DUCATI ST2/ ST4 Stock Socket Rewire Installation Instructions

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Filed Under (Ducati) by admin on 25-10-2010

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STEP #1 Remove necessary fairings. STEP #2 Unplug the stock connector; plug in the new harness. STEP #3 Route wires starting at the bracket end and finishing at the battery. STEP #4 Look over your work. STEP #5 Check the polarity & test. STEP #6 Put everything you took off back on. Detailed Instruction: STEP #1 – Remove the seat, front, right side, & left side tail fairings. See the Ducati service manual. STEP #2 -Locate the white connector on the back of the stock socket. Unplug this connector and ty-wrap it into a safe location. Plug the new wiring harness into the back of the stock socket. The center terminal is plus and the outer ring is negative (see dwg below). Apply either dielectric grease or Vaseline to the terminals. STEP #3 – The harness is designed so the wires leave the connector toward the back of the bike, (this way they will not be seen). Loop the wires up through the gap between the frame & the engine controller (or storage bin). On the left side there is a small gap; do not pinch the wiring. You will need to remove four screws on the engine controller to accomplish this. Next cross over behind the engine controller (or storage bin). Re-tighten the engine controller. The harness is now routed toward the front of the bike [A]. Loosen right tail fairing front clip screw & pass the wiring harness under it [B]. Route the harness between the frame and the engine going towards air box. Using a ty-wrap attach the fuse holder to the back, right, air-box post [C}. In this location the fuse can be easily accessed under the tank. The ground wire is attached to a gas tank hinge bolt [D]. Connect the two wires as follows: RED WIRE = BATTERY POSITIVE BLACK WIRE = GAS TANK HINGE BOLT STEP #4 – Apply the remaining ty-wraps in useful locations. Do NOT allow the harness to directly contact the motor or exhaust

Ducati 1098/ 848 Exhaust System with Carbon Fiber Installation Instructions

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Filed Under (Ducati) by admin on 25-10-2010

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- Install barrel clamps to both slip-on tubes. – Install mufflers and attach using the 8mm bolts and 8mm split lock washers provided. – Align mufflers and tighten the 6x14mm V.A.L.E.™ hardware when the slip-on tube clearance and the muffler alignment is correct. (It may be easier to tighten one bolt first, then remove the slip-on tube assembly to tighten all of the rest of the hardware. – Tighten barrel clamps. Double check all your work to make sure the mufflers are aligned and all hardware is tightened. Before you run the bike, clean off all fingerprints and dirt, as any oily residue will etch the metal and become somewhat permanent when the system gets hot. Run the bike and enjoy. It is normal for some white smoke to appear the first time you start the bike. This is packing/ manufacturing oil from inside the pipe burning off. Check for gaps or leaks. If you find a leak, a little high temperature silicon sealant should fix it. After 50 to 100 miles, recheck all fasteners for tightness

DUCATI ST2 Electronic Cruise Control Installation Manual

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Filed Under (Ducati) by admin on 25-10-2010

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The actuator spool is installed in the CIU housing with the actuator cable. The actuator spool is rotated to fully extend the cable. 2nd step. The carburettor cable and spool are installed and the other end of the carburettor cable is attached to the carburettors. Note the position of the roll pin. It is nearly contacting the end of the groove in the actuator spool. The free play in the carburettor cable must be adjusted so that the cable outer can be pulled out 2 ~ 3mm before the carburettors start to open. This ensures that the cruise control cannot prevent the carburettors returning to idle. If more free play is allowed the response of the cruise control is compromised. This adjustment of free play is usually performed after final assembly of the CIU is completed and the CIU is in its final location. This is because flexing the cable does effect the free play. It is shown at this stage in these diagrams to improve clarity

1999 Ducati 900 Super Sport Carbon Fiber INSTALLATION MANUAL

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Filed Under (Ducati) by admin on 25-10-2010

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I. Stock muffler removal: refer to diagram #1 *All hardware removed in this procedure must be saved for reinstallation. See Figure 2* 1. Loosen the Allen bolt holding the exhaust bracket to the rear foot peg mount. (It may be easier to turn the nut first then the Allen bolt) 2. Remove the nut and then support the muffler while removing the Allen bolt. Be careful not to loose the washer since it will now just drop out. 3. Now slide the spacer from the foot peg support and remove the muffler by sliding it straight out of the header. 4. Now remove the two rubber bushings and put aside so they won’t fall out and become lost. 5. Repeat the procedure for the other muffler. Parts you will need to reuse. x2 Diagram 1 I. Forza installation: refer to diagram #2 1. Determine the left muffler from the right. The Forza sticker faces out and the inlet pipes bend in slightly. See figure 3. 2. Slide the muffler onto its respective header pipe. 3. Replace the two rubber bushings in the foot peg mounts. 4. Slide the muffler clamp over the muffler and align with the bushings. 5. Squeeze the muffler clamp by hand and insert the spacer first: through both holes in the clamp and second: through both bushings. The clamp should be on the outside of the foot peg support (see diagram2). 6. Install the washer then the nut and snug the nut leaving it loose enough to allow muffler to rotate in the clamp. 7. Turn the pipe until the exhaust tip is pointed down. Then check that the muffler clears the swing arm. 8. Repeat the procedure for the other side.

