Ducati Diavel
Free Service and Repair manuals

Ducati Diavel Service Manual: Disassembly of the gearbox shafts

Ducati Diavel Service Manual / Engine / Gearbox assembly / Gearbox shafts / Disassembly of the gearbox shafts

Place the shaft in a vice in such a way as to facilitate the disassembly operations.

Important

Take care not to invert the positions of the shims on reassembly: this would potentially lead to jamming when using the gear selector control, making it necessary to reopen the engine crankcase.

Disassembly of the gearbox secondary shaft

Remove the chain-side shim washer (26) and clutch-side shim washer (15) from the secondary shaft.

Disassembly of the gearbox secondary shaft


Withdraw the first speed driven gear (18) with the roller cage (17) and the shim (19).

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Remove the fifth speed driven gear (20).

Disassembly of the gearbox secondary shaft


Use two flat blade screwdrivers to remove the circlip (7) taking care not to damage the shaft surface.

Remove the circlip (7) and the splined washer (6).

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Withdraw the fourth speed driven gear (21) with the roller cage (4) and splined washer (12).

Remove the

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Remove the third speed driven gear (22) with the roller cage (4) and the splined washer (6).

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Remove the circlip (7) and remove the sixth speed driven gear (23).

Remove

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Remove the circlip (7) and withdraw the splined washer (6) and the second speed driven gear (24).

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Withdraw the roller cage (4) and the shim (3). All the components have thus been removed from gearbox secondary shaft (25).

Disassembly of the gearbox secondary shaft


Disassembly of the gearbox secondary shaft


Disassembly of the gearbox primary shaft

Remove the chain-side shim washer (11) and the clutch-side shim washer (1) from the primary shaft.

Disassembly of the gearbox primary shaft


Remove the second speed driving gear (10). Use two screwdrivers to prise out the circlip (7) and the splined washer (6).

Important

Take care to avoid damaging the surface of the shaft while removing circlip (7).

Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Remove the sixth speed driving gear (9) with its roller cage (4). Remove the splined washer (6) and the circlip (7).

Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Withdraw the third and fourth speed driving gear (8).

Disassembly of the gearbox primary shaft


Remove the circlip (7) and the splined washer (6).

Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Remove the fifth speed driving gear (5) with the roller cage (4).

Disassembly of the gearbox primary shaft


Disassembly of the gearbox primary shaft


Slide the shim (3) off the primary shaft (2).

Disassembly of the gearbox primary shaft


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 s ...

Overhaul of the gearbox
Check the condition of the front coupling dogs of the gears. They must be in perfect condition and with no sign of wear on the edges of the teeth. The idler gears must rotate freely on their sha ...

Other materials:

Refitting the rear footrests
Note The refitting of the rear footrests is described for the right side but it is the same for both. If previously removed, refit the rubber footrest (11) on the rear rh footrest (6), by pushing it until pad (b) engages in the other side. Note The rubber footrest (11) side featuring the le ...

Instrument panel on handlebar
Lcd. Neutral light n (green). Illuminates when the gearbox is in neutral. High beam light  (blue). It turns on to indicate that the high beam lights are on. Engine oil pressure light (red). Illuminates when engine oil pressure is too low. It must turn on at key-on, but ...

Evaporative emissions canister
Sealing washer Union Hose clip Hose Clamp "T" fitting Hose Support Special screw Rubber mounting Hose Hose clip Evaporative emissions canister Hose Spring Spare parts catalogue Diavel abs evaporative emissions canister Diavel carbon abs evaporative emissions ...

2022 | www.dudiavel.com |