5 - | Diagnostic instruments

1 | 97900.0211 Basic DDS (Ducati Diagnosis System)

2 | 97900.0227 Power and diagnostic cable D607

3 | 97900.0222 Power and diagnostic cable 1060838 (Measurement Module)

4 | 97900.0218 Vacuum sensor

5 | 552.1.039.1A Pressure sensor

6 | 97900.0220 Pressure/vacuum pipe

7 | 97900.0221 Pipe fitting

8 | 97900.0228 Battery socket adapter

9 | 814.1.114.1A Oil pressure connector

10 | 514.1.032.1A Auxiliary test cable

11 | 552.1.037.1A Cylinder compression cable with M12 connection

12 | 875.1.065.1A Oil pressure pipe

13 | 97900.0230 Mains power adapter

14 | 97900.0224 Mains power adapter

15 | 88765.1371 Belt tensioning sensor

16 | 88765.1374 Bracket for belt tensioning sensor

17 | 590.1.189.1A Fuel pressure test pipe

18 | 97900.0234 Ammeter clamp

19 | 514.1.033.1A Cigar lighter socket adapter

Parts catalogue

DDS tester
Workshop service tools

Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Description of the Ducati Diagnostic System tester
The Ducati Diagnostic System (DDS) is used for diagnosis of the injection-ignition system via a serial connection. The system is also equipped with functions to test various devices on the motorcycle. The DDS tester can be used to measure current and voltage on any electrical device, to perform tests on individual components and to measure pressure and temperature values.
The DDS tester (1) is comprised of a palmtop display unit (A), a BBAD self-diagnosis module (B) and a display memory card (C).
The touch-screen display unit (A) serves for both data display and input, using the stylus housed on the side of the unit.
The self-diagnosis module (B) enables communication between the DDS tester (1) and the motorcycle’s on-board electronic control unit (ECU).
The user interface software resides in the display memory card (C) which is housed in the palm-top display unit (A).
The display unit is equipped with two connection panels: one at the top of the instrument and one at the bottom.
The top connection panel has 6 connection sockets with the following functions:

- | one VGA output (E);

- | one port for connection of the measurement module (F);

- | one RS232 serial port for connection of peripheral devices (COM1) (G);

- | a second RS232 serial port for connection of peripheral devices (COM2) (H);

- | two generic USB ports (USB1 and USB2) (L).

The bottom connection panel has 3 connection sockets with the following functions:

- | one USB port (M);

- | one power connection socket (N);

- | one diagnostics connection socket (P).

You can connect a printer to the DDS tester (1) to print test reports: connect the printer to the serial port (COM1) (G) located on the top connection panel of the tester (1).
Technical data
Power supply:

- | from the mains - 220 V;

- | from the motorcycle battery - 12 V.

Components supplied with the DDS tester
The DDS tester (1) is supplied in a kit together with the following items:

- | Rechargeable DDS battery

- | Battery charger

- | Mains power adapter

- | USB memory card reader

- | Power and diagnostic cable complete with fuse

- | CD containing DDS installation software for PC

- | USB cable

- | Belt tension sensor

Tester power supply
The DDS tester (1) may be powered in any one of the following ways:

- | from the mains power supply: by connecting the mains adapter (14) to the power connection socket (N);

- | from the motorcycle: by connecting the specific cables (see paragraph “Connection to the motorcycle”);

- | from the tester's internal battery: the battery (Q) is housed in the top part of the tester. To operate the tester (1) using the internal battery and to recharge the battery, refer to the “User Manual” supplied with the DDS tester.

To switch on the display, press the button (T).
Connection to the motorcycle
The tester requires a power supply of between 9 and 16 Volts DC.
When using the tester, take care never to allow the power supply to fall below the minimum voltage: this situation could occur during engine starting and idling on motorcycles in which the battery is not in perfect working order. If the tester detects a power supply voltage of less than 9 Volt, the current procedure will be aborted; when the voltage returns to within the acceptable tolerance limits the procedure must initiated again from the beginning.
The DDS tester (1) may be powered from the motorcycle in any one of the following ways:

- | connect the battery power adapter (13) to the power connection socket (N) on the tester and to the motorcycle battery;

- | connect the power and diagnostic cable (2) to the diagnostic connection socket (P) on the tester; then connect the battery socket adapter (8) to the connection socket (R) on the power and diagnostics cable (2) and to the motorcycle battery.

