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Ducati Diavel Service Manual: Overhaul of the flywheel-alternator assembly

Ducati Diavel Service Manual / Engine / Flywheel - alternator / Overhaul of the flywheel-alternator assembly

Examine the inner part of alternator rotor (24) for signs of damage. Check that the starter clutch is working properly and that the needle races do not show signs of wear or damage of any kind. If there is any malfunction, remove the whole assembly.

Overhaul of the flywheel-alternator assembly


Disassembling the generator flywheel

Unscrew the 8 screws (26) and remove the rotor (24) from the flywheel.

Disassembling the generator flywheel


Insert two of the screws (26) just removed from the flywheel rotor-side in their holes in order to remove the flange (14) and the starter clutch (22) from the flywheel (17). The starter clutch is a slight interference fit on the flange. To remove it, use a suitable drift.

Disassembling the generator flywheel


Disassembling the generator flywheel


Reassembling the flywheel - generator assembly

Install the starter clutch (22) in the flange (14) to bring the edge (a) of the clutch up against the flange.

Important

Assemble the components (starter clutch and flange) so that the edge (a) of the starter clutch is positioned on side of the flange with the bevelled edge (b).

Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Seat the flange (14) with the starter clutch (22) in the flywheel (17), aligning the flange locating hole (c) with the flywheel locating hole (d).

Note

The flange locating hole (c) is the hole with the countersunk lead-in (e).

Note

The locating hole (d) of the flywheel can be either one of the two holes (f).

Note

Use suitable tools to align the locating holes.

Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Important

Assemble the components (flange and flywheel) so that edge (a) of the starter clutch (22) is enclosed between the flange and flywheel.

Reassembling the flywheel - generator assembly


Install the rotor (24) on the flywheel (17), aligning one of the flywheel locating holes (d) with the rotor locating hole (g).

Note

The rotor locating hole (g) is the hole positioned on the same diameter as the fixing holes (h).

Note

Use suitable tools to align the locating holes.

Apply threadlocker to the rotor-flywheel fixing screws (26) and start them in their threads.

Tighten

Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Tighten the screws (26) to a torque of 13 nm (min. 11 Nm - max. 15 Nm) (sect. 3 - 3, Engine torque settings) following the sequence above.

Reassembling the flywheel - generator assembly


Lubricate the surface (l) of the driven gear (21) with engine oil.

Install the driven gear on the starter clutch, ensuring it is properly seated.

Note

To facilitate installation, rotate the driven gear in the direction of the green arrow.

Hold the flywheel (17) with one hand and check that the driven gear can rotate freely in the direction of the green arrow but not in the direction of the red arrow.

If either of these two conditions is not met, this means that the starter clutch has not been installed correctly.

Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Removing the flywheel - generator assembly
Use the tool 88713.3367 Fixed to the m10 side stand fixing holes (d). Secure the tool to the flywheel with the screws (e). Unscrew the alternator-flywheel retaining nut (15). Warning While uns ...

Refitting the flywheel-alternator assembly
Fit the roller cage unit (20) with washer (18) and internal ring (19), applying prescribed grease on the washer (18). Install the roller cage assembly (20) with the washer (18) and inner race ...

Other materials:

Changing the coolant
Warning This operation must only be carried out when the engine is cold. Attempting to change the coolant with the engine hot could lead to burns from hot coolant or scalding steam. Place a container under the engine and place the motorcycle on its side stand. Remove the expansion reserv ...

Key-on/key-off using the red key on the handlebar with the passive key
A key-on can be performed by pressing the red button (6) on the handlebar in the hands free on/off position and in the presence of the passive key (4, fig. 77). Note The passive key (4, fig. 77) Has a range of a few cm, therefore the key (4, fig. 77) Must be positioned near the antenna (2). R ...

Lcd unit functions
Speedometer. Gives road speed Rev counter. Indicates engine revs per minute. Clock. Water temperature indicator. Indicates engine coolant temperature. Important Stop riding if the temperature reaches the maximum value, otherwise the engine might be damaged. ...

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