers

Cylinder head assembly: camshafts

Refitting the intake manifold

Removing the intake manifold

Refitting the camshafts

Check of the camshafts and supports

Removing the camshafts

Cylinder head assembly: valves - rocker arms

Refitting the cylinder heads

Refitting the valves and rocker arms

Overhauling the cylinder head components

Removing the valves and rocker arms

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 gears

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: external components

Refitting the starter motor

Removing the starter motor

Refitting the starter motor idler gear

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

Reassembling the connecting rod assembly

Overhauling the connecting rod assembly

Disassembling the connecting rod assembly

Removing the connecting rod assembly

Symbols - Abbreviations - References

To allow quick and easy consultation, this manual uses graphic symbols to highlight situations in which

maximum care is required, as well as practical advice or information. Pay attention to the meaning of the

symbols since they serve to avoid repeating technical concepts or safety warnings throughout the text. The

symbols should therefore be seen as real "reminders". Please refer to this page whenever in doubt as to

their meaning.

The terms right-hand and left-hand refer to the motorcycle viewed from the riding position.

Warning

Failure to comply with these instructions may put you at risk, and could lead to severe injury or even death.

Important

Failure to follow the instructions in text marked with this symbol can lead to serious damage to the

motorcycle and its components.

Note

This symbol indicates additional useful information for the current operation.

Product specifications

Symbols in the diagram show the type of threadlocker, sealant or lubricant to be used at the points

indicated. The table below shows the symbols used and the specifications of the various products.

Symbol

Specifications

Recommended

product

Engine oil (for characteristics see Fuel, lubricants and other fluids).

SHELL Advance 4T

Ultra

DOT 4 special hydraulic brake fluid.

SHELL Advance

Brake DOT 4

SAE 80-90 gear oil or special products for chains with O rings.

SHELL Advance

Chain or Advance

Teflon Chain

Anti-freeze (nitride, amine and phosphate free) 30 to 40% + water.

SHELL Advance

coolant or

Glycoshell

GREASE

Multipurpose, medium fibre, lithium grease.

SHELL Alvania R3

GREASE

Molybdenum disulphide grease, high mechanical stress and high

temperature resistant.

SHELL Retinax

HDX2 or SHELL

Gadius S2 V220

AD 2

GREASE

Bearing/joint grease for parts subject to prolonged mechanical stress.

Temperature range: -10 to 110 °C.

SHELL Retinax

LX2

GREASE

Protective grease, with anti-corrosive and waterproofing properties. SHELL Retinax

HD2

GREASE

Grease

PANKL - PLB 05

GREASE

Grease

OPTIMOL - PASTE

WHITE T

GREASE

Grease

PANKL - PLB07

GREASE

Grease

KLÜBER

STABURAGS NBU

30 PTM

GREASE

Copper grease

CUPRUM 320

LOCK 1

Low-strength threadlocker.

Loctite 222

LOCK 2

Medium-strength threadlocker, compatible with oil.

Loctite 243 (or

THREE BOND

TB1324)

LOCK 3

High-strength threadlocker for threaded parts.

Loctite 270

LOCK 4

Surface sealant resistant to high mechanical stress and solvents. Resists

high temperatures (up to 200 °C) and pressures up to 350 bar; fills

gaps up to 0.4 mm.

Loctite 510

LOCK 5

Permanent adhesive for freely sliding cylindrical couplings or threaded

couplings on mechanical parts. High resistance to mechanical stress and

solvents. Temperature range: 55 to 175 °C.

Loctite 128455

(former 648 BV)

LOCK 6

Pipe sealant for pipes and medium to large fittings. For water and gases

(except oxygen). Maximum filling capacity: 0.40 mm (diameter

clearance).

Loctite 577

LOCK 7

Instant adhesive for rubber and plastics with elastomer charged ethylic

base.

Loctite 480

LOCK 8

High-strength retaining compound for threaded parts, bearings, bushes,

splines and keys. Operating temperature range: 55 to 150 °C.

Loctite 601 (As an

alternative THREE

BOND TB1378B)

LOCK 9

Medium-strength threadlocker.

Loctite 406

LOCK

Product for metal parts to seal and lock freely sliding cylindrical

couplings or threaded couplings. Resistant to high mechanical stress and

high temperature, excellent resistance to solvents and chemical attack.

Loctite 128443

(former 648 AV)

LOCK

Medium-strength threadlocker.

Loctite 401

LOCK

Instant adhesive gel offering tensile/shear strength.

Loctite 454 gel

DUCATI sealing compound.

THREE BOND

1215

Sealing compound

THREE BOND

1207B

Exhaust pipe sealing compound. Self-sealing paste hardens when

heated and resists temperatures exceeding 1000 °C.

Holts Firegum

Spray used to protect electric systems. Eliminates moisture and

condensation and provides excellent corrosion resistance. Water

repellent.

SHELL Advance

Contact Cleaner

Dry lubricant, polymerising on contact with air.

Molykote D321R

Molykote M55 Plus

Emulsion for lubrication of rubber.

P 80

Protection lubricant emulsion.

KLUBERPLUS S

06/100

Lubricant for mechanical elements

Castor oil

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