Maintenance		Issues
Information on setup and use of JP Diag and IAW Diag ECU diagnostic Software ECU Installed in 2002 ST4s: Magneti Marelli IAW 59M  The TPS is PF09 IAWDIAG ECU Diagnostics Software and ECU Reader and Writer 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)  Electrical Schematic Parts Manual Owners Manual (IT, EN, FR, DE) Ducati ST FAQ (Perry Rosenboom - Archive Copy v1.4)	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 Engine Mount Bolts Torque Values   Ft-Lbs N-ms Rear engine mount bolt -- 12mm bolt thread (14mm bolt head, 15mm nut) 45 60   Link to Other Torque Values	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 12. Tensioner and Idler Pulley Bearing (timing Belt) Replacement: Tensioner and idler bearings are not the same!!! Idler Bearing PN is: SKF 6003-2RS1/C3GJN (GJN is grease spec, high temp) Tensioner Bearing PN is: SKF 61904-2RS1
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 7.  16,400 mi service 8.  18,500 mi service 9,   24,000 mi service 10. 30,000 mi service	Install and Set Timing Belt Tension Values using acoustic vibration: Measure and set Tension on timing belts:  110Hz on new Ducati OEM belts and approx 90-100Hz on existing belts. Set tension at 100Hz for New Exact Fit belts (CA Cycleworks). 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).	Suspension Info Fork Overhaul and Oil Replacement - Ducati ST4s Showa Forks ('02-'03 Ducati ST4s) Fork Overhaul and Oil Replacement - Ducati ST4s Showa Forks ('02-'03 Ducati ST4s) - pdf Preload (24 Dec 20) F1   R1   F2   R2   F3   R3       Front Rear 1-2 Static Sag     1-3 Rider Sag     Ohlins recommendations:     Front Rear 1-2 Static Sag 15-30 10-20 1-3 With Rider 35-50 25-40 *measurements in mm. 25 December 2020 Front Rear Compression Damping     Rebound Damping     Tire Pressures: Front- 33PSI; Rear- 35PSI
	IAW DIAG Setting Trimmer Value IAW5xM ECU has two types of memory: Flash-Memory, where the bin-file (aka fuel map) is stored and EEPROM - electrically erasable programmable read-only memory, where data like Serial number of ECU, TPS-Valence-Trim-Value and is stored When you flash your ECU, it does not change the EEPROM (you may see the eeprom-tool from the guzzidiag-page) therefore, it is not necessary to complete a TPS Reset if you reflash an existing ECU in your bike (No change to the TPS-Valence-Trim-Value stored in EEPROM) It is not harmful, but it is not necessary. Only changing the Hardware (ECU or TPS) makes it necessary to do a TPS Reset, or a worn TPS. For the CO-Trimmer Setting: The 5AM ECU operates stock in Closed Loop Mode, and the CO is controlled by Lambda sensors. The Value of the CO-Trimmer is set to zero from factory, you can’t even change this value as long Lambda sensors are active. If you reflash the ECU with a map "Lambda off" -- as described above the Trimmer-Value remains at Zero. The bike will run, even with no change to the CO-Trimmer.   It will run much better in the Low/mid-rpm range, if CO is set to around 4.0 - 4.5% as measured with a gas-tester.  If no gas-tester, set the CO Trimmer to a value of around 24. According to those with experience, CO level of 4.0 -  4.5% equates to a trimmer value between 22 and 28.	ST4s Non Linear TPS - Set Baseline Adjustment Brad The Bike Boy has a comprehensive page dedicated to this with the CAUTION: Do NOT connect Diagnostic SW and press "TPS RESET" - NO!  Do NOT do it if you have Non Linear TPS (like my 2002 ST4s does) http://www.bikeboy.org/ducati4vthrottleb.html pdf printed version of Brad The Bike Boy's TPS instructions   Vinnie's info on TPS Reset Follow Brad the Bike Boy's instructions. I back probe the TPS at the connector, red lead (+) from my multi-meter to the #2 wire (orange) in the middle of the connector, and my black lead (-) to the #3 wire (black & violet).
		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

 

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

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

[TOP]

 

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.

[TOP]

 

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.

[TOP]

 

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!!!

[TOP]

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:

[TOP]

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

[TOP]

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.

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

 

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

10th Issue...  Brake Shudder / Judder

 

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

[TOP]

ST4s 2002 USA Parts Diagram: click link for pdf