2007-2008 Ducati Hypermotard Installation Instructions

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Filed Under (Ducati) by admin on 26-10-2010

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1. Remove the seat. 2. Remove the fuel side panels. 3 Lay the PCIII near the battery and route the harness down the left hand side of the bike (Fig. A). PCIII harness 6 Plug the YELLOWcolored wires from the PCIII in-line of the rear injector and stock wiring harness (Fig. D). 7 Unplug the stock wiring harness from the front injector (Fig. E). This injector is located on the right hand side of the bike. 8 Plug the ORANGE colored wires from the PCIII in-line of the front injector and stock wiring harness (Fig. F). Fig. D Fig. E Fig

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Ducati 1098 the antihopping clutch "TITAN" Installation procedure

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Filed Under (Ducati) by admin on 26-10-2010

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Please remove your clutch completely (the basket only if it should be exchanged as well), also the black bush on the shaft rear containing an O-ring. Remove the O-ring and push it on the shaft again after it has been cleaned and lightly greased. Afterwards, lightly grease the outside of pos. 1 and push it on the shaft as well. If a new basket is to used as well, now follows the installation of the clutch basket, the screws have to be tightened with a screw locking device and a torque of 30-34 nm. In case of a clutch kit without basket, the original basket must be continued to use, of course. Now, the balls pos. 17 are lightly moistened with grease and placed into the cavities of the adjusting plate pos. 7, then, the kernel pos. 12 is carefully put on so that the kernel can be easily turned clockwise on the balls. This complete unit is now placed on the shaft (none of the balls may be off center), to make this easier 2 springs can be mounted. Then place positions 9 and 4 and finally nut 6 which you should glue in with a screw locking device and tighten with a torque of approx. 190 Nm. Concerning the clutch kit, you have steel plates and clutch plates. The steel plates are available in gage 1.5mm and 2mm as well as curved steel plates with a gage of 1.5mm, to be recognized if you place a straight object flat on the plate.

1999 – up Ducati ST4 Forza Slip -on Installation Instructions

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Filed Under (Ducati) by admin on 26-10-2010

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1. Using a Vise-Grip pliers or hook, Start by removing the spring that holds the lower header together. 2. Next remove the 5mm bolt that holds the pipe on the passenger foot peg. Note You will have to use the lowest bolthole if your bike has the baggage, not the one on the passenger foot peg. 3. Remove the pipe by pulling away from bike. Fast By Ferracci Inc 1901 Davisvill Rd Willow Grove PA 19090 Tel (215) 657 1276 Version #1 07/17/01 4. Install supplied bracket loosely with 8mm bolts as shown in figure 5. Install new pipe in reverse order. First, Place header in to the lower manifold. Next, insert passenger foot peg bolt and tighten. Next tighten the two bolts on the lower part of bracket. Next apply supplied Forza sticker as shown in figure. 6. Repeat steps 2 thru 5 for the other side pipe. Once step 5 has been completed for opposite side. Reinstall spring by attaching both hooks to the new headers.

2001-2004 Ducati Monster S4/ R Installation Instructions

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Filed Under (Ducati) by admin on 26-10-2010

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1 Remove the seat. 2 Prop the fuel tank in the upright position. 3 Remove the airbox lid by disconnecting the two hooks on either side of the airbox (Fig A). Unscrew the bolts on either side of the rear of the airbox or just lift up to remove the air box. 4 Disconnect the two hoses going to the airbox. 5 Remove the velocity stacks by turning them counter-clockwise and lifting up (Fig B). 6 Remove the bolt on the underside of the airbox (Fig. C). 7 The airbox can now be moved out of the way. To totally remove the airbox disconnect the wire connectors from the front of the airbox. Fig. A Fig. B Fig. C Loosen these bolts Remove this bolt Hooks These instructions can be used on either the S4 or S4R. The air box does NOT need to be removed on the S4R. Follow steps 14-20 for the S4R 9 Plug the connectors from the PCIII in-line of the stock connectors (Fig E). The ORANGE colored wires from the PCIII go to the front cylinder and the YELLOWcolored wires go to the rear cylinder. Reinstall spring clips. 10 Locate the thottle position sensor on the underside of the throttle bodies (Fig F). Remove the connector by squeezing the spring clip

