Ducati Diavel Service Manual: Overhaul of the gearbox
Check the condition of the front coupling dogs of the gears. They must be in perfect condition and with no sign of wear on the edges of the teeth.
The idler gears must rotate freely on their shafts.
When refitting, make sure the circlips are correctly positioned.
Check the needle roller bearings for wear.
The threads and splines of the shafts must be in perfect condition.
Also check that the component parts of the gear selector mechanism are in good condition.
Engage
Engage the gears and check that the gearchange mechanism does not stick (selector fork - gear groove, and fork pin - desmodromic drum groove) due to incorrect end float. Restore the correct end float by shimming the gearbox shafts and the selector drum with suitable shims.
For the total gearbox shaft and selector drum end clearance values, refer to sect. 3 - 1.1, Gearbox.
Disassembly of the gearbox shafts
Place the shaft in a vice in such a way as to facilitate the disassembly
operations.
Important
Take care not to invert the positions of the shims on reassembly:
this would potentially lead to jam ...
Inspection of the gear selector forks
Visually inspect the gear selector forks. Bent forks must be renewed as they
may lead to difficulties in gear changing or
may suddenly disengage when under load.
Use a feeler gauge to check the ...
Other materials:
Warning indication (alarms/signals)
The dashboard activates in real-time some warnings / malfunction that are not
dangerous for the correct operation of the
vehicle.
At key-on (at the end of the check) one or more "warnings" are displayed if they
are active.
When a "warning" is triggered, the indication (amber yellow) remai ...
Refitting the engine
Refitting is the reverse of removal.
Important
Apply recommended grease and tighten the special screws (6) to a torque of
60 nm +/- 5% (sect. 3 - 3, Frame torque
settings).
Tighten the nuts (3) to a torque of 48 nm +/- 5% (sect. 3 - 3, Frame torque
settings).
Warning
For the assembly seque ...
Removing outer components
Note
The following removal operations are required in order to renew and/or
clean the crankcase halves. If the original
crankcase halves are to be reused, then the removal of these components is not
essential.
Unscrew the screw (17) and remove the oil breather valve (1) with the o-rings
...