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Ducati Supersport 800 800S 2003 2004 Parts Manual Catalog

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The Ducati Supersport 800, produced between 2003 and 2004, represents a refined blend of sporty performance and everyday usability. Building on Ducati's rich heritage of L-twin engines and Desmodromic valve...
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Ducati Supersport 800 800S 2003 2004 Parts Manual Catalog
The Ducati Supersport 800, produced between 2003 and 2004, represents a refined blend of sporty performance and everyday usability. Building on Ducati's rich heritage of L-twin engines and Desmodromic valve actuation, this model offers a more accessible entry into the brand's sport-touring segment. Its design philosophy prioritizes balanced handling and a comfortable riding position, making it suitable for both spirited rides and longer journeys. The 799.6 cc air-cooled L-twin engine, known for its characteristic torque and sound, delivers approximately 78 horsepower, providing an engaging and rewarding riding experience. This iteration of the Supersport line is characterized by its Italian styling and engineering, aiming to provide riders with the essence of Ducati in a more versatile package. This comprehensive Parts Manual Catalog serves as an essential resource for owners and technicians maintaining the Ducati Supersport 800 (800S) from 2003-2004. It meticulously details every component of the motorcycle, offering exploded views and part numbers crucial for identification and replacement. The manual covers all major systems, including the engine, fuel system, transmission, chassis, suspension, brakes, and electrical systems, along with bodywork and wheels. Its primary purpose is to facilitate accurate part sourcing and to provide clarity on the assembly and disassembly of various components, thereby supporting efficient maintenance and repair. This manual is designed for global usability and detailed technical reference.
🏷️ Basic Information
Identification
Make:
Ducati
Model:
Supersport 800
Model Variant:
800S
Year:
2003-2004
Codes
Platform Code:
DS1000 (shared with Monster 800)
👋 Introduction
Market Position
Bike Segment:
Sport-touring motorcycle with a focus on accessible performance and usability.
Target Audience:
Riders seeking a Ducati experience with a more comfortable riding position and a user-friendly V-twin engine.
Competitive Analysis
Competitors:
Honda VFR800, Suzuki GSX-R750 (older generations), Yamaha FZ8.
Key Features
Engine Architecture:
L-twin, Desmodromic valve actuation.
Riding Ergonomics:
More relaxed riding position compared to pure sportbikes, suitable for longer distances.
Design Philosophy:
Balancing sporty handling with everyday usability and Ducati's signature style.
📋 Manual Details
Coverage Areas
Geographic Coverage:
Global (technical procedures are universal)
Language Availability:
English, German, Italian, Spanish, French
Page Count
Estimated Pages:
Hundreds (exact count not specified, but described as comprehensive)
Manual Type
Type:
Parts Manual Catalog
Format
File Format:
PDF
Delivery
Delivery Method:
Instant Download (.rar/.zip)
📖 Manual Coverage
Systems Covered
Engine:
Complete component breakdown, including cylinder heads, cylinders, pistons, crankshaft, valve train, oil pump, etc.
Fuel System:
Fuel injection system components, injectors, fuel pump, throttle body, fuel lines, etc.
Exhaust System:
Exhaust pipes, mufflers, catalytic converter (if applicable), mounting hardware.
Transmission:
Gearbox internals, clutch components, shift mechanism, chain and sprockets.
Chassis And Frame:
Frame sections, sub-frame, steering head, swingarm, linkages, etc.
Suspension:
Front forks (internals, seals, springs), rear shock absorber, linkages.
Brakes:
Brake calipers, master cylinders, brake lines, discs, pads, master cylinder rebuild kits.
Electrical System:
Wiring diagrams, starter motor, alternator, battery, ignition system components, lighting, sensors, ECU.
Bodywork And Trim:
Fairings, fuel tank, seat, fenders, mirrors, control levers, footpegs, fairing fasteners.
Wheels And Tires:
Wheels, bearings, valve stems, tire specifications.
Procedures Included
Disassembly:
Detailed diagrams and exploded views for complete disassembly of all major components.
Reassembly:
Comprehensive guidance on reassembly, often indicating fastener torque specifications implicitly through part listings and assembly order.
Part Identification:
Crucial for identifying correct replacement parts using OEM part numbers and visual references.
Troubleshooting Support:
Indirectly supports troubleshooting by clearly identifying all components and their interconnections, particularly with wiring diagrams.
Technical Depth
Depth:
High: Focuses on component breakdown and part identification, essential for repair and maintenance.
Diagnostic Support:
Strong for part identification and system relationships, less direct for fault diagnosis (which would be in a service manual).
📊 Manual Specifications
File Format
Format Details:
PDF, downloadable, printable. Likely optimized for digital viewing and printing.
