Ducati Diavel Carbon ABS - Service Manual - Repair Manual

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DUCATI DIAVEL ABS, DIAVEL CARBON ABS - SERVICE MANUAL / REPAIR MANUAL

- English Service Manual / Repair Manual for motorcycle Ducati Diavel Carbon ABS.


CONTENTS:

1 - GENERAL
-1 - How to use this manual
- How to use this manual
- Layout of the manual
-2 - Symbols - Abbreviations - References
- Product specifications
-3 - Hazardous Products - Warnings
- General safety rules
- General maintenance indications
2 - INFORMATION ABOUT THE MODEL
-1 - Identification data
- Diavel identification data
3 - TECHNICAL DATA
-1.1 - Technical specifications
- General
- Colours
- Transmission
- Timing system/valves
- Crankshaft
- Cylinder/Piston
- Gearbox
- Cooling system
- Front wheel
- Front suspension (Diavel ABS)
- Front suspension (Diavel Carbon ABS)
- Rear wheel
- Rear suspension (Diavel ABS)
- Rear suspension (Diavel Carbon ABS)
- Hydraulic brakes
- Charging system/alternator
- Injection-ignition system
- Fuel system
- Injection system
- Lights/instrument panel
-1.2 - Dimensions
-2 - Fuel, lubricants and other fluids
-3 - Torque settings
- Frame torque settings
- Engine torque settings
-4 - Service tools
- Specific tools for the engine
- Specific tools for the frame
- Appropriate diagnosis tools
4 - MAINTENANCE OPERATIONS
-1 - Vehicle pre-delivery
-2 - Scheduled maintenance chart
- Operations to be carried out by the dealer
- List of operations to be performed at 1000 km
- Operations to be carried out by the dealer
- List of operations to be performed every 12000 km / year (first limit reached)
- Operations to be carried out by the customer
- List of operations to be performed every 1000 km
-3 - Maintenance operations
- Reading of the error memory with DDS on the engine control units, vehicle and ABS
- Check engine oil level
- Changing the engine oil and filter cartridge
- Checking valve clearances
- Change timing belts
- Spark plugs replacement
- Changing and cleaning the air filters
- Checking the coolant level
- Changing the coolant
- Changing the brake fluid
- Draining the clutch hydraulic circuit
- Filling the clutch circuit
- Adjusting the steering head bearings
- Adjusting the chain tension
- Checking brake pad wear and changing brake pads
- Adjusting the throttle cable
- Adjusting the clutch lever and front brake lever
- Adjusting the position of the gear change and rear brake pedals
- Adjusting the front fork
- Adjusting the rear shock absorber
5 - FAIRINGS
-1 - Rear view mirrors
- Removal of the rear-view mirrors
- Refitting the rear-view mirrors
-2 - Fairings
- Removal of the fuel tank fairings
- Disassembly of the front half-fairings
- Reassembly of the front half-fairings
- Refitting the fuel tank fairings
-3 - Seat
- Removal of the seat
- Disassembly of the seat
- Reassembly of the seat
- Refitting the seat
-4 - Front and rear mudguard
- Removal of the front mudguard
- Refitting the front mudguard
- Removing the rear mudguard
- Refitting the rear mudguard
-5 - Fairings
- Removal of belly fairing
- Reassembly of belly fairing
-6 - Electrical components support
- Removing the electrical components support
- Reassembling the electrical components support
6 - ELECTRIC SYSTEM AND ENGINE CONTROL SYSTEM
-1 - Wiring diagram
- Key to wiring diagram
- Wiring diagram colour codes
- Rear left fuse box (1) key
- Rear right fuse box (2) key
- Routing of wiring on frame
-2 - Battery charging system
- Checking the battery charging system
- Recharging the battery
- Topping up the electrolyte
- Battery
- Alternator
- Rectifier-regulator
-3 - Electric starting system
- Electric starting system
- Starter motor
- Solenoid starter
-4 - Lights and indicating devices
- Renewal of the headlight
- Changing bulbs
- Headlight aim
-5 - Indicating devices
- Checking the indicating devices
-6 - Protection and safety devices
- Checking protection and safety device components
- Checking the fuses
-7 - Instruments
- Instrument panel
- Instrument panel system
- LCD unit functions
- Vehicle speed indicator
- Engine rpm indicator (RPM)
- Clock
- Coolant temperature
- Instrument panel on tank
- TFT - Parameter setting/display
- Total distance covered indicator: “Odometer“
- “Trip 1“ meter
- “Trip 2“ meter
- Distance travelled on fuel reserve: “TRIP FUEL“
- Indicator “CONS. AVG“ - Average fuel consumption
- Indicator “CONS.“ - Instantaneous fuel consumption
- Indicator “SPEED AVG” - Average speed
- Indicator “TRIP TIME“ - Trip time
- Indicator “AIR” - Air temperature
- Engaged gear indicator
- “Riding Mode set“ indication
- Indication if the “LAP” function is active/not active
- “Riding Style” function (riding style change)
- Maintenance indicator
- First warning - OIL SERVICE 1000 Km
- Residual range indication when the SERVICE is due
- Indication of range reached for SERVICE
- Warning indication (Alarms/Signals)
- “Low” battery level
- Traction Control (DTC) deactivated
- Hands Free key (HF) not recognised
- “Low“ Hands Free key (HF) battery level
