Ducati Diavel
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Ducati Diavel Service Manual: 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 shafts.

When refitting, make sure the circlips are correctly positioned.

Check the needle roller bearings for wear.

The threads and splines of the shafts must be in perfect condition.

Also check that the component parts of the gear selector mechanism are in good condition.

Engage

Overhaul of the gearbox


Engage the gears and check that the gearchange mechanism does not stick (selector fork - gear groove, and fork pin - desmodromic drum groove) due to incorrect end float. Restore the correct end float by shimming the gearbox shafts and the selector drum with suitable shims.

For the total gearbox shaft and selector drum end clearance values, refer to sect. 3 - 1.1, Gearbox.

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 jam ...

Inspection of the gear selector forks
Visually inspect the gear selector forks. Bent forks must be renewed as they may lead to difficulties in gear changing or may suddenly disengage when under load. Use a feeler gauge to check the ...

Other materials:

Dashboard menu option scrolling not possible
Fault codes Dds: no fault code displayed Dashboard: no fault code displayed Location of connections and components Location of left hand handlebar switchgear set connection. Pin numbering for wiring harness side dashboard connector. ...

Removal of the exhaust system
Remove the silencer, as described in the paragraph "removing the silencer" of this section. Loosen the screws (28) and remove the exhaust by-pass valve cover (27). Turn the exhaust valve pulley (a) to facilitate the throttle cable (25) output. Release the end fitting (b) of the cable ...

Refitting the rear mudguard
Place the rear mudguard (8) on the swingarm, fitting the screws (9) with recommended threadlocker. The screw (9) in the bottom hole of the rear mudguard (8) must be installed with the washer (r). Tighten the screws (9) to a torque of 5 nm +/- 10% (sect. 3 - 3, Frame torque settings). ...

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