Ducati SuperSport 800 2006 Workshop Manual

Ducati workshop manual for the SuperSport 800, M.Y. 2006, edition 00, covering maintenance, diagnosis, and repair for European and U.S. configurations.

Searchable Text, Bookmarks, and PDF Contents

Search and diagram detail: Text search is available across the service chapters, with embedded bookmarks for sections and individual procedures. Small wire-color codes, connector numbers, and ECU pin labels in the wiring diagrams require zooming.

One printable PDF in Italian and English, with 544 pages, including the general contents, subject index, and eight blank pages.

Engine Overhaul, Chassis Service, and DDS Testing

The following highlights are a selection of the contents. Other topics include headlight aiming and seat-release mechanism service.

• Engine repair: Engine removal and installation, cylinder-head and valve-train service, cylinder/piston inspection, lubrication-system repair, and crankshaft and connecting-rod overhaul.

• Clutch and gearbox: Wet-clutch inspection, primary-drive service, gear-selector and gearbox-shaft disassembly, bearing checks, shaft shimming, and reassembly.

• Chassis and hydraulics: Wheel-bearing replacement, front-fork overhaul, swingarm inspection, steering service, brake-pad replacement, and brake and clutch fluid bleeding.

• DDS diagnosis and adjustment: Timing-belt measurement, TPS reset, throttle-body balancing, CO adjustment, oil and fuel pressure testing, cylinder-compression checks, and guided diagnosis.

• Electrical systems: Starting and charging tests, immobilizer programming and emergency override, switch checks, wiring diagrams, connector references, and harness-routing illustrations.

• Workshop reference data: Maintenance schedules, separate frame and engine torque tables, fuels and lubricants, wear limits, electrical test values, and factory service-tool identification.

Ducati prepared this publication for Authorized Service Centers and workshop personnel. Its repair operations require senior skilled technicians, with specialist knowledge and the appropriate lifting, measuring, and diagnostic equipment.

Internal Engine Inspection and Reassembly

Step-by-step procedures connect engine removal with internal disassembly, inspection, and reassembly. The belt-driven single-overhead-cam valve train receives dedicated camshaft, valve, rocker-arm, valve-seat, and valve-guide coverage.

Cylinder and piston class markings, component wear limits, and crankshaft, gearbox-shaft, and selector-drum shimming data support parts-selection and reassembly decisions during an overhaul. The manual refers to the separate spare-parts catalog for additional component-fitting information.

Lubrication and rotating assemblies: Oil-pump clearance checks, oil-cooler inspection, oil-breather reservoir service, connecting-rod bearing assessment, and flywheel/generator and starter-clutch work are included. The lubrication-system diagram explains the oil paths and bypass arrangements.

Timing and cylinder-head cautions: The timing chapter identifies roller-index alignment and replacement self-locking ring nuts; a loosened roller can seriously damage the engine. The head-installation section warns that improper tightening can stretch the studs and cause severe engine damage.

Timing-tool references include degree wheel 98112.0002 and timing-check tool 88713.0123.

DDS Setup and Regional Fuel-System Details

The diagnostic chapters explain the 97900.0215 DDS kit with cylinder-vacuum equipment, with a CO tester required for mixture adjustment. TPS zero-setting requirements are tied to replacement of the throttle body, throttle position sensor, or ECU.

The oil-pressure discussion links abnormal readings to possible relief-valve, pump, sealing, and engine-wear faults. This gives technicians a basis for interpreting measurements rather than treating the test as an isolated reading.

Fuel-system procedures cover the tank, pump, filter, pressure regulator, injectors, throttle body, airbox, and exhaust. The catalytic-converter explanation is marked EU only; U.S. canister service includes removal, installation, and hose-routing information. Oil-cooler and bodywork instructions distinguish faired and half-faired mounting arrangements.

Electrical Fault Tracing and Immobilizer Work

The Marelli CPU 5.9M reference data is supported by the fuel injection-ignition system diagram, complete wiring diagram and key, electric-starting circuit, and frame harness-routing views identified as diagrams A–V. Wire-color legends, fuse data, and chapter-opening exploded assemblies provide further component references.

Immobilizer coverage explains key programming, diagnostic indications, and emergency override. Programming depends on the required keys; emergency override uses the vehicle’s electronic code.

Suspension, Brakes, and Repair Limits

Front-fork work includes seals and bushings, with seal-installation tool 88713.1096 identified. Chassis procedures add steering-bearing service, frame dimensional inspection, swingarm-shaft and axial-play checks, and final-drive inspection. Engine/frame support 88713.1515 is listed for engine removal.

Service limits: Rear-shock coverage includes removal, spring and preload service, inspection, and installation, with replacement specified for leakage or other faults; it does not provide an internal damper rebuild. Brake-caliper and master-cylinder work is limited to the permitted service items rather than internal hydraulic overhaul.

Safety guidance addresses the gas-pressurized shock, fuel ignition hazards, battery gases, hydraulic-fluid exposure, and secure support during engine/frame separation.

A Preview of Belt-Tension and Pressure Specifications

The DDS belt-tension section specifies 145 Hz for the horizontal-cylinder belt and 160 Hz for the vertical-cylinder belt, each with a ±5 Hz tolerance, at the illustrated measurement spans and specified cylinder positions.

For a warm engine with oil at least 80°C, the oil-pressure test specifies readings above 0.8 bar at 1,100–1,300 rpm and above 4 bar at 3,500–4,000 rpm.

The fuel-pressure testing section gives a nominal pressure of 3 bar, alongside the DDS measurement setup.