Motorcycle engine repair Ducati ST2 (1997-2003)
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Checking valve clearances
To check and adjust valve clearances it will first be necessary to remove all those components which obstruct access to valve components. Note. For reasons of clarity, the figures show the cylinder head removed from the engine. Remove the spark...
To check and adjust valve clearances it will first be necessary to remove all those components which obstruct access to valve components. Note. For reasons of clarity, the figures show the cylinder head removed from the engine. Remove the spark...
Adjusting valve clearances
It should be remembered that on desmodromic valve timing systems any increase in opening clearances will automatically decrease the closing clearances and vice versa. If you change the opening adjuster you must therefore also change the closing...
It should be remembered that on desmodromic valve timing systems any increase in opening clearances will automatically decrease the closing clearances and vice versa. If you change the opening adjuster you must therefore also change the closing...
Checking and adjusting timing belt tension
Note. For reasons of clarity, the figures show the engine block removed from the frame. Unscrew the retaining screws on the timing belt covers and remove the covers. Loosing the lock screws (1) on the mobile tensioners and fit the service gauge (A,...
Note. For reasons of clarity, the figures show the engine block removed from the frame. Unscrew the retaining screws on the timing belt covers and remove the covers. Loosing the lock screws (1) on the mobile tensioners and fit the service gauge (A,...
Disconnecting the crankcase breather pipe
Loosen the clip (A) and disconnect the crankcase breather pipe from the engine block. Caution! Block off the hole to prevent the entry of dirt or extraneous objects.
Loosen the clip (A) and disconnect the crankcase breather pipe from the engine block. Caution! Block off the hole to prevent the entry of dirt or extraneous objects.
Removing the engine
Loosen and then remove the nuts on the engine mounting bolts at the frame. Extract the plastic plugs from two ends of the swinging arm pivot. To free the swinging arm pivot shaft, remove one of the two circlips locking the shaft to the end of the...
Loosen and then remove the nuts on the engine mounting bolts at the frame. Extract the plastic plugs from two ends of the swinging arm pivot. To free the swinging arm pivot shaft, remove one of the two circlips locking the shaft to the end of the...
Special tools fok engine disassembly/reassembly and testing
ref. code description 1) 88765.0968 TDC gauge 2) 88713.0262 Pin for fitting rocker arms 3) 88713.0146 Clutch drum clamp spanner 4) 88713.0144 Puller for disassembling chain/alternator cover 5) 88700.5644 Timing system pulley clamp spanner 6)...
ref. code description 1) 88765.0968 TDC gauge 2) 88713.0262 Pin for fitting rocker arms 3) 88713.0146 Clutch drum clamp spanner 4) 88713.0144 Puller for disassembling chain/alternator cover 5) 88700.5644 Timing system pulley clamp spanner 6)...
Engine disassembly sequence
This sequence is used for disassembling the engine components. Identify the component to be disassembled and follow the arrows for the parts to be removed.
This sequence is used for disassembling the engine components. Identify the component to be disassembled and follow the arrows for the parts to be removed.
Disassembly timing system belts and pulleys
Remove the spark plugs from the cylinder heads. Unscrew the retaining screws on the timing belt covers. Loosen the retaining screws and remove the adjustable tensioner of each belt. To extract the belts, also remove the fixed tensioner. Mark the...
Remove the spark plugs from the cylinder heads. Unscrew the retaining screws on the timing belt covers. Loosen the retaining screws and remove the adjustable tensioner of each belt. To extract the belts, also remove the fixed tensioner. Mark the...
Disassembly cylinder head
Unscrew the retaining screws and remove the rubber cap. Loosen the cylinder head nuts, working diagonally. Caution! Perform this operation when the engine is cold. Pull out the cylinder head slightly, using a plastic hammer, if necessary. Remove the...
Unscrew the retaining screws and remove the rubber cap. Loosen the cylinder head nuts, working diagonally. Caution! Perform this operation when the engine is cold. Pull out the cylinder head slightly, using a plastic hammer, if necessary. Remove the...
Disassembly cylinder and piston
Extract the О-rings from their seats on the cylinder surface. Loosen the jubilee clips and remove the pump cover cylinder connection hose. Bring the piston to the top dead centre. Carefully extract the cylinder, tapping it gently with a rubber...
Extract the О-rings from their seats on the cylinder surface. Loosen the jubilee clips and remove the pump cover cylinder connection hose. Bring the piston to the top dead centre. Carefully extract the cylinder, tapping it gently with a rubber...
