SRV-TSB-18-019

CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
Date:
To:
From:
January 10, 2019
All required parties in descending order, Dealer Principal, General Manager, Service
Manager, North American Dealer Network
Richard Kenton, Technical Director
Eric Bradley, Technical Training and Publications Manager
Dear Dealers,
Ongoing quality tests and the analysis of our supplier have detected a possible lengthening of
clutch lever stroke.
To rectify the potential condition, it will be required to update the bikes involved in this
Workshop Campaign by replacing the clutch hose with a new part no. 63210852A. This new
clutch hose features an internal diameter of 2 mm (the previous one was 3 mm) and can
prevent the phenomenon described above.
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
Application
You can find the list of VIN numbers involved in CR170 on the DCS, in sections:
VIN HISTORY
CAMPAIGN
You can consult the single frame number.
You can consult all the VIN numbers that Ducati Motor Holding
sent you.
Customer Impact
All bikes in dealer stock (‘to be registered’ or ‘already registered’) and awaiting delivery to final
customers will require this inspection during pre-delivery operations, before delivery to the
final customer. All bikes already delivered to final customers must undergo the below
procedure at the next service appointment. Note: this is not a safety recall.
Parts Distribution
The parts necessary to perform this Workshop Campaign CR170 will not be auto shipped and
must be ordered Individually by VIN
Warranty reimbursement rules
Reimbursement for work associated with this Workshop Campaign will be made through the
regular warranty claim procedure using the “VIN History” section of the DCS. The warranty
claim is pre-filled and is identified as CR170
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
You will be reimbursed for the Parts necessary to complete the operation (clutch fluid hose
Part no. 63210852A,4 copper washers Part no. 85250241A), and 36 minutes (6 labor units)
labor time that includes the time necessary for:








Vehicle reception
Disassembly of battery cover, side fairing and LH air extractor
Removal of clutch fluid hose
Installation of the new clutch fluid hose p/n 63210852A with the 4 copper washers p/n
85250241A
Procedure for clutch system bleed;
Compensation for the cost of Castrol REACT PERFORMANCE DOT 4 oil (or equivalent)
Assembly of LH air extractor, side fairing and battery cover
Soft cleaning of the motorcycle
Table of Contents
Introduction
Page
1
Application
2
Customer Impact
2
Parts Distribution
2
Warranty Reimbursement
2
Spare Parts
4
Service Solution
4
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
Spare Parts
The components to be used for this update are:
Part no.
Description
Photo
Quantity (pcs)
63210852A
Clutch fluid hose Ø 2 mm
1
85250241A
Copper washers
4
(Sourced locally)
Self-locking tie
2
Service Solution
NOTE
To ensure the correct execution of the operation within the provided labor time to
carry out the updates, it is necessary to follow the sequence indicated in the following
instructions
1. Position the bike on the rear paddock stand
2. Remove battery cover and LH fairing (See Sec.5: "Fairing installation - Fairing" of the
Workshop Manual)
3. Remove the M5x12 screw (1) with washer (2) and slide out LH air extractor (3) in order to
disengage the 2 vibration dampers (4) from the pins (5) present on frame
4. Remove the self-locking tie (6) and release clutch cable (7) from the relevant cable guide
(8) present on LH air extractor
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
5. Mark the clutch master cylinder unit with a felt-tip pen as shown in the figure to identify
the correct position of clutch hose union upon assembly
6. Crimp the connection pipe between fluid reservoir and clutch master cylinder using hose
clamp pliers (9) as shown in the figure
NOTE
This enables isolating the clutch fluid reservoir from the circuit, preventing all fluid
from flowing out of the system
7. Remove the L.39 mm button tie (10) joining clutch hose (11) to clutch switch cable (12) and
wiring (13) of left-hand switch
8. Remove self-locking tie (14) securing clutch hose (11) to the radiator duct
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
9. Remove the special screw (15) with washer (16)
NOTE
This operation facilitates ease of removal and subsequent installation of the clutch
hose on the vehicle
10. Remove union screw (17) and the 2 copper washers (18) securing clutch hose to master
cylinder body
NOTE
Protect the concerned areas with a cloth to prevent the fluid inside the circuit from
touching the various components of the bike. Damage to other components due to
brake fluid exposure resulting from improper repairs will not be covered by warranty.