- “High“ engine coolant temperature
- Steering release error - Steering still locked
- Instrument panel diagnosis
- “Setting” menu
- “Riding Mode” customisation
- DTC (Ducati Traction Control) setting function
- Tips on how to select the sensitivity level
- ENGINE setting function (Engine Power Control)
- DEFAULT function (Resetting Ducati default parameters)
- Menu 2 On/Off function
- Background setting function for the instrument panel on tank - DASHBOARD 1
- Backlighting setting function for the instrument panel on handlebar - DASHBOARD 2
- Digital RPM indication function
- LAP Activation/Deactivation function (lap time)
- LAP registration function
- Stored LAP display function
- Stored LAP erase function
- Battery voltage indicator (BATTERY)
- Clock setting function
- Units of measurement modification function
- ABS disabling function
-8 - The “Hands Free” system
- Introduction to the “Hands Free“ system
- Operating principle
- How to turn the motorcycle on
- How to switch the dashboard on
- How to start the engine
- How to start the motorcycle if the active key is not working
- How to start the motorcycle without keys
- How to turn the motorcycle off
- Recovery and emergency procedures
- Recovery procedure with no key
- Recovery in the event of flat active key battery
- Recovery procedure in the event of electric steering lock fault
- Recovery procedure in the event of Hands Free system fault
- Start procedure with PIN code (no keys)
- How to enable engine start with PIN code
- How to enable the PIN code
- How to reset the PIN code
- Wiring diagram of the Hands Free system
- Possible faults of the Hands Free system components
- The Hands Free module
- Communication antenna
- On/off switch on handlebar
- The Hands free relay
- Active key
- Passive key
- Programming/reprogramming keys
-9 - Introduction to the engine control system
- Specific operating strategies
- Inputs and outputs of engine control unit and connection to CAN network
- Layout of engine control system and other components
- Removal of the control unit
- Reassembly of the control unit
- Fuel system circuit
- Injection and ignition
- Operating principle and characteristics of the ride-by-wire system
- Explanation of the function of the ride-by-wire system
- Anti-pollution system and auto-adaptive strategy
- Ignition coils
- Injectors
- Throttle valve operation engine
- Engine start button
- Clutch lever button
- Side stand button
- Injection relay
- Throttle valve actuator motor relay
- Starter motor relay
- Radiator fan relay
- Engine speed-timing sensor
- Accelerator position sensor (throttle grip)
- Throttle valve position sensor
- Component assembling position
- Air temperature sensor
- Engine temperature sensor
- Absolute pressure sensors
- Oxygen sensors
-11 - Diagnostic instruments
- Using a multimeter to check the electrical systems
- Description of the diagnosis instrument (DDS)
- Tester power supply
- DDS diagnosis instrument
- Checking and adjusting timing belt tension
- Checking the idle speed
- Check the idle and the CO amount with warm engine
- Check the engine oil pressure
- Cylinder compression test
- Fuel pressure test
- Guided diagnosis
- Testing the battery charging system
- Deactivating the “service” indication on the instrument panel
- ABS diagnosis
- Icons table
7 - CHASSIS
-1 - Front wheel
- Removal of the front wheel
- Overhauling the front wheel
- Refitting the front wheel
-2 - Rear wheel
- Removing of the rear wheel
- Overhauling the rear wheel
- Refitting the rear wheel
-3 - Front brake control
- Removal of the front brake master cylinder
- Refitting the front brake master cylinder
- Maintenance operations
- Removal of the front brake system
- Removal of the brake discs
- Overhauling the front brake components
- Refitting the brake disks
- Refitting the front brake system
-4 - Rear brake
- Removing of the rear brake control
- Disassembly of the rear brake control
- Refitting the rear brake control
- Removal of the rear brake calliper
- Removal of the rear brake disc
- Refitting the rear brake calliper
-5 - ABS system information
- Operating principle
- ABS system operating information
- ABS system deactivation
-6 - System components
- Replacing the front phonic wheel sensor
- Replacing the rear phonic wheel sensor
- Removing of the ABS control unit
- Refitting the ABS control unit
- Flexible wiring/hoses positioning
- Table A
- Table B
- Table C
-7 - ABS components maintenance
- Adjusting of the AIR-GAP phonic wheel sensor
- Bleeding of the ABS hydraulic system
-8.1 - Handlebar unit: Throttle twistgrip
- Removal of the handlebar
- Refitting the handlebar
- Adjusting the throttle cable
- Removal of the throttle twistgrip
- Refitting the throttle twistgrip
-8.2 - Handlebar unit: Hydraulic clutch control
- Removal of the clutch master cylinder assembly
- Refitting the clutch master cylinder assembly
- Removal of the clutch transmission unit
- Refitting the clutch transmission unit
-8.3 - Handlebar unit: Hands free
