A - General

0B - Information about the model

0C - Technical data

0D - Use and maintenance

0F - Controls - Devices

0G - Wheels - Suspension - Brakes

0L - Fuel/Exhaust System

0M - Fuel injection - ignition system

0P - Electrical system

0GENERAL SUMMARY

1 - How to use this manual 3

Layout of the manual 3

2 - Symbols - Abbreviations - References 5

Product specifications 5

3 - Hazardous Products - Warnings 7

General safety rules 7

General maintenance indications 8

0B - Information about the model

1 - Identification data 3

Hypermotard identification data 3

0C - Technical data

1.1 - Technical specifications 3

Timing system/valves 4

Exhaust system 5

Cylinder/Piston 5

Cooling system 5

Front suspension 6

Rear suspension 6

Hydraulic brakes 7

Charging system/alternator 7

Ignition system 7

Lights/instrument panel 8

1.2 - Dimensions 9

2 - Fuel, lubricants and other fluids 10

3 - Torque settings 11

Frame torque settings 11

Engine torque settings 16

4 - Service tools 19

Specific tools for the engine 19

Specific tools for the frame 23

0D - Use and maintenance

1 - Preliminary checks 3

Running-in precautions 3

Pre-ride checks 4

2 - Starting - Engine warmup 5

Starting the engine 5

3 - Routine maintenance table 6

Programmed maintenance plan: operations to be carried out by the dealer 6

Programmed maintenance plan: operations to be carried out by the customer 7

4 - Maintenance operations 8

Checking the engine oil level 8

Changing the engine oil and filter cartridge 9

Checking valve clearances 12

Changing and cleaning the air filters 14

Changing the brake fluid 17

Draining the brake circuits 20

Filling the brake circuits 22

Changing the clutch fluid 24

Draining the clutch hydraulic circuit 25

Filling the clutch circuit 27

Adjusting the steering head bearings 29

Adjusting the clutch lever and front brake lever 30

Adjusting the chain tension 31

Checking brake pad wear and changing brake pads 33

Adjusting the throttle cables 37

Adjusting the position of the gearchange and rear brake pedals 39

Adjusting the rear shock absorber 40

5 - Diagnostic instruments 42

Description of the Ducati Diagnostic System instrument 43

Tester power supply 46

Checking and adjusting timing belt tension 51

Self-learning throttle position sensor (TPS) 55

Adjusting the idle speed 59

Checking the engine oil pressure 64

Cylinder compression test 68

Fuel pressure test 71

Immobilizer override procedure 74

Guided diagnosis 77

Testing the battery charging system 80

Deactivating the “service” indication on the instrument panel 83

1 - Headlight fairing - hand guards - rear-view mirrors 3

Removal of the hand guards - rearview mirrors 4

Refitting the hand guards - rearview mirrors 5

Removal of the headlight fairing 7

Refitting the headlight fairing 9

2 - Fairings 10

Removal of the side fairings 11

Refitting the side fairings 14

3 - Seat - side panels 15

Removal of the seat 16

Refitting the seat 16

Removal of the rear side panels 18

Refitting the rear side panels 19

4 - Front mudguard 20

Removal of the front mudguard 21

Refitting the front mudguard 22

0F - Controls - Devices

1 - Throttle twistgrip 3

Adjusting the throttle cable 4

Removal of the throttle twistgrip 4

Refitting the throttle twistgrip 5

2 - Hydraulic clutch control 7

Removal of the clutch master cylinder assembly 8

Refitting the clutch master cylinder assembly 9

Removal of the clutch slave cylinder 11

Refitting the clutch slave cylinder 12

3 - Front brake control 17

Removal of the front brake master cylinder 18

Refitting the front brake master cylinder 19

4 - Rear brake control 23

Removal of the rear brake master cylinder 24

Refitting the rear brake master cylinder 26

5 - Gearchange control 31

Removal of the gearchange control 32

Disassembly of the gearchange control 33

Refitting the gearchange control 33

0G - Wheels - Suspension - Brakes

1 - Front wheel 3

Removal of the front wheel 4

Overhauling the front wheel 6

Refitting the front wheel 9

2 - Front fork 11

Removal of the front forks 12

Overhauling the front forks 13

Refitting the front forks 21

3 - Hydraulic front brake 22

