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Ducati Diavel Service Manual: Removal of the cylinder/piston assembly

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

Removal of the cylinder/piston assembly


Removal of the cylinder/piston assembly


Loosen the clamps (7) and remove the hoses (8) and (9) from the cylinder barrels (10) and from the alternator-side crankcase cover.

Removal of the cylinder/piston assembly


Removal of the cylinder/piston assembly


If damaged, unscrew the unions (6).

Removal of the cylinder/piston assembly


Note

The following procedure is described with the engine removed from the frame and the cylinder head removed from the engine (sect. 9 - 4.5, Removal of the cylinder heads).

Remove the gasket (11) from the horizontal thermal unit.

Removal of the cylinder/piston assembly


Remove the bushes (12).

Removal of the cylinder/piston assembly


Use the tool 88765.1523 To bring the piston of the horizontal cylinder near the tdc.

Removal of the cylinder/piston assembly


Carefully lift the cylinder barrel (10) off the crankcase, keeping it vertical.

If necessary, rock the cylinder slightly using both hands or tap its base gently with a rubber mallet. Continue to lift the cylinder until you can access the gudgeon pin (3).

Note

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

Since insertion of piston in the barrel is a difficult operation to perform at the time of reassembly, remove the piston together with the barrel as described below.

Stuff the crankcase opening with a rag or soft paper to prevent foreign material from falling in.

Removal of the cylinder/piston assembly


Remove the circlip (2) from the gudgeon pin (3) on the clutch side.

Removal of the cylinder/piston assembly


Working from the opposite side, drive out the gudgeon pin sufficiently to release the connecting rod.

Lift the barrel-piston assembly clear of the crankcase studs. If work is to be carried out on the piston, carefully withdraw it from the cylinder.

Removal of the cylinder/piston assembly


Remove the four o-rings (a) located on the crankcase studs between the barrel and the base gasket (5).

Removal of the cylinder/piston assembly


To remove the vertical barrel-piston assembly, bring the vertical piston to tdc and proceed as for removal of the horizontal cylinder barrel.

Important

Mark the pistons to show from which cylinder they were removed: v= vertical - h= horizontal.

Cylinder/piston assemblies
Piston Gudgeon pin circlip Gudgeon pin Set of piston rings Cylinder-crankcase gasket Water pump outlet union Hose clip Horizontal cylinder coolant inlet hose Vertical cylinder c ...

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 ...

Other materials:

Refitting the engine
Refitting is the reverse of removal. Important Apply recommended grease and tighten the special screws (6) to a torque of 60 nm +/- 5% (sect. 3 - 3, Frame torque settings). Tighten the nuts (3) to a torque of 48 nm +/- 5% (sect. 3 - 3, Frame torque settings). Warning For the assembly seque ...

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 p ...

Disassembly of gear interlock plunger and pawl assembly
Unscrew the interlock plunger screw (5) and remove the seal (6), spring (7) and the detent ball (8). Unscrew the clutch-side crankcase half screw (3) and remove the pawl (4), washer (2) and spring (1). ...

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