Ducati Diavel Service Manual: Inspection of the gear selector forks
Visually inspect the gear selector forks. Bent forks must be renewed as they may lead to difficulties in gear changing or may suddenly disengage when under load.
Use a feeler gauge to check the clearance of each fork in its gear groove.
If the service limit has been exceeded, check whether or not it is necessary to replace the gear or the fork by referring to the limits specified for each part (sect. 3 - 1.1, Gearbox).
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 ...
Inspection of the gear selector drum
Use a gauge to measure the clearance between fork pin and the slot on the
selector drum.
If the service limit is exceeded, determine which part must be replaced by
comparing these dimensions wi ...
Other materials:
Inspection of the gear selector drum
Use a gauge to measure the clearance between fork pin and the slot on the
selector drum.
If the service limit is exceeded, determine which part must be replaced by
comparing these dimensions with those of new
components (sect. 3 - 1.1, Gearbox).
Also check the wear on the drum support pin ...
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 ...
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).
...