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Ducati ST4 2000-2005 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Ducati Model: ST4 Model Years: 2000, 2001, 2002, 2003, 2004, 2005 Vehicle Type: Sport-Touring Motorcycle 👋 Introduction Market Position Market Position: The Ducati ST4 was...
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Ducati ST4 2000-2005 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Ducati
Model:
ST4
Model Years:
2000, 2001, 2002, 2003, 2004, 2005
Vehicle Type:
Sport-Touring Motorcycle
👋 Introduction
Market Position
Market Position:
The Ducati ST4 was positioned as a high-performance sport-touring motorcycle, bridging the gap between Ducati's raw superbike lineage and the demands of longer-distance riding. It offered a blend of potent performance, sophisticated handling, and a degree of rider comfort.
Key Features
Key Features:
V-twin engine, trellis frame, advanced suspension, capable braking system, and a more relaxed riding position compared to pure sportbikes. Designed for riders seeking performance with the ability to cover longer distances comfortably.
Chassis Type:
Steel Trellis Frame
Competitive Analysis
Competitive Analysis:
Competed with other sport-touring motorcycles of the era from manufacturers like Honda (VFR series), Yamaha (YZF-R series), Kawasaki (ZZR series), and BMW (R series). The ST4 differentiated itself with its Italian flair, V-twin power delivery, and sophisticated chassis dynamics.
📋 Manual Details
Coverage
Applicable Model Years:
2000-2005
Page Count
Page Count:
256
Manual Type
Manual Type:
Workshop Service Manual
Language
Language:
English
Format
File Format:
PDF
Accessibility:
Instant Download
Printability:
Yes
Software Requirement:
Adobe Reader
Operating System Compatibility:
Windows, Mac, Linux OS
📖 Manual Coverage
Systems Covered
Systems Covered:
• Engine Mechanical
• Engine Electrical System
• Fuel System
• Ignition System
• Cooling System
• Exhaust System
• Transmission and Drivetrain
• Chassis and Frame
• Suspension System (Front and Rear)
• Braking System (Front and Rear)
• Wheels and Tires
• Electrical System (Lighting, Gauges, Wiring Harness)
• Bodywork and Fairings
• Clutch System
• Steering System
• Lubrication System
Electrical System Details:
Includes detailed wiring diagrams, component testing, and troubleshooting for the entire electrical system, including lights, ignition, charging system, and instrumentation.
Suspension Details:
Covers fork and rear shock absorber adjustments, servicing, and component replacement.
Procedures Included
Procedures Included:
• Routine Maintenance and Service
• Periodic Inspections
• Troubleshooting and Diagnosis
• Component Removal and Installation
• Disassembly and Assembly Procedures
• Adjustments (Valve Clearances, Carburetor, Clutch)
• Torque Specifications
• Wear Limits and Tolerances
• Fluid Capacities and Specifications
• Electrical System Schematics and Diagnosis
• Repair Procedures for all Major Systems
Engine Rebuild Procedures:
Covers disassembly, assembly, and detailed repair procedures for the engine, including crankshaft, pistons, cylinders, and valve train.
Wheel And Tire Service:
Procedures for wheel removal, installation, tire changes, and balancing.
Technical Depth
Technical Depth:
Comprehensive, detailed step-by-step procedures, explanations, and pictorial diagrams. Includes special notes, important points, service data, precautions, factory specifications, allowable limits, special tool references, and wear limits.
Diagnostic Information:
Includes diagnosis and testing procedures for various systems.
Pictorial Diagrams:
Detailed illustrations, exploded diagrams, drawings, and photos
Special Tool Reference:
References special service tool numbers and depicts their usage.
Troubleshooting Methodology:
Provides systematic troubleshooting guidance based on symptoms, with reference to diagnostic procedures and specifications.
Torque Values:
Extensive list of torque values for all critical fasteners, essential for proper assembly and safety.
