Maintenance and Issues

 

Maintenance

Issues

Information on setup and use of JP Diag ECU diagnostic Software

Info and How to for Superseal 1.5mm AMP connector pin removal and assembly

 

2002 Ducati ST4s Manuals:

Work Shop Manual (large file +35Mb but text searchable) 

Parts Manual

Owners Manual (IT,EN,FR,DE)

 

Handy capacity values for ST4s:
     
Oil Quantity 3.7L ~ 3.9qts
Coolant Quantity 3.5L ~ 3.7qts
Fuel Quantity 21L ~ 5.5gal

Front and rear wheel torque values

  Ft-Lbs N-ms
Front Axel nut -- 28mm socket for nut 46 62
Front Axel Pinch bolts -- 12 mm head 14 19
Front Brake Caliper retaining screw 30 43
Rear Axel nut -- 30mm head 61 83
Rear Chain Adjust bolts -- 12mm head 5.9 8
Front Sprocket Plate bolts -- 8mm head 4.4 6

Oil change related torque values:

  Ft-Lbs N-ms
Oil Filter Cartridge 8 11
Oil Drain Plug 30 42
Oil Mesh Screen 30 42
Oil Mesh Screen outer Cap 30 42

Other Torque Values

  Ft-Lbs N-ms
Rear engine mount bolt -- 12mm bolt thread

(14mm bolt head, 15mm nut)

45 60

 

Install and Set Timing Belt Tension Values using acoustic vibration:

Measure and set Tension on timing belts:  110Hz on new belts and approx 90-100Hz on existing belts.

To set the belt tension, the cylinder you are checking MUST be at TDC so that there is no tension applied to the belts by the closing springs pushing on the rockers.

1.  For the horizontal cylinder it is the forward run between the tensioner pulley and the exhaust camwheel (posn 21).

2.  For the vertical cylinder it is the rearmost run between the idler pulley and the exhaust camwheel (posn 25).
 

1.  Battery would not maintain a charge

2.  Brake reservoir cap corroded

3.  Lower steering head bearings corroded and seized

4.  Installation of Evoluzione license plate re-locator

5.  LCD display module partial failure and repair

6.  Relay failure

7.  High coolant/water temperature under normal running conditions

8.  Output shaft wear and front sprocket retention plate wear

9.  Radiator Pressure Cap part number incorrect in the Ducati Parts Catalogue.  Correct PN is:89310031A

10. Brake Shudder / Judder / Chatter

11. Neutral Switch Failed

 

 

Events and Receipts

1.  600 mi First service

2.  3,000 mi oil change

3.  6,000 mi service

4.  9,000 mi oil change

5.  12,000 mi service

6.  15,000 mi service (self)

7.  16,400 mi service (self)

8. 20,500 mi service (self)

Other ST4s Issues/Troubleshooting Info

1.  ST4s wouldn't rev above 4k

(https://www.ducati.ms/forums/40-sport-touring/44833-st4s-wouldn-t-rev-above-4k.html)

 

Issues

 
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1st Issue...  Battery would not maintain a charge:

        Replaced the Battery and Cables and added Headlight Gizmo (see the Mods page)

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2nd Issue... paint peeling and corrosion of the brake reservoir cap

        Noticed paint peeling and corrosion of the (aluminum?) cap.  I don't park it on the side stand and there is no trace of brake fluid leaking.  L  21 Months after purchase...  wonder if it is covered by warranty?  Well So far, no word on warranty.   Ducati Nashville did order and replace the cap.  $25 for a new one.  The original problem was the rubber seal in the cap had developed a leak (pin hole) and the fluid caused the cap paint to peel and corrode.  There was a small amount of brake fluid between the seal and the cap that caused the problem.

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3rd Issue...  Lower Steering Head bearings corroded and seized:

        This issue was first called to my attention by Ian of www.st4s.com.  He pointed out that several ST4s owners had a similar problem and encourage current ST4s owners to have it checked, especially while under warranty.  Very sound advice.  I had mine looked at during the 6,000 mi service and look how bad the bearings were.  Click on the photo for a more detailed picture, or click here for a very high resolution photo.

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4th Issue...  Not a maintenance issue per se, but the License Plate Relocator Kit from Evoluzione doesn't quite work as advertised.  The result is that the turn signals interfere with the saddle bags (Panniers).  I found a short stalk on LT Snyder's Desmo Times to modify the rear turn signals and the last photos shows them installed with the panniers attached.  Great fix!