Disassembly left side cover
The generator stator, engine sensor and water pump unit are fitted to this cover. If required for disassembly, you can remove the water pump cover (1) by unscrewing the four retaining screws. Remove the left side cover as follows: unscrew the...
The generator stator, engine sensor and water pump unit are fitted to this cover. If required for disassembly, you can remove the water pump cover (1) by unscrewing the four retaining screws. Remove the left side cover as follows: unscrew the...
Disassembly flywheel
Pull out the flywheel and the free wheel assembly including the starting driven gear. Pull out the roller bearing cage.
Pull out the flywheel and the free wheel assembly including the starting driven gear. Pull out the roller bearing cage.
Disassembly timing gear
Pull out the steel bush and the washer. Straighten the safety washer of the timing gear securing nut. Clamp the timing gear shaft in position and stop it from turning by fitting the service tool 88700.5644 to the outer pulley (on the belt side)....
Pull out the steel bush and the washer. Straighten the safety washer of the timing gear securing nut. Clamp the timing gear shaft in position and stop it from turning by fitting the service tool 88700.5644 to the outer pulley (on the belt side)....
Disassembly primary drive gear
Straighten the primary drive gear fixing nut safety washer. Secure the primary drive gear using service tool 88713.0137 and remove the nut. Remove the gear using the puller 88713.1178 and by placing an aluminium drift between the crankshaft and the...
Straighten the primary drive gear fixing nut safety washer. Secure the primary drive gear using service tool 88713.0137 and remove the nut. Remove the gear using the puller 88713.1178 and by placing an aluminium drift between the crankshaft and the...
Disassembly timing system pulieys
Using service tool 88700.5644, secure the timing pulleys and remove the self-locking ring nut. Remove the following: the washer; the spacer; the pulleys; the keys; the guide washer. If it is difficult to pull out the pulleys, use puller 88713.0144...
Using service tool 88700.5644, secure the timing pulleys and remove the self-locking ring nut. Remove the following: the washer; the spacer; the pulleys; the keys; the guide washer. If it is difficult to pull out the pulleys, use puller 88713.0144...
Disassembly engine block fittings
Unscrew the pressure adjustment valve closing screw (A) and remove the spring and the pin. Unscrew the pin screw and remove the seal, the spring and the gearshift cap. Unscrew the screw (B) on the right side crankcase half and remove the ratchet,...
Unscrew the pressure adjustment valve closing screw (A) and remove the spring and the pin. Unscrew the pin screw and remove the seal, the spring and the gearshift cap. Unscrew the screw (B) on the right side crankcase half and remove the ratchet,...
Disassembly crankcase halves
Unscrew the connecting screws from the crankcase half. Re-use the left side cover or a service cover, with puller 88713.0144 fitted. Secure it with the original screws to the crankcase half and begin separation by turning the central pin of the...
Unscrew the connecting screws from the crankcase half. Re-use the left side cover or a service cover, with puller 88713.0144 fitted. Secure it with the original screws to the crankcase half and begin separation by turning the central pin of the...
Disassembly valve covers and upper rocker arms
Note. When disassembling components in the cylinder head, they must be laid out carefully or marked so that they can be reassembled in their exact position. Unscrew the retaining screws and pull out the valve covers. Unscrew the retaining screws and...
Note. When disassembling components in the cylinder head, they must be laid out carefully or marked so that they can be reassembled in their exact position. Unscrew the retaining screws and pull out the valve covers. Unscrew the retaining screws and...
Disassembly valves
Pull out the rocker arm adjuster. Turn the cam shaft and use a screwdriver to raise the end part of the closing rocker arm fitted with drift. Remove the split rings and the return cap. Pull out the valves.
Pull out the rocker arm adjuster. Turn the cam shaft and use a screwdriver to raise the end part of the closing rocker arm fitted with drift. Remove the split rings and the return cap. Pull out the valves.
Disassembly cam shaft and lower rocker arms
Pull out the cam shaft. Do not damage or lose the shims. Hook the end part of the closing rocker arm spring to service tool 88713.0143. Remove the closing rocker arm pins using service tool 88713.0120. Pull out the rocker arms. Do not damage or lose...
Pull out the cam shaft. Do not damage or lose the shims. Hook the end part of the closing rocker arm spring to service tool 88713.0143. Remove the closing rocker arm pins using service tool 88713.0120. Pull out the rocker arms. Do not damage or lose...
