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:
Removal of the timing belt covers
Loosen the screws (4) securing the central external cover (1) and remove it
from the central side.
Undo the fixing screws (4) of the external cover (25) and remove it from the
vertical thermal unit.
Undo the fixing screws (4) of the external cover (3) and remove it from the
horizonta ...
Reassembly of the oil pump
Check that the circlip (3) and tongue (13) are present on the pump.
Fit the pump drive gear (12) on to the oil pump and secure it by installing the
circlip (6) in its groove.
Insert the by-pass valve pump (17), the spring (16) and screw the plug (14).
Tighten the plug (14) to a torque of ...
Distance travelled on fuel reserve: trip fuel
This function shows the distance travelled on fuel reserve (in km or miles
depending on the specific application).
When the fuel light comes on, the display automatically switches to the "trip
fuel" indicator.
Trip fuel reading remains stored even after key-off until the vehicle is
refue ...