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Ducati ST3 2004-2007 Service & Repair Workshop Manual

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🏷️ Basic Information Identification Make: Ducati Model: ST3 Year Range: 2004-2007 Codes Engine Code: L-Twin, 4-stroke, desmodromic, 2 valves per cylinder 👋 Introduction Market Position Market Segment: Sport-touring motorcycle Target...
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类型: Motorcycle
厂商:
斯库: 603177
Ducati ST3 2004-2007 Service & Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Ducati
Model:
ST3
Year Range:
2004-2007
Codes
Engine Code:
L-Twin, 4-stroke, desmodromic, 2 valves per cylinder
👋 Introduction
Market Position
Market Segment:
Sport-touring motorcycle
Target Audience:
Motorcyclists seeking a balance of performance and comfort for long-distance riding and spirited touring.
Competitive Analysis
Competitors:
Honda VFR800, Yamaha FJR1300, Kawasaki GTR1400, BMW R1200RT
Key Features
Design Philosophy:
Ducati's signature L-twin engine with Desmodromic valve actuation, combined with a comfortable riding position and integrated luggage capability for touring.
Engine Characteristics:
Torquey L-twin motor providing strong acceleration and a distinctive character.
Handling Dynamics:
Renowned Ducati chassis and suspension tuning for agile and responsive handling.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine mechanical, Fuel system, Ignition system, Cooling system, Transmission, Clutch, Chassis, Suspension (front and rear), Brakes (front and rear), Electrical system, Bodywork, Troubleshooting, Maintenance
Page Count
Page Count:
Approximately 400-500 pages (estimated based on typical service manual length for this era and complexity)
Manual Type
Manual Type:
Service & Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed information on cylinder head removal/installation, valve clearance adjustment (Desmodromic timing), piston and connecting rod inspection/replacement, crankshaft assembly, oil pump and filter servicing.
Fuel System:
Injection system diagnostics, throttle body servicing, fuel pump and regulator testing, injector maintenance and cleaning procedures, fuel tank inspection and cleaning.
Ignition System:
Spark plug specifications and replacement, ignition coil testing, ECU diagnostics related to ignition timing.
Cooling System:
Radiator and fan servicing, coolant capacity and type, thermostat replacement, hose inspection and replacement, pressure testing of the system.
Transmission And Clutch:
Gearbox disassembly and reassembly, gear inspection, shift drum and fork servicing, clutch fluid type and bleeding procedure, clutch plate inspection and replacement, hydraulic clutch system maintenance.
Chassis And Suspension:
Frame inspection, steering head bearing service, front fork disassembly, seal replacement, oil level and type, rear shock absorber adjustment and overhaul, swingarm bearing service, linkage maintenance.
Brakes:
Front and rear brake pad replacement, caliper servicing and bleeding, brake fluid type and capacity, master cylinder maintenance, disc inspection and measurement, ABS system troubleshooting (if equipped).
Electrical System:
Wiring diagrams, battery maintenance, starter motor testing, alternator function, fuse and relay identification, lighting system troubleshooting, dashboard and indicator light diagnostics.
Bodywork:
Fairing removal and installation, seat servicing, fuel tank removal, accessory mounting guidelines.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, chain adjustment and lubrication, brake fluid flush, coolant replacement, spark plug replacement, valve clearance checks.
Troubleshooting:
Diagnostic charts for common running issues, electrical faults, and mechanical problems; symptom-based repair guidance.
Component Overhaul:
Detailed step-by-step instructions for engine rebuilds, transmission servicing, suspension component overhauls, and brake caliper refurbishment.
Assembly Disassembly:
Comprehensive guides for removing and reinstalling major components, including torque specifications for critical fasteners.
