Ducati Diavel
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Ducati Diavel Service Manual: Overhaul of cylinder head components

Cylinder heads

Remove any carbon deposits from the combustion chamber and its ducts.

Remove any scale from the coolant ducts.

Check for cracking and inspect the sealing surfaces for scoring, ridges or other damage.

Cylinder heads


Check that the cylinder barrel mating surfaces of the cylinder head are free of carbon deposits and scale. If this is not the case, spread diamond dressing compound (6 to 12 micron thickness) on a reference surface and slide the cylinder head on the surface as shown in the figure until a flat finish is obtained.

Cylinder heads


Valve seats

Visually inspect the valve seats: for cracking or pitting.

Valve seats


Minor damage can be repaired by grinding with special 45 and 60 single-blade grinders. Grind the valves and check the seal.

Valve seats


If the valve seats are excessively damaged, fit oversize seats. Replacement seats are available with 0.03 And 0.06 Mm oversized outside diameters.

Important

When you change the valve seats, change the valve guides as well.

Proceed as follows.

Remove the worn seats, grinding carefully to avoid any damage to cylinder head bores.

Check the diameter of head bores and choose the oversized valve seat that will give an interference fit of 0.04 To 0.10 Mm.

Valve seats


Heat the cylinder head gradually and evenly up to 150 C and chill the new valve seats in dry ice.

Drive the seats perfectly square into the head bores using the appropriate valve guide seat installer 88713.2846 And 88713.2847.

Allow the cylinder head to cool down and grind the seats to the following dimensions: ca = ø 41.6 +/- 0.025 Mm.

Cs = ø 33.6+/-0.025 Mm.

S = 1.2 Mm.

D = 0.2 To 0.4 Mm.

Important

Do not use any lapping compound after final grinding.

Valve seats


It is advisable to smooth the joint between the intake valves seats and the intake ducts (f = before; g = after).

Valve seats


Valve guides

Check internal surface of the valve guides: for cracking or distortion.

Valve guides


Thoroughly check the dimensions of the inner surface of the valve guide. Measure the inside diameter with a bore diameter gauge.

Measure the diameter at different positions of the valve guide.

Valve guides


The assembly clearance must be: highest measured value - lowest measured value = 0.03 To 0.045 Mm; the maximum permissible wear limit is 0.08 Mm.

Change the valve guides when the ovality exceeds permissible limit or the clearance to the valve stem is outside the tolerance range.

When you change the valve guide, you must also change the valve.

Valve guides as spare parts are available with outside diameter oversized by 0.03, 0.06 And 0.09 Mm.

Change the valve guides as follows:

A= 22.4+/-0.15 Mm.

B= 28.45+/-0.15 Mm.

Hone the mating surface with a reamer.

Valve guides


Checking the valve

Check that the stem and the valve seat contact surface are in good condition.

There must be no pitting, cracks, deformations or signs of wear.

Warning

The valves cannot be ground.

Checking the valve


Perform the following checks.

Measure the diameter of the valve stem at various points along the section that runs in the valve guide.

Checking the valve


Check the valve stem for buckling. Place it on a "v" block and measure deformation with a dial gauge.

Service limit: 0.053 Mm.

Check the valve stem for buckling. Place valve on a "v" block, set a dial gauge perpendicular to head and measure runout of valve face at 45.

Checking the valve


Use prussian blue or a mixture of minimum and oil to check that the contact surface (w) between the valve and seat is 1.4 To 1.6 Mm (1.05 To 1.35 Mm when new). Grind the seat if the dimension measured is greater than the above limit.

Checking the valve


Checking the valve


Checking the valve seal

After grinding the seats it is important to check the seal between the valve face and the seat: if the seat contact area (s) on the valve is wider than the 45 band (w) this could lead to poor sealing.

Checking the valve seal


Checking the rocker arms

Check for signs of wear, grooves or chrome flaking off.

Check the condition of rocker arm bore and shaft.

Assembly clearance: 0.025 To 0.049 Mm.

Wear limit: 0.08 Mm.

Checking the rocker arms


Checking the rocker arms


Opening and closing shims - springs

Check the condition of the contact surfaces of the valve opening and closing shims: there must be no signs of wear.

Check the condition of the closing rocker arm return springs: check for cracking, distortion, or loss of elasticity.

Opening and closing shims - springs


Removing the valve rocker arms
With the cylinder head in the condition described in the previous paragraph, remove the rocker arms. Unscrew the eight plugs (12) and recover the seals (15). Using an m6 screw, withdraw ...

Reassembly of the cylinder head
The exhaust side can be identified by the three threaded holes on the flange. The intake side can be identified by the presence of four threaded holes on the flange. All the photos in this ...

Other materials:

Reassembly of the control unit
Insert the control unit (4) into the protecting sheath (5) and position it on the airbox. Position the relay supporting bracket (2) by starting and tightening the screws (1) to a torque of 6 nm +/- 10% (sect. 3 - 3, Frame torque settings), and connect the control unit connectors (3). ...

Overhauling the front brake components
Important Critical safety components. The brake calliper manufacturer recommends that you do not attempt to service the internal components of the brake callipers. Incorrect overhaul of this component could endanger rider safety. Operations should be limited to renewal of the pads, fasteners ...

Lap registration function
This function describes the "lap" time registration. If the function is activated (see "lap activation/deactivation description), the lap time can be registered as follows: pressing the flash headlight button (6) the first time starts the "lap timer" for the first lap, and the dashboard show ...

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