Ducati Diavel
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Ducati Diavel Service Manual: Reassembly of structural components and the frame

Ducati Diavel Service Manual / Chassis / Frame inspection / Reassembly of structural components and the frame

Check for the nuts with clips (8).

Reassembly of structural components and the frame


Apply recommended grease on the threads of the adjusters (4) and the ring nuts (5) having care not to have grease on the surface (c) of the adjusters.

Tighten the adjusters on the ring nut side opposite to that featuring flats until bringing the surfaces as close as possible as shown.

Reassembly of structural components and the frame


Start (form the frame external side) the adjusters (4) in the bushes (d) on frame (1).

Tighten to torque of 0.6 Nm +/- 10% (sect. 3 - 3, Frame torque settings) the adjusters (4), until they come out (on the opposite side) of at least 2 mm, as indicated.

Note

If at the specified torque the adjusters should not tighten properly, maybe the adjusters or the frame could be nonconforming.

Loosen the adjusters (4) until bringing the surfaces as close as possible to the bushes internal profiles (d), as shown.

Reassembly of structural components and the frame


Check for the presence of rubber blocks (g) on the tray (23).

Reassembly of structural components and the frame


Note

In case of difficulties upon reassembly of the vibration damping pads (g), it is recommended to use specific lubricant suitable for rubber.

Check for the presence of the rubber pads (t) on the tray (23).

The pads are correctly fitted if the protrusions (p) come out completely on the insertion opposite side.

Reassembly of structural components and the frame


Reassembly of structural components and the frame


Check for the presence of clips (22) and make sure they are fitted aligned with the holes in the gloves compartment (23) front side, as shown in the figure.

Note

The threaded holes of the clips (22) must be perfectly aligned with the holes on the gloves compartment.

Reassembly of structural components and the frame


If removed, insert the rear handgrab (17) fully home through the opening in the gloves compartment (23) as shown.

Note

While inserting the component, make sure to push it past the stop tab (y) without hitting it.

Reassembly of structural components and the frame


Position the spacers (39) at the threaded inserts of the gloves compartment (23).

Reassembly of structural components and the frame


If previously removed, insert pin (30) on spring (31); position the spring (31), together with the pin (30), in the specific seat of the handle (32) guide as indicated.

Insert the screw (38) on knob (33), by orienting the latter as indicated.

Apply prescribed threadlocker on the screw thread (38).

Push down the pin (30) and start the screw (38) on the opposite side.

Tighten the screw (38) to a torque of 5 nm +/- 10% (sect. 3 -3, Frame torque settings).

Reassembly of structural components and the frame


Fit block (32) starting the screws (34) and making sure that the spacers (39) stay in place, centred with the relative threaded inserts.

Tighten the screws (34) to a torque of 20 nm +/- 5% (sect. 3 - 3, Frame torque settings), following a cross-pattern sequence.

Reassembly of structural components and the frame


Place the clips (26) on the tabs (j), fix them starting the screws (25) and tighten the screws to the torque of 2 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Reassembly of structural components and the frame


Position the nut (37) in the suitable seat on the compartment (23).

Fit the immobilizer antenna (36) as shown and tighten the screw (35) on nut (37) to the torque of 2 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Fix the immobilizer antenna wire to the compartment using the three self-locking tie wraps.

Reassembly of structural components and the frame


Reassembly of structural components and the frame


Start the screw (29) on the pin (21).

Place the tank supporting pad (28) in its seat on the gloves compartment (23) and insert the pin until bringing the screw (29) you started before fully home against the compartment (23).

Start the other screw (29) on the free end of the pin (21) and tighten the screw to a torque of 10 nm +/- 10% (sect. 3 - 3, Frame torque settings) holding the screw (29) on the opposite side.

Reassembly of structural components and the frame


Check the presence of the clip (e) on the left plate of the rear subframe (3).

If the blackbox had been removed from the left plate of the rear subframe (3), on refitting start the silent blocks (f) on the plate (3) and tighten them until fully home. Insert the safety washers (l) on the threaded pins of the silent blocks (f).

Reassembly of structural components and the frame


Fit the blackbox supporting bracket (m) starting the nuts (n). Tighten the nuts (n) to a torque of 2 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Reassembly of structural components and the frame


Set the blackbox (q) on the stud bolts (r) of the blackbox supporting bracket (m).

Reassembly of structural components and the frame


Fit the blackbox cover (s) starting the screws (u) and tighten the screws (u) to the torque of 3 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Reassembly of structural components and the frame


Checking the frame
Check the dimensions of the frame against the dimensions shown here to determine whether it needs to be realigned or renewed. Important Damaged frames must be changed, not repaired. Any work carr ...

Reassembling the frame and the lateral footrests
Apply the recommended grease to the thread of the pins (9) and of the nuts (8). Place the frame (1) and the brackets (2) and (3) on the engine block. Start the pins (9) by holding the nuts (8) ...

Other materials:

Draining the clutch hydraulic circuit
Warning Clutch fluid will damage painted surfaces if spilled on them. It is also very harmful if it comes into contact with the skin or with the eyes; in the case of accidental contact, wash the affected area thoroughly with plenty of running water. Remove the dust cap to expose the bleed val ...

Refitting the cylinder heads pulleys/fixed tensioners
Check that the keyway on the end of the camshaft is in good condition and without burrs. Fit a woodruff key (b) in the keyway of each camshaft. Fit the pulley (11) on the camshaft, inserting the woodruff key in the in the slot (c) in the pulley. Apply the recommended grease to the t ...

Removal of the timing gears
Slide out driving gear (a) of timing gear pair (13) and remove the woodruff key (14). Relieve the staking on the lock washer (12) of the nut (11). Restrain the driven timing gear by inserting a pin in one of the holes, and unscrew the nut (11). Remove the nut (11), washer (12) ...

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