Ducati 916 Scottoiler Installation Manual

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Filed Under (Ducati) by admin on 25-10-2010

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Locate the vacuum -There is a vacuum point on the inlet tract, as shown below left. Remove the screw and replace with the M5 Brass Spigot from the Scottoiler kit, using some RTV Silicon Sealant on the threads to ensure an airtight seal. Then press the Damper Elbow, part number 4, onto the spigot. Scottoiler: Ducati 916 Installation Guide for the Ducati 916 Note: This install requires a Single Sided Swingarm adapter, available free of charge from Scottoiler The Dual Injector (sold separately) is not compatible with this model. Note: This is a generic image The Dispenser Assembly is mounted to the swinging arm using the Dispenser Mounting Plates (parts 19 & 27) coupled together using a Single Sided Swingarm Adapter, available Free of Charge from Scottoiler, as shown bottom left. The nib of the dispenser should feed the sprocket between the 6 & 7 o’clock positions on the sprocket, the cut face facing outwards, as shown below. Once fitted, fill and prime the system and set the Adjuster Knob to ‘prime’. Start the engine and turn the adjuster knob until a flow of between 1 and 2 drops per minute is achieved. Check the condition of your chain after a ride, and then adjust as required

2009 Ducati 696 Fuel Controller Installation and Operation Manual

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Filed Under (Ducati) by admin on 25-10-2010

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this product fail to perform for either of the above reasons, two brothers racing will repair or replace it with an equivalent product at no charge, except for postage, to the original retail purchaser. to obtain the benefits of this warranty, the retail purchaser must return the product and proof of purchase to the place of original purchase. We recommend that this performance part be installed by a qualified motorcycle technician. If you have any doubts as to your ability to install this performance part, please consult with your local motorcycle dealer. Read all instructions first before starting installation. Make sure the vehicle and exhaust system are completely cool before starting the installation. Also, make sure the vehicle is secure during installation. Be sure to save all stock components for possible use later. The Juice Box™ is legal ONLY for closed course race vehicles. The Juice Box™ is not applicable, nor inteded for use on EMISSIONS CONTROLLED street, highway or off-road vehicles. The Juice Box™ is not applicable, nor inteded for use on aircraft. Thank *you*for*purchasing*a*genuine*Two*Brothers*Racing* JUICE*BOX™. **This*product*represents*a*radical*step* forward *in*tuning*fuel-injected*motorcycles*and*ATVs*for* optimal *performance*using*”load-based”*technology.** We *at*Two*Brothers*Racing*hope*that*you*will*find*this* development *as*exciting*and*useful*as*we*do. **And* remember: **Proper*Fuel*=*Maximum*Power! Make *sure*the*vehicle*is*completely*cool*before*starting* the *installation. *Also, *make*sure*the*vehicle*is*secure*and* will *not*roll*around. * Remove *the*seat*assembly. * Remove *the*fuel*tank*top*cover*screws. * (fig.1) Remove *fuel*tank*top*cover. * (fig.2) Remove *side*fuel*tank*covers. * (fig.3) Remove *fuel*tank*by*removing*lower*bolt*that*secures* tank *from*sliding*rear-ward. * (fig.4)

Ducati 999/ 749 Light weight composite fuel tanks Installation instructions

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Filed Under (Ducati) by admin on 25-10-2010

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INSTALLATION INSTRUCTIONS • Do not paint the inside diameter where the Fuel Pump O-ring seats. Apply a thin film of grease to it prior to installing the pump body and be patient giving time for the o-ring to conform. BE SURE NOT TO SCRATCH O- RING SURFACE WHEN INSTALLING PUMP! •Cap functions as the vent. •Be careful installing nuts and do not over torque the Fuel Pump & Front Mount fasteners. •Use the stock rubber grommet for the rear mount. Use a heat gun to soften the rubber for removal. •Be sure that the tank is not being rubbed at any point by frame or other hard surface, puncture from abrasion can occur in a short amount of time. • 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