Ducati Front Suspension and Wheel Installation Manual

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Filed Under (Ducati) by admin on 26-10-2010

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It is important to follow the proper installation sequence for installing the front suspension components. With out doing so it is possible to incorrectly align the front axle in the forks or misalign the forks themselves. Be careful to tighten the pinch bolts for the forks and the axle to the correct torque as many of the large diameter axles are thin-walled and can become permanently distorted if over- torqued. It is also possible to distort the fork stanchions or overstress the triple clamp with excessive torque. The forks derive a significant portion of there rigidity from a strong junction with the axle and triple clamp. Always sequentially cross tighten the pinch bolts to allow an even compression. Cogent Dynamics recommends measuring your fork position (height of the “legs”) using the bottom surface of the lower triple clamp as the datum point as shown in the Ducati service manual. Once the height is correctly set, clamp the lower pinch bolts to hold the forks in this position. The top clamp should have all three pinch bolts loose at this point (this includes the steering stem pinch bolt). Also the steering stem top bolt should be loosened. Clean and grease the axle before inserting it into the wheel. Avoid damaging the thin-walled axle, during installation. Once the axle is inserted through the fork lowers and the, line up the holes in the axle with the holes in the axle clamps so that the through-holes allow screwdriver access to the compression valve adjusters (for forks with the bottom compression adjusters.

DUCATI 1098 DIRECT LEVER INSTALLATION MANUAL

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Filed Under (Ducati) by admin on 26-10-2010

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Ducati direct lever sensor installation: 1) Remove original lever assembly 2) Fit the new lever and tight nut. 3) Set toe peg in correct position 4) Connect the sensor with CGS2 and try it: when sensor is pressed a dashes appears on CGS2 SP electronics DUCATI DIRECT LEVER SENSOR INSTALLATION NOTE – The sensor was designed to offer you the best performance and don’t need mechanical maintenance: you mustn’t disassemble or try to repair the lever (See warranty details on our website www.spelectronics.it). – If you intend use our lever sensor with your preferred quick shifter electronic system (Power Commander, Rapid Byke, ecc.) we recommend you to use specific wiring interface (see photo below). Alls connector manipulations on sensor invalidate warranty. SP electronics DUCATI DIRECT LEVER SENSOR INSTALLATION SP electronics is working everyday to improve quality on our products. Unfortunately, perhaps some sensor doesn’t work after some time. Remember that SP electronics will apply warranty substitutions or repairs when products satisfies original complying

1998-2001 Ducati 996 Power Commander Installation Instructions

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Filed Under (Ducati) by admin on 26-10-2010

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1) Lift the rear section. 2) Remove the left hand side fairing. 3) Locate the plug that resides in between the two throttle bodies (Fig. A). This plug has a round, silver retaining ring on the end of it. 4) Unscrew this connector by turning it counter-clockwise. 5) NOTE: You may want to route the wires from the PCIII from the tail section to this area before plugging it in. This will make for a cleaner installation. Plug the female connector from the PCIII into the wiring harness (Fig. B). 6) Plug the male connector from the PCIII into the female connector on the bracket (Fig. C). 7) Route the wires along the frame towards the rear of the bike. Make sure the wires are routed so they do not get pinched. 8) Attach the ground wire from the PCIII to front, left hand, mounting point of the ECU (Fig. D). 9) Attach the PCIII to the top of the ECU using the supplied velcro. (Fig. D). 10) Reinstall the left hand side fairing

Ducati streetfighter HID headlight system installation Manual

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Filed Under (Ducati) by admin on 26-10-2010

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The installation of this kit requires the removal of the Helmholtz air box between the air intakes, located directly in front of the main air box. You will also need to run a wire from the front of the bike to the back of the bike where the battery is located. 1. Remove the seat, tail section, and fuel tank. 2. Remove the headlight assembly. 3. Replace the headlight bulb with the included HID bulb. You will need to modify the cap for the back of the headlight to allow the wires to pass through. 4. You will need to mount the Ballast, igniter, and the relay for the switch box in the area where the Helmholtz was. (see image) 5. Run the red power wire to the back of the bike and connect directly to the positive lead on the battery terminal. 6. Connect the ground wire the frame where the Helmholtz was previously bolted. 7. Plug the HID bulb into the ballast. There are 3 plugs. They can only be connected one way. 8. Connect the main wire harness to the ballast. 9. Turn the key on and turn the ignition on and check that the headlight comes on. 10. Switch on the brights to make sure this is working as well. 11. Once everything is confirmed to be working make sure the wirings are well attached won’t interfere with the fan or with any of the steering components. 12. Re-install the tank, tail section, and seat

