2000–2005 Ducati ST4 Sport Touring Workshop Manual

This workshop manual covers the 2000–2005 Ducati Sport Touring 4 (ST4), with factory procedures for engine, chassis, fuel-injection, and electrical repair.

• Engine and valvetrain: Engine removal, cylinder-head overhaul, piston and crankshaft inspection, desmodromic valve-clearance adjustment, timing-belt tensioning, and engine reassembly.

• Clutch and transmission: Dry multi-plate clutch disassembly, wear inspection, fault diagnosis, gearbox overhaul, selector checks, and shaft and drum shimming.

• Suspension and steering: Showa front-fork overhaul, swingarm and linkage service, rear-shock removal and spring replacement, and steering-head bearing replacement.

• Cooling and lubrication: Coolant-pump overhaul, radiator inspection, coolant replacement, engine oil-pressure checks, and oil-pump and bypass-valve inspection.

• Brakes and hydraulic controls: Pad replacement, brake-fluid renewal and bleeding, disc inspection, clutch-fluid replacement, and brake and clutch hose routing.

• Fuel injection and ignition: Marelli I.A.W. 1.6 M operation, throttle-body synchronization, throttle-position-sensor adjustment, idle-mixture setting, and EPROM replacement.

• Electrical system: Injection-ignition and complete wiring diagrams, connector references, relay and switch tests, charging-system reference data, and harness-routing drawings.

This manual is suited to experienced motorcycle technicians with precision measuring equipment and access to the specified Ducati service tools.

Engine, Timing, and Drivetrain Repair

Motorcycle and engine disassembly sequence charts show which components must be removed to reach a repair area. Cylinder and piston selection classes, connecting-rod bearing combinations, and gearbox shimming data support component matching during a rebuild.

Desmodromic service: The head procedures cover rocker-arm inspection, valve-guide and seat replacement, shim measurement, and camshaft timing checks. Listed tools include rocker-shaft puller 88713.0862 and valve-seal installation tool 88713.1093.

Timing-pulley precautions explain how reused self-locking ring nuts can loosen and cause engine damage.

Clutch diagnosis: Separate symptom lists cover drag, slip, and noise, linking each complaint to possible plate, spring, actuation, housing, or primary-drive faults. This helps narrow the inspection before dismantling the clutch.

Engine and chassis torque tables specify fastener sizes, tightening stages, and assembly products.

Suspension, Steering, and Brake Service

Showa fork coverage includes seals, bushings, springs, and oil-level setup; the damper cartridge is not to be opened. Rear-shock coverage addresses removal, spring replacement, and external adjustments, with separate procedures for linkage bearings and swingarm side play.

The trellis-frame section adds alignment dimensions and steering-head bearing installation. Brembo brake coverage centers on pads, discs, fluid service, and hose positioning; internal caliper and master-cylinder overhaul is excluded.

Brake and clutch hose-routing drawings address connector orientation and moving-part clearance. The manual warns that incorrect brake-hose routing can cause braking faults.

Fuel Injection, Electrical Diagnosis, and Cooling

Throttle-body adjustments distinguish U.S., European, and Swiss baseline settings. The MATHESIS procedures cover sensor positioning, airflow balance, and CO adjustment; component and wiring checks in the injection chapter refer to the separate tester manual.

EPROM replacement instructions specify extraction and insertion tools and chip orientation. The injection-ignition diagram includes control-unit terminal references, while the electrical section provides wire-color legends, switch-continuity tests, and harness attachment locations.

Cooling service extends to water-pump bearings and mechanical seals. The engine lubrication diagram traces pressure delivery, oil-cooler and filter bypasses, and return flow.

A Preview of Clutch, Sensor, and Cooling Data

These examples are a small selection of the manual’s inspection and service specifications. Clutch friction plates have a minimum thickness of 2.8 mm.

The engine-speed/timing sensor section specifies an air gap of 0.6–0.8 mm between the sensor tip and timing-gear teeth. The cooling-system section lists a circuit capacity of 3.5 liters.

PDF Navigation and Page Details

Text search and diagram readability: The service text is searchable, but small labels in the complete wiring diagram are not searchable. There are no embedded PDF bookmarks. Small wiring labels require magnification; the complete electrical schematic has faint lines and labels that can remain difficult to read.

One printable PDF contains 254 pages in English and Italian, including the original cover and five pages containing only page numbers or running footers. These pages are already included in the total; no separate supplements are supplied.