Ducati Diavel
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Ducati Diavel Service Manual: Reassembly of the gearbox shafts

Ducati Diavel Service Manual / Engine / Gearbox assembly / Gearbox shafts / 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).

Reassembly of the gearbox shafts


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).

Reassembly of the gearbox shafts


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.

Reassembly of the gearbox shafts


Slide the washer with three internal points (6) over the shaft until it locates against the circlip you have just fitted.

Reassembly of the gearbox shafts


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).

Reassembly of the gearbox shafts


Reassembly of the gearbox shafts


Fit on the gear the three-pointed washer (12), which can be distinguished from its counterpart (6) by its bigger outside diameter.

Reassembly of the gearbox shafts


Fit another needle roller cage (4) using the method already described.

Fit the 4th speed gear (21).

Reassembly of the gearbox shafts


Reassembly of the gearbox shafts


Fit another safety washer (6) and another circlip (7) into the shaft. Push it inside its seat using the previously used pad.

Reassembly of the gearbox shafts


Reassembly of the gearbox shafts


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 steering head bearings
Note To adjust the steering bearing clearance, follow what is described in sect. 4 - 3, Adjusting the steering head bearings. If the problems found are not solved, check the wear of steering bearings (6) and replace them, if necessary, as described in paragraph "removal of the steering head c ...

Dashboard
Note The dashboard is supplied as a single component; its internal components cannot be renewed separately. Important Whenever the dashboard is renewed, the ignition key programming procedure must be repeated. Loosen the nuts (2) to remove the master dashboard (1) from its seat and disconn ...

Check the idle and the co amount with warm engine
Start the engine; Switch on the dds and check that it does not signal any error (otherwise consult the relevant paragraph of this manual to reset the error and proceed with the idle check); Enter the "self diagnosis" menu by selecting the diavel model in the available vehicle version. ...

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