Market Segment:
Performance Motorcycle / Classic Motorcycle
Target Audience:
Ducati enthusiasts, classic motorcycle restorers, experienced DIY mechanics, and professional motorcycle workshops.
Competitors:
Models from contemporary Italian and European manufacturers like Moto Guzzi, Laverda, and BMW, as well as Japanese multi-cylinder offerings.
Model Significance:
The 860 series represented a significant step for Ducati, featuring a more accessible L-twin engine configuration and a more modern, albeit angular, design compared to earlier models.
Desmodromic Innovation:
Highlights the core Ducati Desmodromic valve actuation system, a key differentiator and performance enhancer.
Systems Covered:
Engine, Transmission, Chassis, Electrical System, Fuel System, Braking System, Suspension, Bodywork, Troubleshooting, Maintenance
Estimated Page Count:
200+
Manual Type:
Workshop Manual / Repair Manual / Service Manual
Format:
Digital Download (PDF)
Engine Mechanics:
Complete overhaul procedures for the 90-degree L-twin Desmodromic engine, including cylinder heads, camshafts, valves, pistons, connecting rods, crankshaft, oil pump, and timing gears.
Transmission And Clutch:
Detailed instructions for gearbox disassembly, assembly, gear inspection, and repair, as well as clutch service, adjustment, and replacement procedures.
Electrical System:
Comprehensive wiring diagrams, component testing (ignition coils, stator, regulator/rectifier, starter motor), lighting system, and instrument panel troubleshooting.
Fuel System:
Carburetor overhaul and adjustment procedures (typically Dell'Orto PHF or VHB), fuel tank maintenance, fuel line inspection, and fuel pump (if applicable) servicing.
Braking System:
Service and repair of front and rear drum or disc brakes (depending on variant), including caliper overhaul, pad replacement, brake fluid flushing, and master cylinder servicing.
Suspension And Steering:
Front fork service (oil changes, seal replacement), rear shock absorber inspection and adjustment, swingarm bearing maintenance, and steering head bearing service.
Chassis And Bodywork:
Frame inspection, wheel bearing replacement, seat and fairing (if applicable) removal and installation, and general bodywork repair guidance.
Routine Maintenance:
Oil and filter changes, spark plug replacement, valve clearance adjustment (Desmodromic system), chain adjustment and lubrication, air filter cleaning/replacement.
Troubleshooting Guides:
Systematic diagnosis of common problems, including starting issues, poor running, electrical faults, and braking system malfunctions.
Rebuild Procedures:
Step-by-step instructions for complete engine and gearbox rebuilds, including torque specifications and critical clearances.
Component Replacements:
Detailed guidance on replacing major components such as the alternator, starter motor, brake calipers, wheel bearings, and suspension units.
Diagnostic Capabilities:
Advanced diagnostic procedures for identifying and resolving complex mechanical and electrical issues, often including voltage readings and resistance checks.
Specifications And Tolerances:
Precise torque values, internal clearances, and measurement specifications for all critical engine and chassis components.
Engine Configuration:
90-degree V-twin (L-twin)
Displacement:
860 cc (approx. 864 cc)
Bore X Stroke:
84.5 mm x 78 mm
Valvetrain:
Desmodromic, 2 valves per cylinder
Horsepower:
Approximately 60-65 hp at 6,500-7,000 rpm (variant dependent)
Torque:
Approximately 7.0-7.5 kg-m (approx. 68-73 Nm) at 5,000 rpm
Carburetors:
Typically dual Dell'Orto PHF 36 or VHB 36 carburetors
Fuel Type:
Unleaded gasoline (may require octane booster for older formulations)
Ignition Type:
Breaker points ignition (earlier models) or electronic ignition (later models)
Oil Capacity:
Approximately 3.5 - 4.0 liters
Oil Type Recommendation:
SAE 20W-50 or SAE 15W-50 motorcycle-specific mineral or synthetic oil
Infotainment System:
N/A (Classic era motorcycle, no integrated infotainment)
Advanced Safety Features:
N/A (No electronic rider aids)
Engine Innovation:
Desmodromic valve actuation is the primary technological highlight, enabling higher RPMs and precise valve control.
Oil Change Interval:
Every 3,000 - 5,000 km (1,800 - 3,000 miles) or annually
Valve Clearance Check:
Every 6,000 - 10,000 km (3,700 - 6,200 miles), critical for Desmodromic system
Carburetor Sync And Cleaning:
As needed, typically every 10,000-15,000 km or if performance issues arise.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Final Drive Oil Type:
SAE 80W-90 API GL-4 or GL-5 gear oil
Spark Plug Recommendation:
NGK B8ES or equivalent (specific plug may vary by year and ignition system)
Electrical Connections:
Corrosion and loose connections in wiring harnesses and connectors are common due to age.
Desmodromic Adjustment:
Requires precise adjustment and can be a source of performance issues if not maintained correctly.
Carburetor Tuning:
Dell'Orto carburetors can be finicky and require diligent tuning and synchronization for optimal performance.
Seals And Gaskets:
Aging rubber seals and gaskets (e.g., crank seals, valve cover gaskets) can lead to oil leaks.
Fuel System Components:
Old fuel lines can degrade, and fuel tanks may require sealing due to rust.
Manufacturer Origin:
Ducati Motor Holding S.p.A., Bologna, Italy
Brand Specialty:
Renowned for its V-twin engines, Desmodromic valve actuation, racing heritage, and distinctive Italian design.
Predecessors:
Ducati 750 series (750 GT, 750 Sport)
Successors:
Ducati 900SS, 900M, Darmah
Designer:
Giorgetto Giugiaro (styling), Ing. Fabio Taglioni (engineering)
Manufacturing Location:
Bologna, Italy
Model Awards:
While specific awards for the 860 series are not widely documented, Ducati motorcycles of this era are highly regarded within the classic motorcycle community for their engineering and performance.
Expert Reviews:
Generally praised for its distinctive L-twin sound, performance for its time, and iconic styling.
Manual Quality:
This workshop manual is a crucial resource for preserving and maintaining these classic Italian motorcycles, reflecting the meticulous engineering of Ducati.
