Ducati Diavel Service Manual: 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.
Withdraw the first speed driven gear (18) with the roller cage (17) and the shim (19).
Remove the fifth speed driven gear (20).
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).
Withdraw the fourth speed driven gear (21) with the roller cage (4) and splined washer (12).
Remove the
Remove the third speed driven gear (22) with the roller cage (4) and the splined washer (6).
Remove the circlip (7) and remove the sixth speed driven gear (23).
Remove
Remove the circlip (7) and withdraw the splined washer (6) and the second speed driven gear (24).
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 primary shaft
Remove the chain-side shim washer (11) and the clutch-side shim washer (1) from the 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).
Remove the sixth speed driving gear (9) with its roller cage (4). Remove the splined washer (6) and the circlip (7).
Withdraw the third and fourth speed driving gear (8).
Remove the circlip (7) and the splined washer (6).
Remove the fifth speed driving gear (5) with the roller cage (4).
Slide the shim (3) off the primary shaft (2).
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:
Key-on/key-off using the pin code (immobilizer release)
Key-on can be performed by pressing the button (7) on the
hands free lock (1, fig. 77) Without the presence of the keys
(3, fig. 77) And (4, fig. 77) And entering the pin code on the
dashboard.
Key-off can be performed by pressing the button (6) on the
handlebar / hands free key (7) / engine ...
Removing the water radiators
Loosen the screws (p) that retain the supports (s) of the front splashguard
to the air ducts (24) and (26).
Loosen the screws (30), to separate the two internal air ducts (24) and (26).
Disconnect the wiring connectors of the main wiring loom (c) from both fans.
Disconne ...
Refitting the clutch master cylinder assembly
Insert the clutch master cylinder assembly (3) and the clamp (6) on the left
handlebar, so that the top mating faces
match the mark (z) on the handlebar as shown.
Couple terminal (6) to the clutch master cylinder control and fix them with
the screws (v).
Tighten the retaining screws ...