Ducati Diavel Service Manual: 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.

If damaged, unscrew the unions (6).

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.

Remove the bushes (12).

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

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.

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

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.

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

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.