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Ducati Diavel Service Manual: Reassembly of the crankcase halves

Ducati Diavel Service Manual / Engine / Crankcase assembly / Crankcase halves / Reassembly of the crankcase halves

If removed, apply threadlocker on the screw (36), insert it with the washer (37) on the crankcase half and tighten it to The torque of 8 nm (min. 7 Nm - max. 9 Nm) (sect. 3 - 3, Engine torque settings).

Reassembly of the crankcase halves


If removed, apply threadlocker on the dowel thread (35), tighten it to a torque of 20 nm (min. 18 Nm - max. 22 Nm) (sect. 3 - 3, Engine torque settings).

Reassembly of the crankcase halves


If removed, apply threadlocker on the plug (19), and tighten it to a torque of 24 nm (min. 21 Nm - max. 27 Nm) (sect. 3 - 3, Engine torque settings).

Reassembly of the crankcase halves


Install the o-ring (32) on its seat (a) in the crankcase half. Fit the pipe (33) in the crankcase half, inserting the end (b) fully in the o-ring. Align the hole (l) of the pipe with the threaded hole (m) in the crankcase half. Apply threadlocker to the screw (34) and start it in the threaded hole (m). Tighten the screw to a torque of 8 nm (min. 7 Nm - max. 9 Nm) (sect. 3 - 3, Engine torque settings).

Reassembly of the crankcase halves


Install the timing belt driveshaft (30) in the roller bearing (4) in the clutch-side crankcase half.

To avoid damaging the oil seal (14) on the timing belt driveshaft, protect the threaded end of the shaft with the special protective cap 88700.5749. Dampen oil seal (14) with alcohol and fit it on the timing layshaft. Push seal until it contacts the roller bearing (4).

Fit the circlip (29) in the groove on the shaft and remove the protective cap.

Reassembly of the crankcase halves


Reassembly of the crankcase halves


Note

When refitting used components, before installing the gearbox assembly in the crankcase half, make sure that the inner races (c) of the gearbox shaft bearings are fitted into the correct bearings and have not been left on the shafts.

Match gearbox shafts, fit the shims and fit them to the clutch-side crankcase half.

Reassembly of the crankcase halves


Reassembly of the crankcase halves


Note

A table and a list of the gearbox components appear in sect. 9 - 7.2, Reassembly of the gearbox shafts.

Insert the forks of 1st- 4th and 2nd- 3rd speed (d) in the corresponding sliding slots of the secondary shaft driven gears and insert the pin (g) in the forks: the two forks must be fitted with the number that indicates the gear facing upwards.

Note

The two selector forks are identical.

Reassembly of the crankcase halves


Reassembly of the crankcase halves


Insert the fork of 5th- 6th speed (e) in the primary shaft driven gear and the pin (g) in the fork (e): the fork must be fitted with the number indicating the gear facing the crankcase half.

Position the pin (g) of the forks (d) in the crankcase half. Holding the gear lever claw, position the gear drum (f) in the crankcase half.

Position the pin (g) of the fork (e) in the crankcase half.

Reassembly of the crankcase halves


Install the crankcase with calculated shims in the crankcase half bearing: the shims (r) of the shaft must be placed with the chamfering facing the shaft. Position the connecting rods (h) matching the corresponding seats of the cylinder.

Important

Make sure that the connecting rods (h) are correctly positioned in the cylinders. Incorrect positioning of the connecting rods at this stage will inevitably lead to the need to re-open the crankcase halves.

Reassembly of the crankcase halves


Reassembly of the crankcase halves


Reassembly of the crankcase halves


Check that the two locating bushes (22) are correctly fitted.

Grease the o-ring (31) to hold it in position and install it.

Apply a uniform and continuous bead of ducati liquid gasket to the mating surfaces of the crankcase halves, going around all the holes as shown in the figure.

Reassembly of the crankcase halves


Reassembly of the crankcase halves


Bring the crankcase halves (3) and (13) together, tapping with a rubber mallet in the area of the shafts if necessary.

Reassembly of the crankcase halves


Apply the recommended grease to the screws and insert them in the crankcase halves (note that the screws are different lengths). Start with the larger diameter screws (m8), and follow the order indicated.


Tighten all screws to the torque indicated below (sect. 3 - 3, Engine torque settings):

Reassembly of the crankcase halves


Reassembly of the crankcase halves


Reassembly of the crankcase halves


Reassembly of the crankcase halves


Reassembly of the crankcase halves


Check that the crankshaft can be turned with a certain amount of interference with the main bearings (the crankshaft should have a pre-load of 0.20 To 0.30 Mm); check also that all the parts you have fitted are free to rotate or move correctly.

Install the cover to reach the mesh filter (sect. 4- 3, Changing the engine oil and filter cartridge).

Install the cartridge filter (sect. 4 - 3, Changing the engine oil and filter cartridge).

Fit the sealing ring (8) on the gear secondary shaft with side (l) to the engine side.

Reassembly of the crankcase halves


Install the bushing of the tool with code 88713.2060 On the secondary shaft. Lubricate the new ring (8) and seat it.

Using the tool's drift, drive the sealing ring fully home so it seats against the crankcase half bearing.

Reassembly of the crankcase halves


Reassembly of the crankcase halves


Shimming the shafts
Before assembling the crankcase halves, calculate the shims required to obtain the correct end float of the crankshaft and gearbox shafts. To determine the correct shim thickness proceed as foll ...

Crankshaft/connecting rods assembly
Special screw Connecting rod assembly Half bearing Grub screw Bushes Crankshaft Grub screw Shim washer Spare parts catalogue Diavel abs connecting rods Diavel carbon abs co ...

Other materials:

Tips for use on the track
We recommend level 8 be used for a couple of full laps (to allow the tyres to warm up) in order to get used to the system. Then try levels 7, 6, etc., In succession until you identify the dtc intervention level that suits you best (always try each level for at least two laps to allow the tyres t ...

Refitting the front footrests
Note The assembly of the front footrests is described only for the right one (2) but it is the same also for the left one. Place the spring (4) bringing the end (a) onto the footrest (2). Place the footrest (2) in the correct position, by inserting the end (c) of the spring (4) in the hole ...

Disassembling the water radiator unit
The procedure is the same for both radiators. Loosen the screws (15), (21) and (25) to remove the air duct (24) from the right radiator (13). Undo the screws (12) and (14) to remove the half-fairing (23) from the radiator. Radiator inspection Visually inspect the oil co ...

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