Ducati Diavel
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Ducati Diavel Service Manual: Disassembly of the gearbox shafts

Ducati Diavel Service Manual / Engine / Gearbox assembly / Gearbox shafts / 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 jamming when using the gear selector control, making it necessary to reopen the engine crankcase.

Disassembly of the gearbox secondary shaft

Remove the chain-side shim washer (26) and clutch-side shim washer (15) from the secondary shaft.

Disassembly of the gearbox secondary shaft


Withdraw the first speed driven gear (18) with the roller cage (17) and the shim (19).

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Remove the fifth speed driven gear (20).

Disassembly of the gearbox secondary shaft


Use two flat blade screwdrivers to remove the circlip (7) taking care not to damage the shaft surface.

Remove the circlip (7) and the splined washer (6).

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Withdraw the fourth speed driven gear (21) with the roller cage (4) and splined washer (12).

Remove the

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Remove the third speed driven gear (22) with the roller cage (4) and the splined washer (6).

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Remove the circlip (7) and remove the sixth speed driven gear (23).

Remove

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Remove the circlip (7) and withdraw the splined washer (6) and the second speed driven gear (24).

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Withdraw the roller cage (4) and the shim (3). All the components have thus been removed from gearbox secondary shaft (25).

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Disassembly of the gearbox primary shaft

Remove the chain-side shim washer (11) and the clutch-side shim washer (1) from the primary shaft.

Disassembly of the gearbox primary shaft


Remove the second speed driving gear (10). Use two screwdrivers to prise out the circlip (7) and the splined washer (6).

Important

Take care to avoid damaging the surface of the shaft while removing circlip (7).

Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Remove the sixth speed driving gear (9) with its roller cage (4). Remove the splined washer (6) and the circlip (7).

Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Withdraw the third and fourth speed driving gear (8).

Disassembly of the gearbox primary shaft


Remove the circlip (7) and the splined washer (6).

Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Remove the fifth speed driving gear (5) with the roller cage (4).

Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Slide the shim (3) off the primary shaft (2).

Disassembly of the gearbox primary shaft


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 s ...

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 sha ...

Other materials:

Final drive
Circlip Nut Washer Nut Rear sprocket flange Cush drive bush Inner ring Chain Spacer Chain cover Screw Nut Lock washer Front sprocket Spacer O-ring Rear sprocket Spare parts catalogue Diavel abs gearbox Diavel abs rear wheel axle Diavel carbon abs gearbo ...

Belly fairing
Rh belly fairing Lh belly fairing Special screw Nylon washer Screw Central belly fairing Oil cooler shield Special screw Clip Washer Clip Screw Bracket Screw Spare parts catalogue Diavel abs belly fairing Diavel carbon abs belly fairing Important Bold refere ...

Removal of the tail light
Disconnect the connectors (a) and (b) of the tail lights (1) and (13). Loosen the screws (4) and slide the tail lights (1) and (13) to the rear side; recover the four spacers (3) and the washers (14). ...

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