Ducati Diavel Service Manual: Removal of the gearbox assembly
Withdraw the selector fork shafts (30).
Move the forks (28) and (29) to disengage them from the slots in the selector drum (14).
Withdraw the selector drum (16) taking care not to lose shims (31) and (27) mounted on the shaft. Note that the positions of the shims must not be inverted.
Once removed, it is possible to replace the special rollers (13).
Remove gear selector forks (29) and (28).
Remove
Remove the gearbox primary (2) and secondary (25) shafts complete with gears, taking care to recover the spacers on the ends of the shafts.
If the bearing inner rings (a) are left on the shafts, slide them off the ends of the gearbox primary (2) and secondary (25) shafts (sect. 9 - 9.2, Separation of the crankcase halves).
Gearbox shafts
Shim, thickness 1
Gearbox primary shaft
Shim, thickness 0.5
Needle roller bearing
5Th speed driving gear
Splined washer, thickness 0.5
Circlip
3Rd- 4th speed driving gear
6Th sp ...
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 ...
Other materials:
Key-on/key-off using the red key on the handlebar with the active key
A key-on can be performed by pressing the red key (6) on
the handlebar in the hands free on/off position and in
the presence of the active key (3, fig. 77).
Note
The active key (3, fig. 77) Has a range of approx. 1.5 M,
therefore it must be located within this range.
Key-off can be performed ...
Overhaul of the connecting rods
Make the following dimensional checks on the connecting rods:
Clearance with gudgeon pin on assembly.
In the event of excessive wear (sect. 3 - 1.1, Crankshaft), replace the
connecting rod.
The small end bushing must be in good condition and firmly driven into its seat.
Check for para ...
Refitting the oil pump
If removed, apply specific threadlocker on the bushing (7) outer thread, and
screw it in the crankcase half, observing the
height.
Position the reference bushings (15) and the oil sealing o-rings (2) and (4)
according to the crankcase lubrication
channels.
Position the oil pump on th ...