Ducati Motorcycle Manuals for Mechanics

2015 DUCATI Hypermotard SP Service Manual HYM.01 - General Symbols - Abbreviations - References Product specifications Hazardous Products - Warnings General maintenance instructions General safety rules HYM.02 - Information about the model Model identification data Identification data HYM.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 Dimensions Dimensions Fuel, lubricants and other fluids Fuel, lubricants and other fluids Tightening torque values Engine tightening torque values Frame tightening torque values Service tools Special diagnosis equipment Special tools for the frame Specific tools for the engine HYM.04 - Maintenance operations Vehicle pre-delivery 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 front fork Adjusting the position of the gear change and rear brake pedals

Adjusting the clutch lever and front brake lever Checking the rear brake pad wear and changing the brake pads Checking the front brake pad wear and changing the brake pads Adjusting the chain tension Adjusting the steering head bearing play Adjusting the clutch control cable Changing the fluid in the rear brake system Changing the fluid in the front brake system Changing the coolant Checking the coolant level Changing and cleaning the air filters Spark plugs replacement Changing the timing belts Checking valve clearance Changing the engine oil and filter cartridge Check engine oil level HYM.05 - Fairings Rear-view mirrors Refitting the rear-view mirrors Removing the rear-view mirrors Headlight fairing Refitting the headlight fairing Removing the headlight fairing Fairings Refitting the fairings Removing the fairings Seat - side panels Refitting the rear side panels Removing the rear side panels Refitting the seat Removing the seat Front and rear mudguard Refitting the rear mudguard Removing the rear mudguard Refitting the front mudguard Removing the front mudguard HYM.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 I

Table H Table G Table F Table E Table D Table C Table B Table A Routing of wiring on frame Key to fuse box Wiring diagram colour codes Key to wiring diagram Battery charging system Rectifier-regulator Generator Battery Topping up the electrolyte Recharging the battery Checking the battery charging system Electric starting Solenoid starter Starter motor Electric starting system Lights Headlight aim Changing bulbs Instruments Other functions Setting the Unit of Measurement (UNITS) Light control Operation PIN CODE entering function for overriding purposes Keys Immobilizer code (PIN CODE) Engine rpm digital indication (RPM) Battery voltage function (BATTERY) Clock setting function (CLOCK) Lap time function (LAP): stored LAP display LAP time function: LAP recording LAP time function: LAP enabling/disabling Instrument panel backlighting regulation function (B.LIGHT) ALL DEFAULT (Restoring the default parameters of all Riding Modes) ENGINE set-up ABS set-up DTC set-up Riding Mode customisation (R.MODE) Error displaying (ERRORS) Riding Mode SET-UP function (riding mode change) Enabled / disabled LAP function indication Active / not active ERRORS indication SERVICE function - Maintenance interventions SET UP - Riding Style set indication Menu 2 functions: Clock Menu 2 functions: Air temperature (AIR) Menu 2 functions: Coolant temperature Menu 2 functions Menu 1 functions: Trip time indicator (TIME TRIP) Menu 1 functions: Average speed indicator (SPEED AVG)

Menu 1 functions: Instantaneous fuel consumption indicator (CONS.) Menu 1 functions: Average fuel consumption indicator (CONS. AVG) Menu 1 functions: Partial fuel reserve counter (TRIP FUEL) Menu 1 functions: Trip meter (TRIP 2) Menu 1 functions: Trip meter (TRIP 1) Menu 1 functions: Odometer (TOT) Menu 1 functions Engine rpm indicator (RPM) Vehicle speed indicator LCD - How to set/display parameters LCD unit functions Function push-buttons Technological Dictionary Display settings and functions HYM.07 - Chassis Front wheel Refitting the front wheel Overhauling the front wheel Removing the front wheel Rear wheel Refitting the rear wheel Overhauling the rear wheel Removing the rear wheel Front brake control Refitting the front brake system Refitting the brake discs Overhauling the front brake components Removing the brake discs 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 calliper Removing the rear brake disc Removing the rear brake calliper Refitting the rear brake control Disassembling the rear brake control Removing the rear brake control ABS information Disabling the ABS ABS operating information Operating principle ABS components Wiring/hose routing 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 the ABS hydraulic system Adjusting the phonic wheel sensor AIR-GAP Handlebar unit: hand guard - throttle control Refitting the throttle twistgrip Removing the throttle twistgrip Refitting the handlebar Removing the handlebar