Maintenance operations 23

Removal of the front brake system 23

Removal of the brake discs 24

Refitting the brake discs 25

Overhauling the front brake components 25

Refitting the front brake system 26

4 - Rear wheel 29

Removal of the rear wheel 30

Overhauling the rear wheel 30

Refitting the rear wheel 32

5 - Rear swingarm 33

Removal of the rear eccentric hub 34

Refitting the rear eccentric hub 36

Removal of the swingarm 38

Inspecting the swingarm pivot shaft 41

Overhauling the rear swingarm 42

Refitting the swingarm 47

6 - Hydraulic rear brake 49

Removal of the rear brake system 50

Removal of the rear brake disc 52

Refitting the rear brake disc 53

Refitting the rear brake system 54

7 - Rear suspension 56

Rear suspension system 57

Removal of the rear shock absorber 57

Overhauling the rear shock absorber 58

Removal of the rear suspension rocker arm 60

Overhauling the rear suspension rocker arm 61

Refitting the rear suspension 63

8 - Final drive 66

Inspecting the final drive 67

Removal of the front sprocket 68

Refitting the front sprocket 69

Renewal of the oil seal on the gearbox output shaft 70

Removal of the rear sprocket 71

Refitting the rear sprocket 73

Washing the chain 74

Lubricating the chain 74

1 - Handlebar 3

Removal of the handlebar 4

Refitting the handlebar 6

Adjusting the steering head bearings 10

Steering angle adjustment 11

Removal of the steering head components 12

Refitting the steering head components 15

4 - Footrest brackets 21

Removal of the footrest brackets 22

Refitting the footrest brackets 25

5 - Sidestands 30

Removal of the sidestand 31

Refitting the sidestand 33

6 - Frame inspection 34

Disassembly of structural components and the frame 35

Removal of the rear subframe 35

Checking the frame 36

Reassembly of structural components and the frame 37

7 - Tail light and number plate holder 39

Removal of the tail light 41

Refitting the tail light 43

Removal of the number plate holder 47

Refitting the number plate holder 48

Removal of the rear turn signals 50

Refitting the rear turn signals 50

0L - Fuel/Exhaust System

2 - Fuel tank 3

Removal of the fuel tank 4

Removal of the fuel tank filler cap 8

Refitting the fuel tank filler cap 8

Removal of the fuel tank flange 10

Refitting the fuel tank flange 11

Refitting the fuel tank 12

6 - Throttle body 23

Removal of the throttle body 24

Refitting the throttle body 28

7 - Air intake 33

Removal of the airbox 34

Removal of the oil breather valve 39

Refitting the oil breather valve 39

Refitting the airbox 40

8 - Exhaust system 45

Removal of the exhaust system 46

Refitting the exhaust system 50

0M - Fuel injection - ignition system

1 - Description of the system 3

General information on the fuel injection-ignition system 3

Operating phases 9

2 - Fuel injection-ignition system 10

3 - System components 11

Electronic control unit (ECU) 11

Removal of the electronic control unit 12

Refitting the ECU 12

Fuel injectors 14

Stepper motor 15

Lambda sensor 16

Throttle Position Sensor (TPS) 18

Rpm/timing sensor 18

Air temperature sensor 19

Air pressure sensor 20

Injection relay 24

1 - Removal - refitting of the engine assembly 5

Removal of the engine 6

Refitting the engine 9

2.1 - Lubrication system: oil pump 11

Removal of the oil pump 12

Disassembly of the oil pump 13

Reassembly of the oil pump 14

Refitting the oil pump 15

2.2 - Lubrication system: oil cooler 16

Removal of the oil cooler 17

Oil cooler inspection 19

Refitting the oil cooler 19

2.3 - Lubrication system: oil breather 22

Removal of the oil breather valve 23

Refitting the oil breather system 24

4.1 - Cylinder head assemblies: checks and adjustments 25

Checking and adjusting valve clearances 26

Checking the engine timing 30

4.2 - Cylinder head assemblies: timing belt covers/timing system 32

Removal of the timing belt covers 33

Removal of the timing system assembly 34

Disassembly and reassembly of the timing belt pulleys 37

Refitting the timing system assembly 38

Refitting the timing belt covers 46

4.3 - Cylinder head assemblies: camshafts 47

Removal of the intake manifolds 48

Refitting the intake manifolds 49