Technical Depth
Depth Level:
Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers routine maintenance to complete engine and chassis rebuilds.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, allowing for clear viewing of diagrams and text.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
Searchability
Searchability:
Searchable text for quick information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Type:
L-Twin, 4-stroke, Desmodromic 2 valves per cylinder
Displacement:
937 cc (approximate, depending on specific ST3 variant)
Bore X Stroke:
98 mm x 61.5 mm (typical for this engine family)
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 105-113 hp @ 9000 rpm (varies slightly by year and tuning)
Torque:
Approx. 9.4 - 9.7 kgm (approx. 92-95 Nm) @ 7250 rpm (varies slightly by year and tuning)
Fuel System
Fuel Delivery:
Fuel injection with electronic throttle control (Weber Marelli or similar ECU)
Fuel Type:
Unleaded gasoline, minimum 95 octane
Ignition System
Ignition:
Electronic ignition, spark plugs (e.g., NGK CR9EK)
🔧 Transmission
Standard
Transmission Type:
6-speed sequential
Gear Ratios:
Specific ratios detailed in manual, typical for sport-touring applications.
Features
Clutch Type:
Wet multi-plate clutch, hydraulically actuated
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2130 mm (varies slightly)
Width:
Approx. 820 mm (at handlebars, varies)
Height:
Approx. 1250 mm (at handlebars, varies)
Weights
Dry Weight:
Approx. 191 kg
Wet Weight:
Approx. 212 kg (fully fueled)
Fuel Tank Capacity:
21 Liters (incl. 3.5L reserve)
Wheelbase:
Approx. 1470 mm
🛡️ Safety Features
Ratings
Crash Test Data:
N/A (Motorcycle safety is typically assessed differently than cars; focus is on structural integrity and rider protection features.)
Active Features
Braking System:
Dual 320 mm discs with 4-piston calipers (front), Single 245 mm disc with 2-piston caliper (rear). Potential for ABS on some later models or optional fitment.
Passive Features
Lighting:
Halogen headlight, LED taillight.
Frame Design:
Trellis frame for rigidity and predictable handling.
💡 Technology Features
Infotainment
Dashboard Features:
Digital and analog instrumentation, trip computer, fuel gauge, gear indicator, warning lights.
Driver Assistance
ABS System:
Optional ABS on some models, diagnostic procedures for ABS modules would be covered if present.
Connectivity
ECU Diagnostics:
The manual will detail diagnostic port locations and basic ECU error code interpretation, likely requiring specialized Ducati diagnostic tools for full access.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 12 months, whichever comes first. (Consult manual for exact specification)
Desmo Service Interval:
Every 12,000 miles or 24 months for valve clearance check and adjustment. (Crucial Ducati maintenance)
Belt Replacement Interval:
Every 24,000 miles or 24 months. (Critical for Desmo timing)
Fluid Specifications
Engine Oil Type:
Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50, meeting API SG/SH/SJ or JASO MA standards. (e.g., Motul 5100 10W-40)
Engine Oil Capacity:
Approx. 3.8 Liters (with filter change)
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid.
Clutch Fluid Type:
DOT 4 or DOT 5.1 brake fluid (shared reservoir with brakes on many Ducati models).
Known Issues
Desmo Service:
Neglecting Desmodromic valve clearance checks can lead to poor performance and potential engine damage. This is a key maintenance item.
Regulator Rectifier:
Early Ducati models can be prone to regulator/rectifier failure, leading to charging system issues. Manual will guide diagnosis.
Fuel Pump Reliability:
While generally good, fuel pump issues can occur. Manual provides testing procedures.
Starter Solenoid:
Occasionally, starter solenoids can fail. Troubleshooting steps are included.
📚 Vehicle History
Brand Heritage
Brand Focus:
Ducati is renowned for its V-twin engines, Desmodromic valve actuation, performance motorcycles, and racing heritage.
Model Evolution
Predecessor:
Ducati ST2
Successor:
Ducati ST3s (with later updates), eventually replaced by Multistrada series for sport-touring focus.
Key Development:
The ST3 introduced a more modern, fuel-injected engine with 3 valves per cylinder, offering improved performance and smoother power delivery compared to its predecessors.
Production
Production Period:
2004-2007
Manufacturing Location:
Bologna, Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
The ST3 was generally well-received for its blend of performance, comfort, and Ducati's characteristic style, though often reviewed against its more established competitors.
Segment Performance:
Praised for its tractable engine and comfortable ergonomics for long-distance touring compared to other Ducati sportbikes.
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