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Ducati Diavel Service Manual: Refitting the cylinder/piston assembly

Ducati Diavel Service Manual / Engine / Cylinder/piston assemblies / Refitting the cylinder/piston assembly

If new units are used, it is necessary to couple the cylinders and pistons of the same selection (see paragraph "overhaul Of the cylinder barrel/piston components" of this section).

If the pistons have been separated from their cylinders, before reassembling these components, position the piston ring gaps at 120 from one another (the markings must always face the piston crown).

Note

For better sealing the piston ring gaps should be positioned at 180 intervals.

Use a universal tool to carefully insert the piston into the cylinder (first lubricate the inside of the cylinder with engine oil). Position the cylinder with the smallest valve recess is on the side of the exhaust port.

Remove

Refitting the cylinder/piston assembly


Refitting the cylinder/piston assembly


Remove any deposits and degrease the contact surfaces of the crankcase half and the cylinders.

Check for the presence of the cylinders centring dowels (b) and the o-ring (c) on the base.

Apply sealant to the gasket (5) then locate the gasket on the crankcase.

Refitting the cylinder/piston assembly


Using the cap 88713.1920, Fit the o-rings (a) on each stud bolt and guide them into their seats in the crankcase.

Refitting the cylinder/piston assembly


Bring the connecting rod small end close to tdc and slide the barrel-piston assembly (1-10) onto the crankcase studs.

Push the connecting rod small end into the piston close to the gudgeon pin (3) bore. Lubricate and insert the gudgeon Pin.

Refitting the cylinder/piston assembly


The gudgeon pin (3) must slide smoothly in the connecting rod small end bush and in the piston (1).

Close the crankcase opening with a cloth to prevent foreign objects from falling inside and then fit the retainer ring (2) as shown in the figure.

Important

Always fit new circlips (2) on reassembly.

Refitting the cylinder/piston assembly


Refitting the cylinder/piston assembly


Push the cylinder barrel (10) down until it seats against the crankcase.

Refitting the cylinder/piston assembly


Refit the bushes (12).

Refitting the cylinder/piston assembly


Fit the cylinder head gasket (11) over the studs. The side marked with the part number must be facing the cylinder head.

Note

The shape of the gasket prevents incorrect fitting, provided that the coolant flow holes are aligned with those on the cylinder.

Refitting the cylinder/piston assembly


Repeat the procedure for the other cylinder and refit the cylinder heads (sect. 9 - 4.5, Refitting the cylinder head assemblies).

In case they have not been assembled, apply prescribed threadlocker to unions (6) and tighten them to a torque of 25 nm (min. 23 Nm - max. 27 Nm) (sect. 3 - 3, Engine torque settings).

Refitting the cylinder/piston assembly


Fit the tubes (8) and (9) and tighten clamps (7) to a torque of 2.5 Nm (min. 2 Nm - max. 3 Nm) (sect. 3 - 3, Engine torque settings).

Refitting the cylinder/piston assembly


Refitting the cylinder/piston assembly


Refitting the cylinder/piston assembly


Overhaul of the cylinder barrel/piston components
Overhauling the cylinder Check that the walls of the cylinder bore are perfectly smooth. Measure the cylinder bore diameter at 50 mm from the top face and determine the size class to which it belo ...

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