Ducati Diavel
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Ducati Diavel Service Manual: Refitting the exhaust system

Refit the heat guard on the manifold (10) by tightening the nuts (9) to a torque of 10 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Refitting the exhaust system


Position the vertical exhaust manifold (22) on the vertical cylinder head with the gasket (23).

Tighten the fixing nuts (21) to a torque of 10 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Refitting the exhaust system


Refitting the exhaust system


If removed, tighten the vertical lambda sensor (20) to a torque of 25 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Refitting the exhaust system


Position the horizontal exhaust manifold (24) on the horizontal cylinder head with the gasket (23).

Tighten the fixing nuts (21) to a torque of 10 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Refitting the exhaust system


Refitting the exhaust system


If removed, tighten the horizontal lambda sensor (20) to a torque of 25 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Refitting the exhaust system


Check the presence of clips (15) on the upper exhaust pipe (19).

Refitting the exhaust system


Fit the aramid washers (12) on the screws (11) using the recommended threadlocker.

Insert the screws (11) in the holes of the heat guard (13).

Insert the other two washers (12) and the spacers with collar (14) on the protruding ends of the screws (1).

Note

The two spacers (14) must be oriented with the collar (w) facing the heat guard (13) as shown.

Fit the heat guard (13) starting the screws (11) and tighten the screws (11) to the torque of 8 nm +/- 10% (sect. 3 - 3, Frame torque settings), making sure the washers (12) are centred to the collars (w) of the spacers (14).

Refitting the exhaust system


Insert the upper exhaust pipe (19) into the vertical exhaust pipe (22) and block it with the spring (16).

Refitting the exhaust system


Insert the central exhaust pipe (26) in the upper exhaust pipe (19) and the horizontal flange (24), and fix them with the springs (16).

Refitting the exhaust system


If the exhaust valve motor had been removed, fit the vibration dampers (35) into the suitable holes of the exhaust valve (34) on refitting. Fit the exhaust valve motor (34) and position it as shown on the cover (32), bringing its vibration dampers (35) fully home on the stud bolts (e).

Refitting the exhaust system


Refitting the exhaust system


Fix the exhaust valve motor (34) to cover (32) starting the screws (37) with washers (36) in the vibration dampers (35) installed previously. Tighten the screws (37) to a torque of 3 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Fit the vibration dampers (31) on the cover (32) at the positions shown.

Insert the spacers with collar (30) into the vibration dampers (31) as shown.

Refitting the exhaust system


Fit the exhaust valve motor cable (m) inserting the end fitting (f) in the suitable hole of pulley (g).

Note

The exhaust valve motor cable (m) must be positioned above the wiring (h) of the exhaust valve motor (34).

Insert the cylindrical terminal (l) into the suitable seat of the exhaust valve motor (34) and make sure to bring it fully home.

Note

If it proves difficult to insert the terminal (l) fully home into its seat, apply lubricant for rubber to the terminal.

Tie the wiring (h) using a large self-locking tie wrap (n) in the area of the cover (32) shown.

Refitting the exhaust system


If previously removed, place the exhaust valve motor assembly (32) on the right plate of the rear subframe, start the screws (29) with washers (30) and tighten them to a torque of 10 nm +/- 10 % (sect. 3 - 3, Frame torque settings).

Refitting the exhaust system


Position the control cable (25) in the plate (c).

Insert the end fitting (b) on the exhaust valve (d) and block it with the circlip (39).

Warning

Make sure the end fittings (b) at cable ends are properly fitted onto the pulleys of the exhaust valve and of its motor.

Check that the cylindrical terminal (l) is fully inserted (fully home) into the suitable seat of the exhaust valve motor.

After assembly, the cable (25) on exhaust valve and exhaust valve motor is adjusted automatically by dashboard software, that causes the valve to open fully at the first key-on, and then goes back to rest position with the valve fully closed.

Refitting the exhaust system


Refitting the exhaust system


Refit the exhaust by-pass valve cover (27) by starting and tightening the screws (28) to a torque of 8 nm +/- 10% (sect. 3 - 3, Frame torque settings), starting with the front one.

Refit the silencer, as described in the paragraph "refitting the silencer" of this section.

Refitting the exhaust system


If removed, fit the copper washers (18) to the plugs (17), start the plugs into the vertical (22) and horizontal (24) head exhaust manifolds and tighten them to the torque of 25 nm +/- 10% (sect. 3 - 3, Frame torque settings).

Refitting the exhaust system


If the silencer heat guard had been removed, check the presence of clips (43) on the silencer (4).

Refitting the exhaust system


Important

Assembly operations described below must be performed following sequence x - y - z.

Fit the washers (12) on the screws (40).

Insert the screws (40) in the holes of the heat guard (41).

Insert the other three washers (12) and the spacers with collar (42) on the protruding ends of the screws (40).

note

The spacers (42) must be oriented with the collar (j) facing the heat guard (41) as shown.

Fit the heat guard (41) by starting the screws (40).

Tighten the screws (40) to a torque of 5 nm +/- 10% (sect. 3 - 3, Frame torque settings), following sequence z - x - y and making sure the washers (12) are centred to the collars (j) of the spacers (42).

Refitting the exhaust system


Check the presence of the rubber pad (46) on the heat guard (45).

Refitting the exhaust system


Fit the washers (12) on the screws (44) using the recommended threadlocker.

Insert the screws (44) in the holes of the rear heat guard (45).

Insert the other two washers (12) and the spacers with collar (47) on the protruding ends of the screws (44).

Note

The spacers (47) must be oriented with the collar (k) facing the heat guard (45).

Fit the heat guard (45) by starting the screws (44).

Tighten the screws (44) to a torque of 8 nm +/- 10% (sect. 3 - 3, Frame torque settings), making sure the washers (12) are centred to the collars (k) of the spacers (47).

Refitting the exhaust system


Removal of the exhaust system
Remove the silencer, as described in the paragraph "removing the silencer" of this section. Loosen the screws (28) and remove the exhaust by-pass valve cover (27). Turn the exhaust valve pul ...

Refitting the silencer
Position the silencer guard (41) and fix it by starting the screws (40). Tighten the screws (40) to a torque of 8 nm +/- 10% (sect. 3 - 3, Frame torque settings). Insert the silencer (4) int ...

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Spark plugs are essential to smooth engine running and should be checked at regular intervals. The condition of the spark plugs provides a good indication of how well the engine is running. Have the spark plugs inspected or replaced at a ducati dealer or authorised service centre; they will ...

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