General notes on engine overhaul
Cleaning components All metal components must be cleaned with fuel and dried with compressed air. Warning! Inflammable fumes are created and metal particles may be thrown out by the engine during cleaning. Therefore, work in a room free from naked...
Cleaning components All metal components must be cleaned with fuel and dried with compressed air. Warning! Inflammable fumes are created and metal particles may be thrown out by the engine during cleaning. Therefore, work in a room free from naked...
Overhaul cylinder
Note. The following paragraphs deal with measuring the engine parts to see if they are worn. Check that the walls are perfectly smooth. Measure the diameter of the cylinder (D) at three different heights and in two directions at 9CF from one...
Note. The following paragraphs deal with measuring the engine parts to see if they are worn. Check that the walls are perfectly smooth. Measure the diameter of the cylinder (D) at three different heights and in two directions at 9CF from one...
Overhaul piston
Clean the crown of the piston and the piston recesses from carbon deposits. Inspect the dimensions of the piston carefully: there must be no signs of shrinkage, scoring, cracks or damage. The diameter of the piston (D1) must be measured at 10...
Clean the crown of the piston and the piston recesses from carbon deposits. Inspect the dimensions of the piston carefully: there must be no signs of shrinkage, scoring, cracks or damage. The diameter of the piston (D1) must be measured at 10...
Overhaul gudgeon pin
It must be perfectly smooth, without scorings, steps or bluish stains due to overheating. Note. If you change the gudgeon pin, you must also replace the connecting rod small end. Gudgeon pin-piston coupling Coupling clearance at assembly:...
It must be perfectly smooth, without scorings, steps or bluish stains due to overheating. Note. If you change the gudgeon pin, you must also replace the connecting rod small end. Gudgeon pin-piston coupling Coupling clearance at assembly:...
Overhaul piston rings
The piston rings must not show any signs of forcing or scoring. Note. Spare pistons are supplied with piston rings and gudgeon pin. Piston ring-piston groove coupling The figure shows the axial clearance of the piston rings. Upper piston ring wear...
The piston rings must not show any signs of forcing or scoring. Note. Spare pistons are supplied with piston rings and gudgeon pin. Piston ring-piston groove coupling The figure shows the axial clearance of the piston rings. Upper piston ring wear...
Overhaul connecting rods
The connecting rod small end bush must be in good condition and firmly set in its seat. Check the parallelism error measured at 100 mm/3.93 in. from the longitudinal axis of the connecting rod: it must be H-h lower than 0.02 mm/0.00078 in. If not,...
The connecting rod small end bush must be in good condition and firmly set in its seat. Check the parallelism error measured at 100 mm/3.93 in. from the longitudinal axis of the connecting rod: it must be H-h lower than 0.02 mm/0.00078 in. If not,...
Overhaul crankshaft
The main bearings and the connecting rod big end bearings must not be grooved or scored; the threads, the key housings and the slots must be in good condition. Use a micrometer to measure the oval and the taper of the connecting rod bearings....
The main bearings and the connecting rod big end bearings must not be grooved or scored; the threads, the key housings and the slots must be in good condition. Use a micrometer to measure the oval and the taper of the connecting rod bearings....
Overhaul cylinder head
Remove the carbon deposits from the combustion chamber. Clean any deposits in the inner cooling ducts. Check that there are no cracks and that there are no grooves, steps or damage of any kind On the seal surfaces. It must be completely flat and the...
Remove the carbon deposits from the combustion chamber. Clean any deposits in the inner cooling ducts. Check that there are no cracks and that there are no grooves, steps or damage of any kind On the seal surfaces. It must be completely flat and the...
Overhaul valves and valve seats
Valve seat The valve seat must not be too recessed and must not show any signs of pitting or cracks. If the seat is slightly damaged, grind the valves and then mill the seat, using 45° single blade cutters. Valve guide Thoroughly check the inner...
Valve seat The valve seat must not be too recessed and must not show any signs of pitting or cracks. If the seat is slightly damaged, grind the valves and then mill the seat, using 45° single blade cutters. Valve guide Thoroughly check the inner...
Overhaul rocker arms
Check that the work surfaces are in perfect condition, without any signs of wear, grooves or breaks in the chrome coating. Check the condition and the diameters of the rocker arm hole and the corresponding pin hole: Rocker arm inner hole nominal...
Check that the work surfaces are in perfect condition, without any signs of wear, grooves or breaks in the chrome coating. Check the condition and the diameters of the rocker arm hole and the corresponding pin hole: Rocker arm inner hole nominal...
