Ducati Diavel Service Manual: Reassembly of the gearbox shafts

Figure 1 shows all the parts to be reassembled on the gearbox primary shaft (2), with the calculated end shims (1) and (11) (sec. 9 - 9.2, Reassembly of the crankcase halves).

Figure 2 shows all the parts to be installed on the gearbox secondary shaft (25), with calculated end shims (15) and (26) (sec. 9 - 9.2, Reassembly of the crankcase halves).

Reassemble the gears on the gearbox shafts by reversing the disassembly procedure.

Take particular care when installing the idler gears. The assembly of the 3rd and 4th speed gears and the relative fixing components on the secondary shaft is given as an example.

Fit the circlip (7), checking that it is fully inserted into its groove on the shaft. Push the circlip into position with a suitable size tubular drift.

Slide the washer with three internal points (6) over the shaft until it locates against the circlip you have just fitted.

To fit the needle roller cage (4) onto the shaft, first lubricate it with plenty of grease (of recommended type) and then open it slightly to make it easier to slide on to the shaft.

Fit the 3rd speed gear (22).

Fit on the gear the three-pointed washer (12), which can be distinguished from its counterpart (6) by its bigger outside diameter.

Fit another needle roller cage (4) using the method already described.

Fit the 4th speed gear (21).

Fit another safety washer (6) and another circlip (7) into the shaft. Push it inside its seat using the previously used pad.