Notes
For connection of the various devices required for self-diagnostic procedures, consult the instruction handbook supplied with the tester.
DDS tester
The main functions of the DDS tester can be summarised as follows:

- | Retrieval of errors (faults) of the ignition-injection system stored in the engine control unit memory and their subsequent deletion, if required.

- | Reading of engine parameters (rpm, coolant and air temperature, atmospheric pressure, throttle opening, battery voltage, injection times and ignition advance, etc.).

- | Active diagnostics. Activation of ignition-injection system transducers to test functionality and control signals (fuel pump, ignition coils, rev counter, injectors, etc.). With this function it is also possible to enter the code to override the immobilizer.

- | Road test. Allows the technician to store engine parameters recorded within a previously specified engine speed range interval. The resulting parameters can then be analysed and displayed once they have been acquired.

- | With specific sensors connected, the DDS tester can read electrical voltages, current, temperature, timing belt tension, and pressure values (lubrication and fuel supply circuits for example).

Checking and adjusting timing belt tension
Notes
The on-screen icons used during this procedure are explained in a table at the end of this section.
Notes
This operation, which is performed using the DDS tester, has the advantage that it can be carried out on both timing belts with the engine still installed on the frame. An optical reader is connected to the DDS tester. The optical reader has a green LED that serves to determine that the reader is correctly positioned in front of the belt to be tested. It is also equipped with an infrared transmitter (A) and receiver (B) designed to detect oscillations of the belt when caused to vibrate with the flick of a finger.

Operation | Section reference
Remove the timing belt covers | N 4.2, Removal of the timing belt covers

Remove the spark plugs.
Position the crankshaft so that the piston of the horizontal cylinder is at TDC of its power stroke.
This is achieved by aligning the timing mark (C) on the timing driveshaft pulley (28) with the reference notch (D) on the clutch cover (20).
Take the measurement on section (23) of the horizontal belt as described in the paragraph “Measuring timing belt tension”.
Turn the crankshaft through 270° in the direction of rotation of the engine (so that the piston of the vertical cylinder is at TDC of the power stroke) and repeat the procedure used for the horizontal cylinder, measuring the tension on section (22) of the vertical cylinder timing belt.
Remove the belt tension sensor and disconnect the DDS tester from the motorcycle.

Operation | Section reference
Refit the timing belt covers | N 4.2, Refitting the timing belt covers

Measuring timing belt tension
Switch on the DDS tester (1); see paragraph “Tester power supply”.
Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (F) on the DDS tester (1).
Connect the belt tension sensor (15) to the connector (V) of the power and diagnostics cable (Measurement Module) (3).
Fix the mounting bracket of the belt tension sensor (15) using the timing belt cover bolt (21).
Aim the central green LED of the sensor (15) at the mid-point of the belt run, with the reader parallel to the belt and at a distance of about 1 to 1.5 cm from it.
On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “Belt Tension” icon followed by the “Start” icon to access the “Mechanical belt tension” screen.
The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C.
Flick the belt lightly with your finger and read the frequency value (Hz) on the DDS tester.
Notes
Do not flick the belt several times repeatedly, as the minimum time necessary for the DDS tester to take a reading is 1 second.
Correct tension values are as shown in Sect. C 1.1, Timing system/valves and must be checked with the engine cold: apply the installation values when fitting a new belt, and the reset values when belt tension reaches 70 Hz.
Warning
The timing belts can become slack during normal operation. When checking belt tension, if the reading is less than 70 Hz, retension the belt to restore the specified nominal values (Sect. C 1.1, Timing system/valves).
If the tension value is incorrect, tighten or slacken the belt by loosening the bolts (24) and (25) and moving the tensioner pulleys.
Manually raise the tensioner pulley (26) to increase belt tension or lower it to reduce belt tension.
Notes
If the engine as been removed from the frame, adjust the bolt (24) using the special tool (27), positioning the contact point (U) of the tool on the tensioner.
Important
Rotate the contact point (U) anti-clockwise to increase belt tension or clockwise to reduce it.
Re-check the timing belt tension.
Repeat the above procedure until the correct belt tension is obtained.
Then tighten the screws (24) and (25) to the specified torque (Sect. C 3, Engine torque settings).
Adjusting the idle speed
Check that the motorcycle is fitted with a genuine Ducati ECU, intake system and exhaust system; if not, fit genuine components.
Connect the inserts of the Exhaust Gas analyser part no. 88713.1010 to the outlets on the exhaust pipes, using the connection fittings (20).
Check that the throttle body linkage is seated against the stop screw (throttle fully closed and choke not activated). Make sure that the throttle cable freeplay is correctly adjusted.
Check:

- | that the throttle angle values read by the DDS with the engine stopped is 0°.