WARNING
The clutch fluid is harmful in case of contact with your eyes or skin. Wash the affected
area with plenty of water in case of accidental contact.
11. Remove dust protection cap (19) of bleed valve
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
12. Remove union screw (20) and the 2 copper washers (21) securing clutch hose to clutch
actuator unit
13. Remove clutch hose (11)
14. Bring the new clutch hose (A) Part no. 63210852A
NOTE
The new clutch hose (A) P/n 63210852A differs from the old one for “2 mm” value of
internal diameter stamped outside the hose itself as shown in the figure
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
15. Install the new clutch hose (A) on the bike as shown in the figure
NOTE
The union with the notch (23) must be positioned on the clutch actuator unit
16. Install the L.39 mm button tie (10) joining clutch hose (A) and clutch switch cable (12) and
wiring (13) of left-hand switch
17. Install the new self-locking tie (B) joining clutch hose (A) to the radiator duct on the
grommet present on the hose, as shown in the figure
18. Tighten the special screw (15) with the relevant washer (16) to6 Nm ± 10%
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
19. Insert the union screw (17) with the 2 new copper washers (C) on the clutch control hose
union and position it on the previously marked point on the master cylinder body as shown
in the figure
20. Tighten the union screw (17) to 27 Nm ± 5% and delete the mark previously made with the
felt-tip pen
21. Insert the union screw (20) with the 2 new copper washers (C) on the clutch control hose
union as shown in the figure and position it on the clutch actuator unit
22. Tighten the bleed screw (20) to 27 Nm ± 5%
NOTE
Check that there is NO contact between the clutch control hose union and the
sprocket cover as shown in the figure
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
23. Remove the service pliers (9)
24. Remove the cap (24) of clutch fluid reservoir, the baffle (25) and the diaphragm (26)
25. Mark the initial fluid level with a tap indicator as shown in the figure
26. Bleed the clutch system first at the bleed valve of the clutch actuator unit and then at the
clutch master cylinder bleed valve
26.1 Insert the wrench (27) in the bleed valve key of the clutch actuator unit
26.2 Fit the hose (28) of the bleeder vessel on the bleed valve
26.3 Slacken the bleed valve and pump the clutch lever, while regularly filling the reservoir
so that the fluid level never goes below the half of the reservoir
26.4 Pump the clutch lever until you no longer see air bubbles coming out of the bleeder
hose
26.5 Remove the hose and the wrench, tighten the bleed valve (29) to 6 Nm ± 10% and fit the
bleed cap (19)
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
27. Repeat the procedure by operating on the bleed valve (30) of the clutch master cylinder as
explained previously
28. Tighten the bleed valve (30) to a torque of 14 Nm ± 10% and fit the bleed cap (31)
29. Top up the clutch fluid reservoir until reaching the level indicated by the reference arrow
and remove the adhesive tape
30. Flush the diaphragm, the baffle and the cap with WATER and dry with compressed air
31. Install in the following sequence
31.1
Install the diaphragm (26) aiming it as shown in the figure
31.2
Install the baffle (25) aiming it as shown in the figure
31.3
Install and turn the cap (24) clockwise
31.4
Tighten cap (24) to 1.5 Nm
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
32. Before assembling the LH air extractor (3), insert the clutch cable (A) inside the cable guide
(8) and tie the clutch hose to the air extractor with a new self-locking tie (D) as shown in the
figure
33. Install the LH air extractor (3) by inserting the 2 pins (5) present on frame inside the
relevant vibration dampers (4) on the air extractor and tighten the M5x12 screw (1) with
washer (2) to 2.5 Nm ± 10%
WARNING
Once the LH air extractor has been assembled, make sure that the expansion reservoir
breather tube does NOT show any kinking, as shown in the figure
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CR170 – Clutch Hose Replacement
Panigale V4 - Panigale V4 S - Panigale V4 Speciale
Technical Service Bulletin SRV-TSB-18-019
34. Install LH side fairing and battery cover (See Sec.5: "Fairing installation - Fairing" of the
Workshop Manual)
35. Remove the bike from the rear paddock stand
For Questions and information about this Technical Service Bulletin,
Contact your regional Service Area Manager
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