Refitting the hand guards Removing the hand guards Handlebar unit: clutch control Refitting the clutch unit Disassembling the clutch unit Handlebar unit: ignition switch Refitting the ignition switch Removing the ignition switch Gearchange mechanism Refitting the gearchange mechanism Disassembling the gearchange control Removing the gearchange mechanism Fork - steering head: front fork Refitting the front forks Overhauling the front forks Removal of the front forks Fork - steering head: steering Refitting the steering tube components Removing the steering head components Steering angle adjustment Adjusting the steering head bearing clearance Rear shock absorber unit 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 Refitting the rear wheel eccentric hub and rear wheel shaft Removing the rear wheel eccentric hub and the rear wheel shaft Final drive Lubricating the chain Washing the chain Refitting the rear sprocket Replacing the rear sprocket Refitting the front sprocket Removing the front sprocket Inspecting the final drive Footpeg brackets Refitting the footpegs Removing the footpegs Stands Refitting the side stand Removing the side stand Frame inspection Refitting the rear frame Reassembling structural components and frame Checking the frame Removing the rear frame Disassembling structural components and frame Tail light - number plate holder Refitting the tail light Removing the tail light Refitting the number plate holder Removing the number plate holder

Electrical component tray Refitting the electrical component tray Removing the electrical component tray HYM.08 - Fuel system / Exhaust system Fuel tank Refitting the fuel tank Refitting the fuel tank flange Removing the tank flange 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 Refitting the exhaust system Removing the exhaust system Removing the silencer Canister filter Refitting the Canister filter Removing the Canister filter Canister filter system HYM.09 - Engine Removing-refitting the engine assembly Refitting the engine Removing the engine Lubrication system: oil pump Refitting the oil pump Reassembling the oil pump Disassembling the oil pump Removing the oil pump Cooling system: water tank Refitting the water tank Removing the water tank Cooling system: water radiator Refitting the cooling system hoses and unions Removing the cooling system hoses and unions Refitting the water radiator Replacing the cooling fan Removing the water radiator Cooling system: water pump Refitting the water pump Removing the water pump 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 layshaft pulley Removing the timing layshaft pulleys

Reassembling the timing pulleys Disassembling the camshaft pulleys Refitting the idler and tensioner pulley mounting pins Removing the tensioner pins Refitting the cylinder heads pulleys/idler pulleys Removing the cylinder head pulley/idler pulley Refitting the timing belts Removing the tensioner pulley/timing belt Refitting the timing outer covers Removing the timing belt covers Cylinder head assembly: camshafts Refitting the intake manifold and water union Removing the intake manifold and water union Refitting the camshafts Checking the camshafts and supports Removing the camshafts Cylinder head assemblies: valves - rocker arms Refitting the cylinder head assemblies Reassembling the cylinder head Overhauling the cylinder head components Removing the valve rocker arms Removing the valves 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 Reassembling the clutch Checking and overhauling the components Removing the clutch Description of the clutch assembly Clutch assembly: clutch cover Reassembling the clutch cover Disassembling the clutch cover Refitting 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: gearchange mechanism Refitting the gear interlock plunger and ratchet Disassembling gear interlock plunger and ratchet Refitting the gearchange mechanism 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 Overhauling the flywheel-generator assembly Refitting the flywheel-generator assembly Removing the flywheel - generator assembly Refitting the generator cover

Disassembling the generator cover Removing the generator cover Crankcase assembly: outer components Refitting the starter motor Removing the starter motor Refitting the starter motor gear Removing the starter motor idler gear Refitting the timing gears Removing the timing gears Refitting the external components Removing outer components Crankcase assembly: crankcase halves Closing the crankcase halves Shimming the shafts Reassembling the crankcase halves Main bearing shells Overhauling the crankcase halves Separating the crankcase halves Crankcase assembly: connecting rods Refitting the connecting rod assembly Reassembling the connecting rod assembly Overhauling the connecting rods 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 A Multipurpose, medium fibre, lithium grease. SHELL Alvania R3 GREASE B Molybdenum disulphide grease, high mechanical stress and high temperature resistant. SHELL Retinax HDX2 GREASE C Bearing/joint grease for parts subject to prolonged mechanical stress. Temperature range: -10 to 110 °C. SHELL Retinax LX2

GREASE D Protective grease, with anti-corrosive and waterproofing properties. SHELL Retinax HD2 GREASE E Grease PANKL - PLB 05 GREASE F Grease OPTIMOL - PASTE WHITE T GREASE G Grease PANKL - PLB07 GREASE H Grease KLÜBER STABURAGS NBU 30 PTM GREASE I Copper grease CUPRUM 320 LOCK 1 Low-strength threadlocker. Loctite 222 LOCK 2 Medium-strength threadlocker, compatible with oil. Loctite 243 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 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

You're Reading a Preview

Ducati Motorcycle Manuals for Mechanics

Description

Reviews

Q&A

Recently Viewed