📊 Manual Specifications
File Quality
PDF Quality:
High-resolution, printable pages
Completeness
Completeness:
100% Complete and Intact, no missing/corrupt pages/sections
Binding Type
Binding Type:
Digital (PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Desmodromic, 4-stroke, Liquid-cooled V-twin
Displacement:
916 cc (for earlier models, ST4S typically 996 cc - the manual covers the ST4, implying the 916cc variant)
Bore X Stroke:
92 x 68 mm (typical for 916cc)
Valve Actuation:
Desmodromic valve control
Engine Designer:
Massimo Tamburini (engine based on 916)
Performance
Horsepower:
Approximately 107 hp @ 8500 rpm (for 916cc ST4 variant)
Torque:
Approximately 9.5 kgm @ 7500 rpm (for 916cc ST4 variant)
Engine Breathing:
Desmodromic valve actuation, fuel injection
Compression Ratio:
Approximately 10.5:1 (typical for 916cc)
Fuel System
Fuel Delivery:
Fuel Injection (MPI - Multi-Point Injection)
Fuel Type:
Unleaded gasoline, minimum 95 octane
Throttle Body Size:
Dual 45mm throttle bodies
Cooling System
Cooling Type:
Liquid-cooled
Engine Codes
Engine Code:
L-Twin (typically derived from the 916 series engine)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Clutch Type:
Hydraulically actuated wet multi-plate clutch
Drivetrain
Final Drive:
O-ring sealed chain
Features
Gearbox Features:
Close-ratio gearset for sporty performance
📐 Dimensions
Weights
Dry Weight:
Approximately 198 kg (436 lbs)
Wet Weight:
Approximately 214 kg (472 lbs)
Payload Capacity:
Not explicitly stated but designed for rider and passenger with luggage.
Exterior
Wheelbase:
Approximately 1430 mm (56.3 inches)
Seat Height:
Approximately 810 mm (31.9 inches)
🛡️ Safety Features
Ratings
Safety Notes:
Manual emphasizes safety precautions, DANGER, CAUTION, and NOTE remarks for hazardous operations. Stresses using correct tools and safety procedures to prevent injury or vehicle damage.
Active Features
Active Safety Features:
Powerful dual disc front brakes, single rear disc brake, responsive suspension. ABS was not standard on early ST4 models but may have been an option or standard on later ST4S.
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation: speedometer, tachometer, coolant temperature gauge, fuel level warning light, oil pressure warning light, neutral indicator. No advanced infotainment features.
Driver Assistance
Driver Assistance Features:
Limited by era; focus is on mechanical and electrical systems. ABS availability may vary by specific model year/variant.
🔧 Maintenance
Service Intervals
Major Service Interval:
Refer to the manual for specific intervals, but typically involves valve clearance checks and Desmodromic service every 10,000 - 12,000 km (6,000 - 7,500 miles).
Oil Change Interval:
Recommended every 5,000 - 6,000 km (3,000 - 3,700 miles) or annually.
Spark Plug Replacement Interval:
Refer to manual, typically around 10,000 - 12,000 km (6,000 - 7,500 miles).
Fluid Specifications
Engine Oil Type:
High-quality synthetic motorcycle oil, e.g., SAE 10W-40 or 15W-50 API SG/SH/SJ, JASO MA (Specific grade and quantity detailed in manual)
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, mixed with distilled water (50/50 ratio)
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid
Clutch Fluid Type:
DOT 4 brake fluid (shared with brake system)
Gearbox Oil Type:
Specific gear oil for the transmission (details in manual)
Fork Oil Type:
Specific suspension fork oil (viscosity and quantity detailed in manual)
Known Issues
Known Issues:
• Desmodromic valve adjustment complexity
• Electrical connectors and wiring harness integrity
• Fuel pump reliability
• Alternator output and charging system
• Clutch slave cylinder leaks
• Fairing mounting points and vibration issues
Throttle Cable Wear:
Can cause sticky throttle operation.
Maintenance Philosophy
Maintenance Philosophy:
Emphasizes timely adherence to periodic maintenance schedules, using genuine Ducati parts, and employing correct tools and procedures to ensure reliability and performance. Highlights the importance of understanding construction and function before undertaking repairs.
Maintenance Schedules
Periodic Maintenance Chart:
Manual provides a periodic maintenance chart outlining required service tasks at specific intervals to maximize vehicle life.
Fluid Capacities
Engine Oil Capacity:
Approximately 3.5 liters (3.7 US qt) with filter change (verify in manual)
Coolant Capacity:
Approximately 2.5 liters (2.6 US qt) (verify in manual)
📚 Vehicle History
Brand Heritage
Brand Heritage:
Ducati is an Italian manufacturer with a rich history in motorcycle racing, renowned for its performance-oriented V-twin engines, distinctive design, and trellis frame technology. This heritage heavily influences the engineering and character of models like the ST4.
Model Evolution
Model Evolution:
The ST4 was part of Ducati's ST (Sport-Touring) series, which aimed to leverage the powerful engines and chassis of their superbikes (like the 916) and adapt them for greater versatility and longer-distance comfort. It followed earlier models and evolved into variants like the ST4S.
Production
Production Philosophy:
Embraced Ducati's philosophy of producing high-performance, driver-focused motorcycles with advanced engineering and premium components.
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