Overhaul cam shaft
Check that the work surfaces of the cams are free of scratches, grooves, steps and waving. Worn cams are often the cause of irregular timing which reduces the power of the engine. Insert the cam shaft between two tailstocks and check the deviation...
Check that the work surfaces of the cams are free of scratches, grooves, steps and waving. Worn cams are often the cause of irregular timing which reduces the power of the engine. Insert the cam shaft between two tailstocks and check the deviation...
Overhaul pulleys — tensioners — beits
The pulleys must not show any signs of wear or damage of any kind. Check the key seat: it must not be damaged or worn by contact with the key. Caution! To prevent accidental loosening that would cause serious damage to the engine, always use new...
The pulleys must not show any signs of wear or damage of any kind. Check the key seat: it must not be damaged or worn by contact with the key. Caution! To prevent accidental loosening that would cause serious damage to the engine, always use new...
Overhaul free wheel and starter
Check that the free wheel is working properly and that the roller tracks do not show any signs of wear or damage of any kind. If the unit is not working properly, you can remove the circlip (2) and then extract the free wheel (1) from the flange....
Check that the free wheel is working properly and that the roller tracks do not show any signs of wear or damage of any kind. If the unit is not working properly, you can remove the circlip (2) and then extract the free wheel (1) from the flange....
Overhaul crankcase halves
Carefully inspect the engine block. Check, on a reference surface, that the surfaces of the crankcase halves are perfectly flat. Check that the bearings and the bushes are in perfect condition. If you have to change the main bearings, they must be...
Carefully inspect the engine block. Check, on a reference surface, that the surfaces of the crankcase halves are perfectly flat. Check that the bearings and the bushes are in perfect condition. If you have to change the main bearings, they must be...
Overhaul main bearings
The main bearings must always be changed in pairs and must be fitted in the right direction in the respective crankcase half bushes. Inspect the bearing to establish the side (1) in which the thickness (S) of the outer ring is lower. The bearing...
The main bearings must always be changed in pairs and must be fitted in the right direction in the respective crankcase half bushes. Inspect the bearing to establish the side (1) in which the thickness (S) of the outer ring is lower. The bearing...
General rules for engine reassembly
For correct reassembly, follow the disassembly procedures in reverse order, paying particular attention to the individual operations mentioned specifically. Seals, oil seals, circlips, clips, gaskets (e.g. copper, aluminium, fibre, etc.,) and...
For correct reassembly, follow the disassembly procedures in reverse order, paying particular attention to the individual operations mentioned specifically. Seals, oil seals, circlips, clips, gaskets (e.g. copper, aluminium, fibre, etc.,) and...
Reassembly head parts
Place the oil seal grommet on the valve guide, noting the color: green for the exhaust valve and black for the intake valve. Insert the valves. Place the lower rocker arm and spring on service tool 88713.0143. Insert the tool-rocker arm-spring...
Place the oil seal grommet on the valve guide, noting the color: green for the exhaust valve and black for the intake valve. Insert the valves. Place the lower rocker arm and spring on service tool 88713.0143. Insert the tool-rocker arm-spring...
Adjusting the connecting rod
Check that the flexible centring pins are between every cap and connecting rod. Fit the cap and connecting rod with markings on the same side. Lubricate heavily with engine oil and position the connecting rods and caps on the crankshaft. Insert the...
Check that the flexible centring pins are between every cap and connecting rod. Fit the cap and connecting rod with markings on the same side. Lubricate heavily with engine oil and position the connecting rods and caps on the crankshaft. Insert the...
Closing the crankcase half
Before inserting the gearbox assembly in the left crankcase half, ensure that the inner raceway (A) of the bearing on the end of the primary shaft Is fitted in the bearing and has not remained on the end part of the primary shaft. The same applies...
Before inserting the gearbox assembly in the left crankcase half, ensure that the inner raceway (A) of the bearing on the end of the primary shaft Is fitted in the bearing and has not remained on the end part of the primary shaft. The same applies...
Reassembly timing pulleys
If it has been removed, refit the seal ring (1) on the right crankcase half using a drift. Position it with the side with the spring facing inwards. To prevent damage to the ring seal, insert a protection cap 88700.5749 on the end of the timing...
If it has been removed, refit the seal ring (1) on the right crankcase half using a drift. Position it with the side with the spring facing inwards. To prevent damage to the ring seal, insert a protection cap 88700.5749 on the end of the timing...
Reassembly primary drive gear and oil pump
Thoroughly degrease the conical surface of the crankshaft and the corresponding surface of the primary drive. Position the key and the gear of the primary drive on the crankshaft. Position the safety washer and secure the gear using service tool...