Start the engine and wait for the engine temperature to reach 100 °C.
When the engine temperature reading reaches 100 °C, carry out the adjustment operations described below.
The idle speed must be between 1250±1350 rpm (1300±50):

- | if the idle speed is lower or higher than the specified range, open or close the bypass screws (21) of both cylinders by a 1/4 turn, and, once the correct idle speed has been obtained, check that the CO level in both cylinders is between 0.4% and 1.4%. The CO level of both cylinders should be automatically maintained by the engine ECU within the specified range.

If the idle speed adjustment procedure is unsuccessful, proceed as follows:

- | overhaul the cylinders (clearances, timing, valve seats, etc.);

- | repeat the entire idle speed adjustment procedure;

- | check the vacuum pressures downstream of the butterfly valve (carry out this check only after completing the steps described above).

Warning
If the engine is shut off before proceeding with adjustment of the CO level, wait three minutes after restarting for the enrichment phase to finish and for the lambda sensors to start working.
If the ifle speed is high and cannot be corrected by adjusting the air bypass screws, check the seals under the throttle body, in particular check for cracks or other damage in the intake manifolds and thelatter are fimrly fixed to the engine, cuts in the pressure sensor pipes, etc.
Warning
Idle speed adjustment takes priority over balancing the vacuum pressures downstream of the butterfly valve. Differences in pressure between the horizontal and vertical cylinder are therefore acceptable, provided that the idle speed is adjusted correctly.

- | If you are unable to reach the desired idle speed setting, try reducing the vacuum differential downstream of the butterfly valve as described in the following paragraph “Throttle body balancing”;

- | repeat the entire idle speed adjustment procedure.

Choke adjustment
By turning adjuster screw (22) of the choke control cable, adjust the choke lever (23) so that the small lever (24) moves through its full travel. Check that the lever (24) moves the full distance between the two stops when the choke lever (23) is operated and released. Check that the choke lever remains in the same position when the handlbars are turned through their full travel.
Throttle body balancing
Connect the Measurement Module cable (3) to the Measurement Module connector on the DDS tester (see paragraph “Description of the Ducati Diagnostic System tester”).
Connect the vacuum/pressure pipes (6) to the connectors (A) and (C) of cable (3) and connect the fittings (7) to the pipes.
Switch on the DDS tester; see the paragraph “Tester power supply”.
Enter the “Measurement module” function. Press the “Cylinder synchronisation” icon.
The socket to which the Measurement Module cable (3) is to be connected is indicated on the screen with a capital letter: A, B or C.
Remove the screws (25) from the cylinder heads and install the fittings (7) in their place.
Open both bypass screws (21) by one turn from the fully closed position.
Warning
Press the “Reset” icon (G), then connect the sensors (4) and (5) to connectors (A) and (C) of the cable (3) and to the vacuum/pressure pipes (6).
Press the “Start” icon to begin the cylinder pressure measurement procedure.
The onscreen indicator light (E) will turn red when the function is active.
Start the engine.
The values may be displayed in two different ways: in numerical form or in graphic form; to select the desired display type, press the “Value display” icon (F).
The values can be reset by pressing the “Reset” icon (G).
To adjust the balance, turn the bypass screws (21) until the two lines on the graph coincide, if in graphic mode, or until identical numerical values are displayed, if in numerical mode.
Correct balancing is obtained when the two lines of the graph are superimposed or when the two numerical values indicated are equal.
