Ducati Diavel Service Manual: Reassembly of the gearbox shafts
Figure 1 shows all the parts to be reassembled on the gearbox primary shaft (2), with the calculated end shims (1) and (11) (sec. 9 - 9.2, Reassembly of the crankcase halves).
Figure 2 shows all the parts to be installed on the gearbox secondary shaft (25), with calculated end shims (15) and (26) (sec. 9 - 9.2, Reassembly of the crankcase halves).
Reassemble the gears on the gearbox shafts by reversing the disassembly procedure.
Take particular care when installing the idler gears. The assembly of the 3rd and 4th speed gears and the relative fixing components on the secondary shaft is given as an example.
Fit the circlip (7), checking that it is fully inserted into its groove on the shaft. Push the circlip into position with a suitable size tubular drift.
Slide the washer with three internal points (6) over the shaft until it locates against the circlip you have just fitted.
To fit the needle roller cage (4) onto the shaft, first lubricate it with plenty of grease (of recommended type) and then open it slightly to make it easier to slide on to the shaft.
Fit the 3rd speed gear (22).
Fit on the gear the three-pointed washer (12), which can be distinguished from its counterpart (6) by its bigger outside diameter.
Fit another needle roller cage (4) using the method already described.
Fit the 4th speed gear (21).
Fit another safety washer (6) and another circlip (7) into the shaft. Push it inside its seat using the previously used pad.
Inspection of the gear selector drum
Use a gauge to measure the clearance between fork pin and the slot on the
selector drum.
If the service limit is exceeded, determine which part must be replaced by
comparing these dimensions wi ...
Reassembly of the gearbox
To refit the gearbox components follow the procedure under sect. 9 - 9.2,
Reassembly of the crankcase halves, relating to
reassembly of the engine crankcase.
As a final practical test, ensure th ...
Other materials:
Adjusting the rear shock absorber
The adjuster (1) located on the lower connection holding the shock absorber
to the swingarm adjusts the damping during
the rebound phase (return).
The knob (2), located on the left side of the motorcycle, adjusts the preload of
the shock absorber external spring.
Turn the adjuster (1) clock ...
Removal of the fuel tank filler cap
Remove tank covers (sect. 5 - 2, Removal of the fuel tank fairings).
Remove hoses (8) and (15) from the filler cap assembly (10).
Open the filler cap.
Unscrew the outer screws (17) securing the ring nut to the filler cap recess.
Remove the filler cap assembly (10).
...
Removal of the gearbox assembly
Withdraw the selector fork shafts (30).
Move the forks (28) and (29) to disengage them from the slots in the selector
drum (14).
Withdraw the selector drum (16) taking care not to lose shims (31) and (27)
mounted on the shaft. Note that the
positions of the shims must not be inverte ...