1991-1998 DUCATI 750ss 900ss POWERLET Installation Instructions

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Filed Under (Ducati) by admin on 25-10-2010

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STEP #1 Remove tail fairing & seat. STEP #2 Route wires starting at the battery and finishing at the bracket. STEP #3 Attach the wires to the socket and test. STEP #4 Mount the bracket. STEP #5 Look over your work. STEP #6 Put everything you took off back on. Detailed Instruction: STEP #1 – Remove the tail fairing, & seat. See the Ducati service manual. STEP #2 – Stretch out the wiring harness. Locate a wiring harness behind the frame rail[B]. Grab the socket end of the harness and start routing the harness by looping the wires up through the gap between the frame members just behind the battery[B]. You should be following the wiring harness behind the frame rail. The wires will exit in the underside of the seat area, just like the existing harness[D]. Attach the ground (black) wire under the hinge mounting bolt[C]. Tie wrap the harness under the cross member[E]. Go back to the battery area and install the fuse in the fuse holder than, tuck the fuse holder under the rubber strap in front of the plus terminal of the battery[F]. Slip the red wire under the red battery boot[F]. Connect the red wire to the battery posts as follows: RED WIRE = BATTERY POSITIVE STEP #4 -Attach the wires to the socket. The center terminal is plus and the outer ring is negative (see dwg below). Apply either dielectric grease or Vaseline to the terminals. Use a voltmeter to check if the polarity is correct

Ducati Monster 600/750/900; Buell S1, X1, M2, Blast Sequential LED Tail Light Installation Manual

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Filed Under (Ducati) by admin on 25-10-2010

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1. Please use supplied sub harness to connect the sequential signals 2. Connect the blue and yellow wire on the shorter end of the sub-harness to the corresponding blue and yellow on the LED tail light. Make sure the connector is pushed all the way in and use the green covers to insulate. 3. Disconnect and remove factory signal lamps. We recommend one at a time. 4. Locate the longer end of the sub-harness and connect the blue/black wires to the left signal output and the yellow/black wire to the right signal output. 5. Insulate as necessary and cable tie any wires out of the way

DUCATI CLUTCH INSTALLATION INSTRUCTIONS

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Filed Under (Ducati) by admin on 25-10-2010

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When a vehicle is so equipped, the pilot must be replaced. The pilot is located in either the engine’s crankshaft or in the center of the flywheel. To remove a flywheel-fit pilot, remove the flywheel from the engine and drive or press out the pilot from the backside of the flywheel. Press or gently tap new pilot into flywheel after flywheel has been machined (where applicable). For crankshaft-fit pilots, an effective means for removal is to select a drift punch or wooden dowel that fits snugly into the old pilot. Then, pack the old pilot tightly with grease. Using the drift punch (or dowel) and a hammer, drive the grease toward the engine. The grease will not compress and will in turn push the old pilot out of the crankshaft. Install the new pilot carefully using a bearing driver. NOTE: Do not grease new pilots. New pilot bearings come pre-greased (often with special synthetic grease). Bronze pilot bushings have oil in the pores of the material that grease will clog. For bushings, a few drops of 30W oil can be used if desired. PRESSURE PLATE AND DISC Install flywheel (refer to flywheel section above) . Always tighten flywheel to crankshaft bolts in a star pattern to manufacturer’s torque specification. Before installing the disc, make sure that it slides smoothly on the transmission input shaft. Apply a thin coat of high temperature grease (such as wheel bearing grease) to the splines of the input shaft. DO NOT USE ANTI-SEIZE! It does not cling to rotating parts. Slide the disc back and forth on the input shaft and remove any extra grease that squishes out of the splines of the disc. Do not get grease or oil on the disc facing. Any grease or oil on a disc facing can be removed with alcohol or brake cleaner if done quickly. Lay the disc on the flywheel noting the flywheel side of the disc and hold it in place with the alignment tool. Clean the pressure ring of the pressure plate with brake cleaner to remove the rust inhibiting coating. Do not spray the entire pressure plate with brake cleaner as lube for internal parts will be removed. Set the pressure plate on the flywheel dowel pins (if equipped) and hand tighten the hold-down bolts. With hand tools, tighten pressure plate bolts ½ turn at a time in a star pattern until the manufacturer’s torque specification is met. Remove the alignment tool. NOTE: Different brands of the same pressure plate may have a difference in appearance and uninstalled lever height. These are not issues. Appearance can vary greatly and the installed lever height will be the same.

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