Thoroughly degrease the conical surface of the crankshaft and the corresponding surface of the primary drive. Position the key and the gear of the primary drive on the crankshaft. Position the safety washer and secure the gear using service tool...
Reassembly timing system gear
Fit the timing gear with the reference aligned with the reference on the crankshaft gear. Position the safety washer and tighten the nut at the specified torque. Bend the washer.
Fit the timing gear with the reference aligned with the reference on the crankshaft gear. Position the safety washer and tighten the nut at the specified torque. Bend the washer.
Reassembly flywheel
Insert the inner ring (B) and the washer (A), centering it in the ring mentioned above. Then fit the roller cage, the starter driven gear with free wheel and the flywheel. If the free wheel has been removed from the flywheel during disassembly, turn...
Insert the inner ring (B) and the washer (A), centering it in the ring mentioned above. Then fit the roller cage, the starter driven gear with free wheel and the flywheel. If the free wheel has been removed from the flywheel during disassembly, turn...
Reassembly left casing
Before refitting, check that the following have been fitted correctly to the left casing: the generator stator; the crankshaft bearing; the motor sensor; the bush; the gearbox lever shaft seal ring; the water pump assembly. Degrease and remove any...
Before refitting, check that the following have been fitted correctly to the left casing: the generator stator; the crankshaft bearing; the motor sensor; the bush; the gearbox lever shaft seal ring; the water pump assembly. Degrease and remove any...
Reassembly cylinder-piston-head assemblies
If the pistons have been separated from the cylinders during disassembly, before insertion, position the openings of the piston rings at 12CP to each other (the punched writing TOP must always be facing the crown of the piston). Use a universal...
If the pistons have been separated from the cylinders during disassembly, before insertion, position the openings of the piston rings at 12CP to each other (the punched writing TOP must always be facing the crown of the piston). Use a universal...
Reassembly head timing pulleys
If the cam shaft or the support bearings have been changed during disassembly, the parts removed must be refitted: First insert the inner spacer (1) and then the outer bearing (2). The bearing must be inserted with a tubular drift which rests on...
If the cam shaft or the support bearings have been changed during disassembly, the parts removed must be refitted: First insert the inner spacer (1) and then the outer bearing (2). The bearing must be inserted with a tubular drift which rests on...
Reassembly timing belts
As it must be rotated, fit service tool 88713.0123 on the left side of the crankshaft. Rotate the crankshaft until the reference on the pulley is aligned with the reference on the clutch cover. Turn the cam shaft pulleys until the reference on the...
As it must be rotated, fit service tool 88713.0123 on the left side of the crankshaft. Rotate the crankshaft until the reference on the pulley is aligned with the reference on the clutch cover. Turn the cam shaft pulleys until the reference on the...
Testing the engine timing
The timing must be tested and reset whenever major timing components (e.g. timing shafts, valves or pulleys) have been changed or when very worn engines are overhauled. Proceed as follows, always maintaining the timing belts at a tension of 11.5...
The timing must be tested and reset whenever major timing components (e.g. timing shafts, valves or pulleys) have been changed or when very worn engines are overhauled. Proceed as follows, always maintaining the timing belts at a tension of 11.5...
Testing the engine sensor air gap
The air gap between the ends of the engine sensor and the front surface of the timing gear teeth must be: 0.6-0.8 mm/0.0236-0.0314 in. There is a plug (A) with seal to facilitate testing of the air gap on the left crankcase half. Insert the blade of...
The air gap between the ends of the engine sensor and the front surface of the timing gear teeth must be: 0.6-0.8 mm/0.0236-0.0314 in. There is a plug (A) with seal to facilitate testing of the air gap on the left crankcase half. Insert the blade of...
Tightening torques for threaded connections
application threading (mm) Nm±5% tolerance note Head nuts (final torque) 10x1.5 38.5 (1) GREASE C Connecting rod screws (final torque) 10x1 66.5 (2) GREASE C Crankshaft gear nut 22x1 140 Alternator rotor nut 20x1 181.5 LOCK 8 Gear lever retaining...
application threading (mm) Nm±5% tolerance note Head nuts (final torque) 10x1.5 38.5 (1) GREASE C Connecting rod screws (final torque) 10x1 66.5 (2) GREASE C Crankshaft gear nut 22x1 140 Alternator rotor nut 20x1 181.5 LOCK 8 Gear lever retaining...
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- Information for owner
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