 

     

FIX!!!

 

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5th Issue...  LCD Module display (LCD Panel) partial failure.  About a month after a very rainy and wet ride, my LCD display started to fail.  It would only display the top half and lower right portion of the display, I could see temperature and time, but only half my tank of gas.  This seems to be a common problem or so I have read on some of the forums.  I spent the time on a cold Sunday afternoon and removed the LCD module and set about repairing it.  This is how I did it: 

Click on any of the photos for higher resolution image

    1.  Remove the upper fairing to get at the instrument mounting plate.

    2.  Disconnect  the speedometer (odometer) cable.

    3.  Remove the bolts attaching the instrument mounting plate.

    4.  Detach the instrument cluster from the mounting plate.

    5.  Remove the single cap nut from the back of the LCD module and disconnect the two pig-tail electrical connectors.  (the connectors will pass through the back of the housing one at a time with care.

    6.  I placed  the LCD module on a towel and removed the three small Phillips head screws.

 

    7.  Using a sharp sturdy blade, drew along seam at the bottom of the module until cutting the glue bond,  then using a small flat tip screwdriver worked the plastic halves apart by slowly and gently first the bottom half then the rest of  the module.  (you can see I accidentally scored a bit of the plastic)

 

  8.  Once halves of cover are apart, remove the LCD display and circuit card assembly.  My LCD module had a considerable amount of water in it and corrosion on the circuit card.  Used a Q-tip with a little contact cleaner to remove the corrosion,  then used a dry Q-tip to remove any residue.

   

 

    9.  When I put it together, I used black silicon RTV all around the edges of the two halves and the three screw holes.  I also used RTV around the grommet where the electrical pigtail passes, I think that is  the culprit that allowed the water into the LCD module in the first place.

 

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6th Issue...  Relay failure of primary relay located next to fuse panel under left side instrument trim.  Replaced with Duralast Relay PN# 19283

   

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7th Issue... High coolant/water temperature under normal running conditions.  Drained and flushed cooling system (used Liqui-Moly cooling system flush) rinsed and refilled with Engine Ice.  Temperature sensors replaced, and replaced radiator pressure cap. ** Note the part number for the pressure cap is incorrectly shown in the Ducati Parts Catalog.  Got it straightened out with Ducati North America by working with Ducati, Omaha...they are super.  Checked the water pump impeller, all looking good; refitted water pump housing.  Straightened radiator cooling fins.  Second Cooling Fan Installed - Right Side, manual switch controls both fans.

 

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8th Issue...  Output Shaft wear in the channel caused by front sprocket retention plate, due to misaligned chain!

   

The donor sprocket below and the resulting spacer after machined down:

 

spacer in place:

 

 

Installed and chain aligned!!!  Note the difference in swing arm reference marks with the chain CORRECTLY aligned!!!

   

 

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9th Issue...  Radiator Pressure Cap part number incorrect in the Ducati Parts Catalogue.  Correct PN is:89310031A

Listed in the ST4s Parts Catalogue as, PN 893.4.006.1A  (CATALOGUE No: 915.1.130.1A , ISSUED: 05 - 01) which is NOT the right Part Number for the cap required.  Use Ducati Part Number 893.1.003.1A

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10th Issue...  Brake Shudder / Judder 

Common issue noted by many riders not just ST4s, not just Ducati but, this is an issue noted on several Ducati forums (Ducati.ms (https://www.ducati.ms/forums/40-sport-touring/2151-brake-chatter.html) and DucatiSportingClub.com http://www.ducatisportingclub.com/showthread.php?t=25990)  So I opted to try the Ducati PN 69922861A - UNION+WASHERS KIT MTS03 Brembo banjo bolt.
 

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11th Issue...  Neutral Switch Failure 

Another common issue noted by many Ducati riders (ST4s) included is the intermittent and eventual failure of the neutral switch aka gear switch, Ducati PN 539.1.021.1A.  In the photo below you can see where the plunger that makes contact in the gearbox to complete a path to ground when in neutral is worn down.


 

Old switch on left, new one on right.

 

Cut away view of the worn switch

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ST4s 2002 USA Parts Diagram: click link for pdf