Print Quality
Quality:
High (implied by 'hundreds of photos & wiring diagram')
Binding Type
Binding:
N/A (Digital download)
Paper Type
Paper:
N/A (Digital download)
Searchability
Text Search:
Likely searchable PDF, enabling quick access to specific parts or sections.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled L-twin (Desmodromic 2 valves per cylinder)
Displacement:
799.6 cc
Bore X Stroke:
94 mm x 71.5 mm
Compression Ratio:
9.4:1
Cooling System:
Air-cooled
Valve Actuation:
Desmodromic
Performance
Horsepower:
Approximately 78 hp (58 kW) @ 8,700 rpm
Torque:
Approximately 70 Nm (52 lb-ft) @ 6,700 rpm
Fuel System
Fuel Delivery:
Fuel injection, likely Marelli electronic injection with single throttle body.
Fuel Type:
Unleaded gasoline, minimum 95 octane
Lubrication
Oil System:
Wet sump
Oil Capacity:
Approx. 3.5 liters
Oil Specification:
SAE 10W-40 Synthetic or Semi-Synthetic (refer to manual for specific Ducati approved oils)
🔧 Transmission
Standard
Type:
6-speed manual
Final Drive:
Chain driven
Clutch Type:
Wet, multi-plate, hydraulic actuation
Features
Gear Ratios:
Detailed gear ratios will be present in the parts catalog for each gear, allowing for identification and comparison.
Fluid Specifications
Transmission Oil:
Gearbox oil (specific viscosity and API rating typically SAE 75W-90, GL-4 or GL-5, refer to manual for exact spec)
📐 Dimensions
Exterior
Wheelbase:
Approx. 1,410 mm (55.5 in)
Length:
Approx. 2,100 mm (82.7 in)
Weights
Dry Weight:
Approx. 180 kg (397 lbs)
Wet Weight:
Approx. 195 kg (430 lbs) (including fluids)
Fuel Capacity
Fuel Tank Capacity:
15 liters (3.96 US gal)
🛡️ Safety Features
Ratings
Crash Safety:
N/A for motorcycles (focus is on rider protection through design and equipment).
Active Features
Braking System:
Dual 320mm discs with 2-piston calipers front, single 245mm disc with 2-piston caliper rear. Potential for ABS on some models/markets (verify specific VIN).
Lighting:
Halogen headlight, LED taillight, turn signals.
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, digital speedometer, LCD display for odometer, trip meter, clock, and warning lights.
Driver Assistance
ABS:
Optional on some models, not standard across the range. The parts manual will differentiate components if present.
Connectivity
Connectivity Features:
N/A (No Bluetooth or advanced digital connectivity features expected for this era).
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 6,000 - 7,500 km (3,700 - 4,700 miles) or annually, whichever comes first.
Desmo Service:
Desmodromic valve clearance checks and adjustments are crucial, typically recommended every 10,000 - 12,000 km (6,200 - 7,500 miles), but consult the actual service manual for precise intervals.
Major Service:
More comprehensive checks and replacements (e.g., timing belts) often fall around 20,000 - 24,000 km (12,000 - 15,000 miles).
Fluid Specifications
Engine Oil:
SAE 10W-40 Synthetic or Semi-Synthetic motorcycle oil (API SG or higher, JASO MA recommended).
Brake Fluid:
DOT 4 or DOT 5.1 (refer to manual for specific preference and change interval).
Coolant:
N/A (Air-cooled engine)
Gearbox Oil:
SAE 75W-90 GL-4 or GL-5 (verify exact spec in service manual).
Known Issues
Desmo Service Intervals:
Failure to adhere to desmo service intervals can lead to valve train damage.
Fuel Pump Reliability:
Some earlier models of this era had reports of fuel pump issues; regular fuel with proper additives can help. The manual's part breakdown is vital for replacement.
Electrical Connectors:
Corrosion on electrical connectors can sometimes cause intermittent issues, especially in humid environments. The wiring diagrams in the manual are key for diagnosis.
Parts Identification
Importance:
Critical for sourcing correct OEM parts, ensuring proper fitment and performance.
📚 Vehicle History
Brand Heritage
Founding Principles:
Ducati is renowned for its L-twin engines, Desmodromic valve system, and racing pedigree.
Model Evolution
Supersport Lineage:
The Supersport line has historically offered a more road-biased, sport-touring alternative to Ducati's flagship sportbikes, emphasizing comfort and versatility.
Specific Era:
The 2003-2004 Supersport 800/800S models represented a move towards smaller displacement, more accessible Ducati models, utilizing the well-regarded air-cooled L-twin engine derived from the Monster line.
Production
Manufacturing Location:
Bologna, Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Journals:
While specific awards for the 800S might be scarce, the Ducati Supersport line generally received praise for its handling, engine character, and distinctive Italian styling.
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