Ducati Monster Light weight composite fuel tanks Installation instructions

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Filed Under (Ducati) by admin on 26-10-2010

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1. All though every precaution is taken in the manufacture of your new FuelCel, in house testing procedures unfortunately cannot reproduce the dynamic conditions of the installation on the motorcycle. Under certain conditions of vibration, heat and gasoline, a minute pinhole can develop in rare cases that escape our detection. We are more than willing to repair a leak that might develop so long as the following procedure is done first. 2. Install all necessary plumbing and hardware for the mounting, install on the bike then fuel it to capacity and run at least half of it through by running the engine, BEFORE PAINTING the tank. 3. Field repair procedure as performed by the factory is outline below for latent pinhole migration. (Extremely rare) 4. FuelCel Warranty. If you should damage your Fuelcel repairs can be made in certain instances. Generally if 30% of the exterior surface is damaged it will be considered totaled. ➨ INSTALLATION INSTRUCTIONS • Use the stock rear hinge mount. The hinge bushings must have their faces thinned by .05″ each for the tank to fit on the bike. DO NOT BEND the aluminum bracket wider ! ! ! ! • The cap now serves as the vent . • The water drain is not used. • Use the hose barb provided for the Fuel pickup, the threaded connection is no longer needed. Fuel is picked up at the same location inside from the supply barb on the inside. •Be sure the tank is not being rubbed by something on the outside, puncture from abrasion can occur in a short amount of time . •Once the tank is in place, locate the frame rubbers and bond them to the tank using a thin layer of silicone sealer after the tank is painted. • WARNING; Composites are not “malleable” like metal, since weight reduction is the main goal of the FuelCel design, rupture of the tank can occur instead of denting. • This Fuel tank is sold without Warranty expressed or implied by the manufacturer and its final suitability for use is determined by the operator of the motorcycle on which it is installed

Ducati Hypermotard Large Fuel Tank Installation Instructions

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Filed Under (Ducati) by admin on 26-10-2010

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REMOVING THE OEM FUEL TANK GO FOR A RIDE The best way to remove fuel from your original fuel tank is to RIDE your bike. You should already be familiar with how low you can go and the less fuel that’s in your tank before you start means the less mess you make when draining it. HM69 Fuel Tank Installation Instructions This manual is provided for marketing and informational purposes only and is a guide to assist experienced motorcycle technicians with the installation of the HM69 fuel tank. This installation involves gasoline. Improper installation, adjustment, alteration, service or maintenance regarding the HM69 fuel tank can cause property damage, personal injury or death. At-home Do-It-Yourself mechanics should not install the HM69 fuel tank if you are uncertain of your ability to properly install it and refer the installation to an authorized Ducati service department. ! REMOVE THE SEAT Remove the seat bolt at the rear of the seat with a 4mm hex key. To remove the seat, grasp both sides of the seat, lift the rear of the seat slightly, and pull the seat to the rear of the bike. The front of the seat engages onto bolts on either side of the fuel tank and can be stubborn. THIS KIT ALSO CONTAINS: © 2009 California Cycleworks, Inc. Questions? Email orders@ca-cycleworks.com 1
REMOVE THE BODYWORK The tank cover is fi rst. Remove the fuel fi ller cap and then the 4 screws you see: 2 near the front of the cover and the two aside the fi ller neck. Lift up on the forward portion of the cover and move the entire cover rearward so that the back of the cover is away from the retaining contour on the fuel tank. SIDE PANELS Remove the right side panel’s inner cover using a large coin. Both left and right side covers are retained by 3 screws with 4mm hex heads. Remove the 2 screws on the side of the tank (which were revealed with the removal of the seat). While holding the side covers to support them, remove the bottom screw. The left side cover pulls away naturally – take care not to drop the cover as the tool kit is housed inside of it, adding unexpected weight

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