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Ducati Diavel Service Manual: Overhaul of the flywheel-alternator assembly

Ducati Diavel Service Manual / Engine / Flywheel - alternator / Overhaul of the flywheel-alternator assembly

Examine the inner part of alternator rotor (24) for signs of damage. Check that the starter clutch is working properly and that the needle races do not show signs of wear or damage of any kind. If there is any malfunction, remove the whole assembly.

Overhaul of the flywheel-alternator assembly


Disassembling the generator flywheel

Unscrew the 8 screws (26) and remove the rotor (24) from the flywheel.

Disassembling the generator flywheel


Insert two of the screws (26) just removed from the flywheel rotor-side in their holes in order to remove the flange (14) and the starter clutch (22) from the flywheel (17). The starter clutch is a slight interference fit on the flange. To remove it, use a suitable drift.

Disassembling the generator flywheel


Disassembling the generator flywheel


Reassembling the flywheel - generator assembly

Install the starter clutch (22) in the flange (14) to bring the edge (a) of the clutch up against the flange.

Important

Assemble the components (starter clutch and flange) so that the edge (a) of the starter clutch is positioned on side of the flange with the bevelled edge (b).

Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Seat the flange (14) with the starter clutch (22) in the flywheel (17), aligning the flange locating hole (c) with the flywheel locating hole (d).

Note

The flange locating hole (c) is the hole with the countersunk lead-in (e).

Note

The locating hole (d) of the flywheel can be either one of the two holes (f).

Note

Use suitable tools to align the locating holes.

Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Important

Assemble the components (flange and flywheel) so that edge (a) of the starter clutch (22) is enclosed between the flange and flywheel.

Reassembling the flywheel - generator assembly


Install the rotor (24) on the flywheel (17), aligning one of the flywheel locating holes (d) with the rotor locating hole (g).

Note

The rotor locating hole (g) is the hole positioned on the same diameter as the fixing holes (h).

Note

Use suitable tools to align the locating holes.

Apply threadlocker to the rotor-flywheel fixing screws (26) and start them in their threads.

Tighten

Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Tighten the screws (26) to a torque of 13 nm (min. 11 Nm - max. 15 Nm) (sect. 3 - 3, Engine torque settings) following the sequence above.

Reassembling the flywheel - generator assembly


Lubricate the surface (l) of the driven gear (21) with engine oil.

Install the driven gear on the starter clutch, ensuring it is properly seated.

Note

To facilitate installation, rotate the driven gear in the direction of the green arrow.

Hold the flywheel (17) with one hand and check that the driven gear can rotate freely in the direction of the green arrow but not in the direction of the red arrow.

If either of these two conditions is not met, this means that the starter clutch has not been installed correctly.

Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Reassembling the flywheel - generator assembly


Removing the flywheel - generator assembly
Use the tool 88713.3367 Fixed to the m10 side stand fixing holes (d). Secure the tool to the flywheel with the screws (e). Unscrew the alternator-flywheel retaining nut (15). Warning While uns ...

Refitting the flywheel-alternator assembly
Fit the roller cage unit (20) with washer (18) and internal ring (19), applying prescribed grease on the washer (18). Install the roller cage assembly (20) with the washer (18) and inner race ...

Other materials:

Removing of the abs control unit
Drain the hydraulic fluid that is inside the front and rear braking system tubes by disconnecting them from the master cylinder and the calliper (sect. 4 -3, Changing the brake fluid). Disconnect the connector (a) of the abs control unit (6). Loosen the screws (16) that retain the abs ...

Fuel pressure test
Note The on-screen icons used during this procedure are explained in a table at the end of this section. Undo the screws (2) and remove the flange cover (1). Remove one of the two pipes of the fuel system (3). Use the fuel pressure pipe (4) part no. 590.1.189.1A by connecting one e ...

Tips on how to select the sensitivity level
Warning The 8 level settings of the dtc were calibrated using tyres of the same make, model and size as those originally fitted to the motorcycle. The use of tyres of different size to the original tyres may alter the operating characteristics of the system. In the case of minor differenc ...

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