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Ducati St4 St4s 2002-2005 Bike Full Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Ducati Model: ST4 Model Variant: ST4s Model Years Covered: 2002-2005 Codes Engine Code: DS996 (based on Superbike 996) 👋 Introduction Market Position Segment: Sport Touring...
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类型: Motorcycle
厂商:
斯库: 473054
Ducati St4 St4s 2002-2005 Bike Full Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Ducati
Model:
ST4
Model Variant:
ST4s
Model Years Covered:
2002-2005
Codes
Engine Code:
DS996 (based on Superbike 996)
👋 Introduction
Market Position
Segment:
Sport Touring Motorcycle
Target Audience:
Performance-oriented riders seeking comfort for longer distances, with a focus on Italian engineering and V-twin character.
Competitive Analysis
Competitors:
Honda VFR, Yamaha FJR, Kawasaki GTR, BMW R series (e.g., R1100S).
Key Features
Engine Character:
Desmodromic valve actuation, characteristic L-twin torque delivery, potent performance for its class.
Chassis Suspension:
ST4s featured higher-spec Öhlins suspension and lighter Marchesini wheels, enhancing handling and ride quality.
Design Philosophy:
Blending sportbike performance with touring ergonomics, a hallmark of Ducati's approach to sport-touring.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Workshop Service and Repair
Page Count
Estimated Pages:
300+
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, disassembly, assembly, tuning, troubleshooting, component identification.
Fuel System:
Fuel injection system, throttle bodies, fuel pump, injectors, fuel pressure regulator, diagnostics.
Ignition Injection:
Ignition timing, ECU mapping, sensor diagnostics (TPS, MAP, Crankshaft position), ignition coil testing.
Brake System:
Front and rear brake calipers, master cylinders, brake lines, fluid bleeding, ABS (if applicable), rotor inspection.
Suspension:
Front fork (Öhlins on ST4s), rear shock absorber, linkage, adjustments, seal replacement, spring rates.
Wheels Tires:
Wheel bearing replacement, tire mounting and balancing, recommended tire pressures, wheel specifications.
Electric System:
Wiring diagrams, component testing, battery, charging system, starter motor, lighting, fuses, relays, ECU diagnostics.
Frame Body:
Frame inspection, bodywork removal and installation, fairings, seat, fuel tank, ergonomics.
Exhaust System:
Exhaust pipe inspection, muffler replacement, catalytic converter (if applicable), lambda sensor.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance checks.
Repair:
Engine rebuilds, transmission overhauls, suspension fork rebuilds, brake caliper rebuilds, electrical component replacement.
Troubleshooting:
Diagnostic procedures for common faults, error code interpretation, symptom-based troubleshooting guides.
Installation:
Installation of accessories, bodywork components, and key mechanical parts.
Technical Depth
Depth:
Comprehensive, from basic owner maintenance to full engine and transmission rebuilds, including detailed torque specifications and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable if digitally sourced and properly processed.
Print Quality
Print Readability:
High, assuming original documentation quality.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Quality:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, 90° L-twin (Desmodromic valve actuation)
Displacement:
996 cc
Bore X Stroke:
98 mm x 66 mm
Compression Ratio:
11.5:1 (typical for this engine family)
Valvetrain:
Desmodromic, 4 valves per cylinder
Performance
Horsepower Est:
113 hp @ 8500 rpm (ST4), 124 hp @ 8500 rpm (ST4s - approx.)
Torque Est:
94 Nm @ 7000 rpm (ST4), 98 Nm @ 7000 rpm (ST4s - approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Weber Marelli or similar)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Throttle Body Size:
54 mm (typical)
🔧 Transmission
Standard
Type:
6-speed sequential
Clutch:
Hydraulically operated, wet multi-plate
Final Drive:
Chain drive
Features
Gearbox Design:
Cassette-type gearbox for easier maintenance (typical for Ducati performance models).
📐 Dimensions
Exterior
Wheelbase:
Approx. 1470 mm (57.9 in)
Seat Height:
Approx. 800-820 mm (31.5-32.3 in)
Weights
Dry Weight:
Approx. 206 kg (454 lbs) for ST4, slightly less for ST4s with lighter components.
Wet Weight Est:
Approx. 228 kg (503 lbs)
🛡️ Safety Features
Ratings
Safety Standards:
Compliant with relevant European and international motorcycle safety standards for its era.
Active Features
Braking System:
Dual 320 mm discs with 4-piston calipers (front), Single 245 mm disc with 2-piston caliper (rear). ST4s often featured Brembo components.
ABS:
Optional ABS was available on some models during this period, but not standard on all ST4/ST4s.
Passive Features
Lighting:
Halogen headlamp, LED taillight, turn signals.
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, digital speedometer, trip computer, coolant temperature gauge, clock, warning lights.
Driver Assistance
Traction Control:
Not typically available on these models.
Connectivity
Diagnostic Port:
OBD-II or proprietary Ducati diagnostic connector for ECU reading (requires specialized tools).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 km or 12 months. Check manual for specific Ducatidrive recommendations.
Desmo Service Interval:
Valve clearance (Desmodromic service) typically every 10,000-12,000 km. This is a critical and specialized service for Ducati engines.
Belt Replacement Interval:
Timing belt replacement every 2-3 years or 20,000 km, whichever comes first. Crucial to prevent catastrophic engine damage.
Fluid Specifications
Engine Oil:
Synthetic 10W-40 or 20W-50, meeting API SG/SH/SJ or higher. Ducati often recommended specific brands or viscosity grades.
Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 4 or DOT 5.1 (check manual for precise specification), changed every 2 years.
Clutch Fluid:
DOT 4, same as brake fluid.
Gearbox Oil:
SAE 75W-90 or 80W-90 gear oil (API GL-4 or GL-5).
Known Issues
Desmo Service:
Proper adjustment of desmodromic valve clearances is critical; neglect can lead to valve damage. Requires specialized knowledge.
Timing Belts:
Belts degrade over time; failure is catastrophic. Regular replacement is non-negotiable.
Electrical Connections:
Some older Ducatis experienced issues with corroded electrical connectors, particularly in humid environments.
Fuel Pump:
In-tank fuel pumps can be a point of failure; proper diagnosis is key.
Regulator Rectifier:
While less common than on earlier models, checking charging system output is always prudent.
📚 Vehicle History
Brand Heritage
Ducati Legacy:
Ducati's reputation for performance V-twins, racing pedigree, and distinctive Italian design.
Model Evolution
St Series Origin:
The ST series evolved from Ducati's desire to create a more versatile sportbike capable of comfortable long-distance touring without sacrificing performance.
St4 Vs St4S:
The ST4 utilized the 916 engine, while the ST4s (introduced later) incorporated the more powerful 996 engine, along with upgraded suspension (Öhlins) and wheels (Marchesini) for improved performance and handling.
Production
Manufacturing Location:
Bologna, Italy
🏆 Awards & Recognition
Recognitions
Sport Touring Accolades:
While specific awards may not be documented here, the ST series was generally well-regarded for its blend of sportbike performance and touring capability, often praised by enthusiasts for its V-twin character and handling.
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