Check the engine oil pressure
Notes
The on-screen icons used during this procedure are explained in a table at the end of this section.
To measure the pressure of the lubrication circuit, use the engine oil pressure test point (21) as described below.
Disconnect the wiring connector (A) and remove the pressure switch (21), taking care to recover the seal.
Insert the fitting (9) into the connection on the hose (12), interposing the two copper sealing washers (20). Insert the fitting (9) of the pipe (12) in the threaded hole (M10x1 mm) of the right-hand crankcase cover and screw it fully home. Refit the pressure switch (21) on the fitting (9) along with its seal, and reconnect the wiring connector (A).
Connect the pressure sensor (5) to the pipe (12) to transform the pressure signal into an electrical signal.
Switch on the DDS tester (1); see paragraph “Tester power supply”.
Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (B) on the DDS tester (1).
Connect the pressure sensor (5) to socket (A) of the cable (3).
On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “PressureTest” icon (D) followed by the “Start” icon (E).
The letter A is displayed on the screen to indicate the connection socket of the Measurement Module cable (3).
Start the engine.
The values may be displayed in three different ways: in one numerical form or in two graphic forms; to select the desired display type, press the “Value display” icon (F).
The measured value is indicated alongside the letter (A) or (C) identifying the cable used for the measurement: i.e. if you used connector (A) of the cable (3), the value measured will displayed next to the letter (A) on the screen.
Oil pressure test values:
Warm engine
(Minimum oil temperature = 80 °C)
1100 to 1300 rpm
greater than 0.8 bar.
3500 to 4000 rpm
greater than 4 bar.
Important
The maximum pressure must never exceed 6.0 bar.
Excessively high pressure may indicate that the relief valve is stuck. Excessively low pressure, on the other hand, may be caused by the relief valve being stuck in the open position, the relief valve spring being too weak, or a faulty oil pump. Other causes are excessively worn seals and gaskets or a badly worn engine.
Remove the tool and refit the pressure switch (21) along with its seal. Tighten the pressure switch to the specified torque (Sect. C 3, Engine torque settings).
Reconnect the electrical system connector (A) to the pressure switch.
Disconnect the DDS tester.
Cylinder compression test
Notes
The on-screen icons used during this procedure are explained in a table at the end of this section.
Engine performance is directly correlated to the pressure that can be measured in the combustion chambers of the two cylinders. Excessive or insufficient pressure, or an excessive difference between the two cylinders, will result in a reduction in engine performance and can lead to component failure.
Run the engine and allow it to warm up to the point at which fan operation starts, at least once.
Remove the HT leads (20) from both spark plugs.
Remove the spark plug from the cylinder to be tested.
Position the HT lead carefully to avoid sparking.
Screw the cylinder compression fitting (11) into the spark plug bore.
Connect the pressure sensor (5) to the cable (11).
Switch on the DDS tester (1); see paragraph “Connection to the motorcycle”.
Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (B) on the DDS tester (1).
Connect the pressure sensor (5) to socket (A) of the cable (3).
Notes
Measure the compression on one cylinder at a time.
On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “Cylinder Compression” icon (D) followed by the “Start” icon (E).
The letter A is displayed on the screen to indicate the connector of the Measurement Module cable (3).
Open the throttles completely.
Turn over the engine with the starter motor until the pressure stops rising.
Check the pressure in each cylinder:

