Ducati Diavel
Free Service and Repair manuals

Ducati Diavel Service Manual: Overhaul of the cylinder barrel/piston components

Ducati Diavel Service Manual / Engine / Cylinder/piston assemblies / Overhaul of the cylinder barrel/piston components

Overhauling the cylinder

Check that the walls of the cylinder bore are perfectly smooth. Measure the cylinder bore diameter at 50 mm from the top face and determine the size class to which it belongs in accordance with the values specified in sect. 3 - 1.1Cylinder/piston. Repeat measurement of the diameter at three heights a (10 mm from the upper surface), b (50 mm from the upper surface) and c (100 mm from the upper surface) and in two direction at 90 between them; check that the measurements of taper and ovality in the bore fall within the range specified in sect. 3 - 1.1, Cylinder/piston.

In the event of damage or excessive wear the barrel must be renewed as it has a silicon carbide coating (which provides the cylinder walls with excellent anti-friction and anti-wear properties) and therefore cannot be rebored.

The cylinder barrels are marked with letters (stamped between two oil return ways) indicating their size class.

Always match cylinders with pistons from the same size class.

Overhauling the cylinder


Overhauling the cylinder


Overhauling the cylinder


Overhaul of the piston

Clean the piston crown and piston ring grooves, removing any carbon deposits.

Inspect the piston and check its dimensions carefully: there must be no signs of scuffing, scoring, cracks, or other damage.

The piston diameter must be measured at 7.5 Mm up from the bottom of the skirt and in perpendicular direction to the pin axis.

The pistons must always be renewed as a pair.

Overhaul of the piston


Overhaul of the piston


Checking the piston-cylinder clearance

The pistons are marked with a letter (punched into the piston crown) that indicates the size class to which they belong.

Always match cylinders with pistons from the same size class.

The prescribed values are given in sect. 3 - 1.1, Cylinder/piston.

Checking the piston-cylinder clearance


Overhauling the gudgeon pins

Gudgeon pins must be perfectly smooth without signs of scoring, steps, or blueing due to overheating. The well-lubricated gudgeon pin must slide smoothly inside the piston without stiffness.

Coupling clearance values with the piston and the connecting rod, see sec. 3 -1.1, Cylinder/piston.

If a new gudgeon pin is fitted, you must also change the connecting rod small end bush.

Overhauling the gudgeon pins


Overhauling the gudgeon pins


Overhauling the piston rings

The piston rings must not show any signs of scuffing or scoring. Replacement pistons are supplied complete with piston rings and gudgeon pin.

Overhauling the piston rings


Checking the piston ring-grooves clearance

The maximum permissible wear limit is 0.15 Mm for the top segment (1st) and 0.10 Mm for the others (2nd and oil scraper ring).

The piston rings must always be installed with markings facing upwards.

Checking the piston ring-grooves clearance


Checking the piston ring-grooves clearance


Checking the piston ring-grooves clearance


Checking the piston ring-grooves clearance


Checking the piston ring/cylinder clearance

Insert the ring in the cylinder bore so that it is positioned 50 mm from the top face of the cylinder barrel; make sure that the ring is positioned perfectly square to the cylinder walls by checking with a gauge at several points around the ring that the top surface of the ring is exactly 50 mm from the top face of the cylinder barrel.

Measure the piston ring gap (a):


Checking the piston ring/cylinder clearance


Checking the piston ring/cylinder clearance


Removal of the cylinder/piston assembly
Loosen the clamps (7) and remove the hoses (8) and (9) from the cylinder barrels (10) and from the alternator-side crankcase cover. If damaged, unscrew the unions (6). Note T ...

Refitting the cylinder/piston assembly
If new units are used, it is necessary to couple the cylinders and pistons of the same selection (see paragraph "overhaul Of the cylinder barrel/piston components" of this section). If the pist ...

Other materials:

Refitting the starter motor gear
Position the washer (20) and the gear (19) in the pin (21) and take the pin into contact with the crankcase half. ...

Routing of wiring on frame
The routing of the wiring has been optimised to ensure the minimum obstruction. Each section is designed to prevent interference with parts that might damage wires or cause operating failures when riding. The plates on the following pages show the origins ("0" points) for correct re-routin ...

Evaporative emissions canister
Sealing washer Union Hose clip Hose Clamp "T" fitting Hose Support Special screw Rubber mounting Hose Hose clip Evaporative emissions canister Hose Spring Spare parts catalogue Diavel abs evaporative emissions canister Diavel carbon abs evaporative emissions ...

2021 | www.dudiavel.com |