Ducati Scrambler 800 - Service manual > Refitting the secondary air system

Remove the previously inserted cloth from the duct.

Warning Do not invert the positions of the covers and components of the two valves of the secondary air system.

Refer to the reference notches present on the secondary air system valve cover and on head cover.

If disassembled, refit the secondary air system valves following the procedure described below.

Fit the retaining screw (15) in the secondary air system base (14).

Working on the opposite side, install O-ring (16) as shown in the figure.

Position the secondary air system base on the cylinder head and apply indicated threadlocker to screw (15).

Tighten screw (15) to a torque of 15 Nm (Min. 13 - Max. 17).

Position the spark arrestor plate (13) and pay attention to the insertion direction.

Fit the reed valve (12) on cover (11).

Position the secondary air system cover (11) on the vertical and horizontal cylinder head cover, as shown in the figure.

Tighten the screws (17) to a torque of 6 Nm (Min. 5 - Max. 7).

Working on the vertical head, position hose (5) as shown in the figure and fix it with clip (8).

Repeat the operation on the horizontal cylinder head, orienting hose (6) as shown in the figure and fixing it with clip (9).

If previously removed, connect hose (7) to the airbox as shown and fix it with the suitable clip.

Connect the secondary air system sensor to the vertical head through hose (5); repeat the operation with the horizontal cylinder head hose (6) and hose (7) coming from the airbox.

Fix the three hoses with clips (4). Connect the secondary air sensor connector (3).

Fit the lateral cover so that pins (17) engage in their seat (18).

Tighten the screw (2) to a torque of 5 Nm +- 10%.

Removing the secondary air system

Remove the seat (Removing the seat).

Remove the fuel tank (Removing the fuel tank).

Remove the lateral cover (1), loosening screw (2).

Disconnect connector (3) of the secondary air system.

Remove clips (4) and disconnect vertical cylinder pipe (5), horizontal cylinder pipe (6) and airbox pipe (7).

For a better understanding, the image below refers to an engine removed from the frame.

Work on the vertical head and remove clip (8) and disconnect pipe (5).

Repeat the operation on the horizontal head, removing clamp (9) and hose (6).

If necessary, disassemble secondary air system valves following the same procedure for both of them: Loosen the two screws (10) and slide out, in this sequence, cover (11), reed valve (12), spark arrestor plate (13), secondary air plate base (14), the relevant retaining screw (15) and O-ring (16).

Note block off the secondary air system duct on head cover with a clean cloth so as to avoid any impurities from entering the duct.

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