- | standard value: 11 to 12 bar;

- | minimum value: 10 bar;

- | maximum permissible difference between cylinders: 2 bar.

An excessively high pressure value can be caused by:

- | build up of deposits in the combustion chamber.

An excessively low pressure value can be caused by:

- | gas escaping between the cylinder head and the barrel;

- | worn valve seats;

- | bent valve stems;

- | incorrect valve clearances;

- | worn cylinder or piston rings.

Refit the spark plugs and reconnect the HT leads (20).
Fuel pressure test
Notes
The on-screen icons used during this procedure are explained in a table at the end of this section.
Lift the fuel tank (Sect. L 2, Removal of the fuel tank).
Remove the fuel feed hose (20).
Take the fuel pressure pipe test (17) and connect one end (D) to the outlet fitting on the tank and the other end (E) to the fuel feed hose (20) in this way, the fuel pressure can be measured at the test outlet (F).
Connect the pressure sensor (5) to the test outlet (F) of the pipe (17) to transform the pressure signal into an electrical signal.
Switch on the DDS tester (1); see paragraph “Tester power supply”.
Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (E) on the DDS tester (1).
Connect the pressure sensor (5) to socket (A) or (C) of the cable (3).
On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “Pressure Test” icon (F) followed by the “Start” icon (G).
The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C.
The values may be displayed in three different ways: in one numeric form and in two graphic forms; to select the desired display type, press the “Value display” icon (H).
The measured value is indicated alongside the letter (A) or (C) identifying the cable used for the measurement: i.e. if you used connector (A) of the cable (3), the measured value will be displayed next to the letter (A) on the screen.
The maximum pressure must be 3 bar (nominal).
On completion of the test, remove all the components of the test instrument, refit the fuel feed pipe (20) securing it with the clamp.
Replace the seat.
Immobilizer override procedure
Notes
The on-screen icons used during this procedure are explained in a table at the end of this section.
In the event of a malfunction of the immobilizer system, it is possible to start the engine using the emergency procedure described in Sect. P 8, Immobilizer and transponder, which requires a secret code which may be entered using the DDS tester.
Switch on the DDS tester (1); see paragraph “Tester power supply”.
Connect the power and diagnostics cable (2) to the diagnostics connector (H) on the tester and to the diagnostics socket (L) on the motorcycle.
Enter the general functions menu by pressing the icon “Menu 1” (A).
Press the “Select vehicle” icon and, on the next screen, press the “Select motorcycle” icon; select the motorcycle model and confirm, then select the version and confirm.
Press the icon “Select system” to display a list of the bike’s systems that can be analysed.
Select “Engine electronics” and press the “Confirm” icon (B). Next, press the “Self-diagnosis” icon to access the corresponding function.
The DDS tester will interrogate the electronic control unit and display the parameters analysed with their relative values.
Notes
Make all connections with the motorcycle ignition key in the OFF position.
Press the “Actuators” icon (C) to display the actuators and other components connected to the ECU.
Select the option “Immobilizer Override” and then press the icon “Apply” (D).
A screen will appear in which you can enter the 5 digit secret code. Use the red arrows (E) and (F) to enter each digit: after entering each digit, press the “Confirm” icon (B).
One the entire code has been entered, press the “Confirm” icon (B) again.
On completion of the operation, the message “Was the operation completed successfully?” will appear; press “Confirm”.
If any problems were encountered during the operation, the tester will display the relative error messages: each message must be confirmed by pressing the “Confirm” icon, or rejected by pressing the “Exit” icon (G).
Disconnect the tester.
Guided diagnosis
Notes
The on-screen icons used during this procedure are explained in a table at the end of this section.
The DDS tester guides the operator step-by-step through the various diagnostic procedures, providing descriptions and documentation for motorcycle components, wiring diagrams for the electronic systems and information on the locations of specific components.
Switch on the DDS tester (1); see paragraph “Tester power supply”.
Connect the power and diagnostics cable (2) to the diagnostics connector (F) on the tester and to the diagnostics socket (G) on the motorcycle.
Enter the general functions menu by pressing the icon “Menu 1” (A).
Press the “Select vehicle” icon and, on the next screen, press the “Select motorcycle” icon; select the motorcycle model and confirm, then select the version and confirm.
Press the icon “Select system” to display a list of the bike’s systems that can be analysed.
Select “Engine electronics” and press the “Confirm” icon (B).
Press the “Guided diagnosis” icon (C) to access the corresponding function.
A series of screens are displayed indicating the operations required for correct diagnosis.
To determine whether the system has any internal problems, you can access the “Self-diagnosis” function by pressing the corresponding icon. If any errors are present, the symbol (D) will be displayed. To determine the type of errors present, press the “Errors” icon (E). Once errors have been detected, you can then resolve them through the guided diagnosis procedure; the “Guided Diagnosis” icon (C).
The DDS tester will interrogate the electronic control unit and display the parameters analysed with their relative values.
Testing the battery charging system
Notes
The on-screen icons used during this procedure are explained in a table at the end of this section.
You can determine the engine rpm required for the alternator to produce sufficient current to charge the battery, power the injection/ignition system and all the electrical equipment on the motorcycle. When applied to a cable, the ammeter clamp (18) detects the magnetic field generated by the current passing through that cable.
Remove the fuel tank (Sect. L 2, Removal of the fuel tank).
Switch on the DDS tester (1); see heading “Tester Power Supply”.
Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (D) on the DDS tester (1).
Connect the ammeter clamp to the connector (E) of the power and diagnostics cable (Measurement Module) (3).
Warning
The ammeter clamp must not be connected to wires through which electrical current is flowing.
Apply the ammeter clamp to the battery positive terminal lead with the arrow on the clamp pointing towards the battery positive terminal (+).
On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “Ammeter” icon (F) followed by the “Start” icon.
The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C.
If the measured current is a positive quantity, this means that alternator is powering all the electrical equipment and charging the battery at the same time. If the current has a negative sign, this means that the charging system is not able to power the electrical loads and a significant amount of the current required must be supplied by the battery, which is therefore discharging.
Important
If polarity is reversed when clamping the ammeter onto the cable, the sign of the readings will also be reversed, giving rise to incorrect diagnosis.
Icons table

Symbol | Description
| Confirm
| Exit
| Measurement module
| Belt tension
| Start/stop
| Menu 1
| Select vehicle
| Select motorcycle
| Self-diagnosis
| Settings
| Apply
| Cylinder synchronisation
| Value display
| Reset
| Pressure test
| Cylinder compression
| Actuators
| Guided diagnosis
| Select system
| Errors
| Ammeter clamp