Removal of the inner timing belt covers and camshaft end caps 50

Removal of the valve covers 52

Refitting the valve covers 53

Removal of the camshafts 54

Inspecting the camshafts 56

Checking the oil seals 56

Refitting the camshafts 57

Refitting the camshaft end caps 60

4.4 - Cylinder head assemblies: valves - rocker arms 62

Removal of the cylinder head assembly 63

Overhaul of cylinder head components 67

Refitting the cylinder head assembly 75

Refitting the cylinder heads 81

5 - Cylinder/piston assemblies 83

Removal of the cylinder/piston assembly 84

Overhaul of the cylinder barrel/piston components 87

Refitting the cylinder/piston assembly 93

6.1 - Clutch assembly: APTC wet clutch 97

Description of the APTC clutch assembly 98

Removal of the APTC clutch 99

Disassembly of the clutch hub-plates-centre assembly 101

Overhaul and inspection of the APTC clutch components 102

Reassembly of the clutch hub-plates-centre assembly 104

Refitting the APTC clutch 106

6.2 - Clutch assembly: clutch-side crankcase cover 109

Removal of the clutch-side crankcase cover 110

Disassembly of the clutch-side crankcase cover 111

Reassembly of the clutch-side crankcase cover 112

Refitting the clutch-side crankcase cover 113

6.3 - Clutch assembly: primary drive gears 115

Removal of the primary drive gears 116

Refitting the primary drive gears and checking backlash 118

7.1 - Gearbox assembly: gearchange mechanism 121

Removal of the gearchange mechanism 122

Disassembly of the gear interlock plunger and pawl assembly 125

Reassembly of the gear interlock plunger and pawl assembly 126

Refitting the gearchange mechanism 128

7.2 - Gearbox assembly: gearbox shafts 130

Removal of the gearbox assembly 131

Disassembly of the gearbox shafts 133

Overhaul of the gearbox 141

Inspection of the gear selector forks 142

Inspection of the gear selector drum 143

Reassembly of the gearbox shafts 144

Reassembly of the gearbox 148

8 - Flywheel-alternator 149

Removal of the alternator-side crankcase cover 150

Disassembly of the alternator-side crankcase cover 151

Removal of the flywheel-alternator assembly 152

Checking the flywheel/alternator assembly 154

Refitting the flywheel-alternator assembly 159

Reassembly of the alternator-side crankcase cover 161

Refitting the alternator-side crankcase cover 162

9.1 - Crankcase assembly: external components 165

Removal of external components 166

Refitting the external components 169

Removal of the timing gears 173

Refitting the timing gears 174

Removal of the starter motor idler gear 175

Refitting the starter motor idler gear 176

9.2 - Crankcase assembly: crankcase halves 177

Separation of the crankcase halves 178

Overhaul of the crankcase halves 181

Overhaul of the main bearings 183

Reassembly of the crankcase halves 184

Shimming the shafts 185

Reassembly of the crankcase halves 188

9.3 - Crankcase assembly: crankshaft/connecting rods assembly 195

Removal of the crankshaft/connecting rods assembly 196

Disassembly of the crankshaft/connecting rods assembly 197

Overhaul of the connecting rods 197

Reassembly of the connecting rods 203

Refitting the crankshaft/connecting rod assembly 205

0P - Electrical system

1 - Wiring diagram 4

Key to wiring diagram 5

Wiring colour codes 6

Key to fuse box 6

Routing of wiring on frame 7

2 - Battery charging system 44

Checking the battery charging system 44

Recharging the battery 45

Topping up the electrolyte 46

Regulator/rectifier 55

3 - Electric starting system 58

Electric starting system 58

Starter motor 59

Starter contactor 62

4 - Lights and indicating devices 65

Removal of the instrument panel 65

Changing bulbs 66

Headlight aim 69

5 - Indicating devices 71

Checking the indicating devices 71

Changing bulbs 78

6 - Protection and safety devices 79

Checking protection and safety device components 79

Checking the fuses 81

7 - Instruments 82

Instrument panel 82

Instrument panel system 83

Display settings and functions 85

8 - Immobilizer and transponder 118

9 - Diagnostic instruments 123

Using a multimeter to check the electrical systems 123

10 - USB Data Acquisition kit 125