Ducati Diavel
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Ducati Diavel Service Manual: Shimming the shafts

Before assembling the crankcase halves, calculate the shims required to obtain the correct end float of the crankshaft and gearbox shafts.

To determine the correct shim thickness proceed as follows.

Shimming the crankshaft

Shimming the crankshaft


Shimming the crankshaft


Add 0.30 Mm preload for crankshaft axial bearings to bed in correctly into their seats (inner rings seated inside outer ring).

Thus, we obtain: sa=la1+la2+0.30-La.

To calculate the thickness of each shim note that: sa=sa1+sa2 where "sa1" and "sa2" represent the shims for the clutch-side crankcase half 1 and the alternator-side crankcase half 2.

Considering the alignment of the shaft, this gives: sa1=la1+0.15-La/2; and finally, the second shim thickness: sa2=sa-sa1.

Shimming the crankshaft


Shimming the crankshaft


In addition to the above procedure, the following is a practical shimming method, providing a guide on how to calculate the crankshaft shim thickness accurately.

Install a shim of minimum thickness (1.90 Mm) on each side of the crankshaft to prevent contact between the crankshaft web and the crankcase.

Install the crankshaft and assemble the two crankcase halves.

Fit four m8 screws in the seats indicated in figure and tighten them to a torque of 19 nm (min. 17 Nm - max. 21 Nm) (sect. 3 - 3, Engine torque settings).

Shimming the crankshaft


Place a dial gauge (c) with magnetic base on a support plate fixed to crankcase.

Bring the stylus into contact with the end of the crankshaft and set the dial gauge to zero in this position.

Shimming the crankshaft


Place a lever (d) between crankcase and crank web of the crankshaft pushing towards dial gauge.

Note on the dial gauge the total clearance and add a preload of (0.30 Mm) plus the thickness of the shims used (1.90X2=3.8 Mm).

Divide the resulting value by two to obtain the thickness of the shim packs to be installed at either end of the crankshaft.

Note

After assembling the crankcase halves, the crankshaft should turn with some interference in the new bearings.

Shimming the crankshaft


Shimming the gearbox shafts

The following thickness spacers are supplied as spare parts.


Shimming the gearbox selector drum

The following thickness spacers are supplied as spare parts.


Reassembly of the crankcase halves
The crankcase halves must be in good condition and perfectly clean. The mating surfaces must be perfectly flat and free from burrs. Overhauling the alternator-side crankcase half The following pa ...

Reassembly of the crankcase halves
If removed, apply threadlocker on the screw (36), insert it with the washer (37) on the crankcase half and tighten it to The torque of 8 nm (min. 7 Nm - max. 9 Nm) (sect. 3 - 3, Engine torque sett ...

Other materials:

Refitting the fuel tank fairings
Make sure that the following components are fitted on the tank fairing (22): Spacers (18); Seals (20). Fit the clips (19) to the central cover (22) at the positions shown, inserting the tabs (h) into the slots (l). Apply threadlocker to the screws (14). Place the tank fairing (22) ...

Removal of the lubrication system
Disconnect the sensor (12) of the main wiring. Open the pipe grommet (11). Undo the screw (8) and slide out the plate (9). Slide the tubes (7) out of the half-casing having care not to damage the tubes o-rings (a) that guarantee the coupling sealing. Undo and remove the sc ...

Refitting the front forks
Refit the fork legs, positioning them at the height shown in the figure relative to the upper surface of the bottom yoke. Warning The difference in height between the two fork legs must be no greater than 0.1 Mm. Position the fork legs (5) and (6) on the yoke base (4) and on the steering ...

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