Ducati Diavel
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Ducati Diavel Service Manual: Reassembly of the connecting rods

Before starting, check that the crankshaft main bearing journals and big-end journals are free of burrs or evident signs of machining: if necessary, clean the surfaces with very fine emery cloth and oil.

Check that the grooves are in perfect condition with no signs of forcing.

Clean the crank pin (o) on the crankshaft (6) thoroughly and lubricate.

Reassembly of the connecting rods


Take the bearings (3) necessary to shaft/connecting rod coupling, following the indications provided (sect. 3 - 1.1, Cylinder/piston).

Insert the bearings in the connecting rod seats matching the tooth (m) of the bearings with the corresponding marks (n) on the connecting rod cap (f) and on the connecting rod small end (g). It is essential that the tooth (m) adheres perfectly with its own mark (n).

Warning

In the case of blue and yellow bearing coupling, fit the yellow on the connecting rod and the blue on the connecting rod cap.

Lubricate the bearing (3) fitted on the connecting rod small end.

Reassembly of the connecting rods


Reassembly of the connecting rods


Check that each connecting rod (2) and cap are fitted with their locating pins (d).

Wash the pins and dry them with compressed air.

Fit the connecting rod on the crankshaft, in the same position in which it was removed.

Insert the connecting rod in the crankshaft, so that the centring pins face the internal side.

Reassembly of the connecting rods


Reassembly of the connecting rods


Join the connecting rod cap (f) with the corresponding connecting rod small end (g), checking that the progressive number stamped on the two pieces is the same, as shown in the figure.

 Reassembly of the connecting rods


Important

Check that the progressive numbers of a connecting rod are next to the selection of the other connecting rod.

Reassembly of the connecting rods


Fill the recommended grease into the two ends of the hole to lubricate threads and underside of the new screws (1) and the thread of the shaft.

Reassembly of the connecting rods


Warning

The grease utilised is an irritant in contact with the skin. Wear protective gloves.

Important

Lubrication of big-end cap screws is essential to obtain the correct coupling and to prevent breakage of the parts.

The big-end cap screws may only be used for one tightening.

Tighten the screws (1) by hand.

If this proves difficult or if the screws jam, undo them and lubricate them again.

Remove excess grease. Tighten the screw by hand until the head seats against the connecting rod.

Reassembly of the connecting rods


Reassembly of the connecting rods


Fit the spacer (h) of the tool 88713.2878 Between the connecting rods and take up residual axial clearance with the fork feeler gauge (i) of the tool 88713.2878 Which is available in the following thicknesses: 0.1 Mm - 0.2 Mm - 0.3 Mm.

Temporarily fit the gudgeon pin (l) to align the connecting rods, and then tighten the screws.

Reassembly of the connecting rods


Tighten the screws (1) with a torque wrench and angle reading (degree wheel) in accordance with the procedure described below (observe the same tightening sequence at each step as that of the previous step):

  1. First torque each screw to a value of 20 nm;
  2. Now carry out a second tightening stage applying a torque of 35 nm on each screw;
  3. Now tighten each screw, reading the angle of rotation, to 70 nm, checking that the final angle is between 55 and 75.

Important

If the final angle is less than 55 or greater than 75, repeat the procedure using two new screws.

Reassembly of the connecting rods


Reassembly of the connecting rods


Overhaul of the connecting rods
Make the following dimensional checks on the connecting rods: Clearance with gudgeon pin on assembly. In the event of excessive wear (sect. 3 - 1.1, Crankshaft), replace the connecting rod. ...

Refitting the crankshaft/connecting rod assembly
Install the connecting rod assembly (6) and (2) in the crankcase, carry out the shimming and crankcase half reassembly procedure as described in sect. 9 - 9.2, Reassembly of the crankcase halves. ...

Other materials:

Removing of the cylinder head pulley/fixed tensioner
Insert the tool code 88713.1806 In the pulleys to lock their rotation and use the bush supplied to loosen the fixing nuts (21) of the pulleys. important On reassembly, always use new nuts. Remove the nuts (21) and the pulleys (11) from the camshafts. Loosen the nut (8), and remove the was ...

The battery charging circuit and power distribution
On the diavel, the +15v (key on power) voltage does not come from a conventional ignition key, but from pin 30 of the hands free relay. This relay is switched to closed state by the hands free unit when the latter enables power on for the ignition and engine. The hands free relay receives +30v ...

Recharging the battery
Examine the label on the battery showing the check intervals in order to determine when to test the voltage. Charge the battery if the open circuit voltage is lower than 12.8 V. Leaving the battery discharged for more than one month could damage it. Check the battery charge with a voltmete ...

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