- Removing the Hands Free
- Refitting the Hands Free
-9 - Gearchange mechanism
- Removal of the gearchange control
- Disassembly of the gearchange mechanism
- Refitting the gearchange mechanism
-10.1 - Fork - Steering head: front fork
- Removal of the front forks
- Overhauling the front forks
- Refitting the front forks
-10.3 - Fork - steering head: Steering
- Adjusting the steering head bearings
- Steering angle adjustment
- Removal of the steering head components
- Refitting the steering head components
-12 - Rear shock absorber assembly
- Rear suspension system
- Removal of the rear shock absorber
- Overhauling the rear shock absorber
- Disassembly of rear shock absorber - rocker arm - linkage assembly
- Reassembly of rear shock absorber - rocker arm - linkage assembly
- Refitting the rear suspension
-13 - Swingarm
- Removal of the rear wheel eccentric hub and rear wheel shaft
- Refitting the rear wheel eccentric hub and rear wheel shaft
- Removal of the swingarm
- Inspecting the swingarm pivot
- Overhauling the rear swingarm
- Refitting the swingarm
-14 - Final drive
- Inspecting the final drive
- Removing of the front sprocket
- Refitting the front sprocket
- Replacing of the rear sprocket
- Refitting the rear sprocket
- Washing the chain
- Lubricating the chain
-15 - Footrest brackets
- Removal of the front footrests
- Refitting the front footrests
- Removing the front footrest brackets
- Reassembling the front footrest brackets
- Removing of the rear footrests
- Refitting the rear footrests
-16 - Stands
- Removing of the side stand
- Refitting the side stand
-17 - Frame inspection
- Disassembly of structural components and the frame
- Removal of the tool tray
- Removing the frame and the lateral footrests
- Checking the frame
- Reassembly of structural components and the frame
- Reassembling the frame and the lateral footrests
- Reassembly of the tool tray
-18 - Tail light - number plate holder
- Removal of the licence plate holder
- Refitting the number plate holder
- Removal of the tail light
- Refitting the tail light
8 - FUEL SYSTEM / EXHAUST SYSTEM
-2 - Fuel tank
- Removal of the fuel tank
- Removal of the fuel tank filler cap
- Refitting the filler cap
- Replacing the tank flange and fuel sensor
- Refitting the fuel tank flange
- Refitting the fuel tank
-6 - Airbox - Throttle Body
- Removal the airbox and throttle body
- Refitting the airbox and throttle body
-7 - Air intake
- Removal of the air filters
- Refitting the air filters
-8 - Exhaust system
- Removing the silencer
- Removal of the exhaust system
- Refitting the exhaust system
- Refitting the silencer
-10 - Evaporative emissions canister
- Evaporative emissions canister system (USA versions only)
- Removal of the evaporative emissions canister
- Refitting the evaporative emissions canister
9 - ENGINE
-1 - Removal-refitting of the engine assembly
- Removal of the engine
- Refitting the engine
-2.1 - Lubrication system: oil pump
- Removal of the oil pump
- Disassembly of the oil pump
- Reassembly of the oil pump
- Refitting the oil pump
-2.2 - Lubrication system: oil cooler
- Removal of the lubrication system
- Oil cooler inspection
- Refitting the lubrication system
-3.1 - Cooling system: coolant expansion tank
- Removal of the expansion tank
- Refitting the expansion tank
- Removal of the cooling system hoses and unions
- Refitting the cooling system hoses and unions
-3.2 - Cooling system: water radiators
- Removing the water radiators
- Disassembling the water radiator unit
- Renewal of the cooling fan
- Reassembling the water radiator unit
- Refitting the radiator
-3.3 - Cooling system: water pump
- Removal of the water pump
- Refitting the water pump
-4.1 - Cylinder head assemblies: checks and adjustments
- Checking and adjusting the valve clearances
- Checking valve lift
- Checking the engine timing
-4.2 - Cylinder head assemblies: timing system
- Removal of the timing belt covers
- Removal of the movable tensioner/timing belt
- Removing of the cylinder head pulley/fixed tensioner
- Removal of the tensioner and idler pulley mounting studs
- Disassembly of the camshaft pulleys
- Removing the timing belt driveshaft pulleys
- Refitting the timing belt driveshaft pulleys
- Refitting the idler and tensioner pulley mounting studs
- Reassembly of the timing pulleys
- Refitting the cylinder heads pulleys/fixed tensioners
- Refitting the timing belts
- Refitting the timing covers
-4.4 - Cylinder head assemblies: camshafts
- Removal of the camshafts
- Checking the camshafts and supports
- Refitting the camshafts
- Removal of the intake manifold and coolant union
- Refitting the intake manifold and coolant union
-4.5 - Cylinder head assemblies: valves - rocker arms
- Removal of the cylinder heads
- Removing the valves
- Removing the valve rocker arms
- Overhaul of cylinder head components
- Reassembly of the cylinder head
- Refitting the cylinder head assemblies
-5 - Cylinder/piston assemblies
- Removal of the cylinder/piston assembly
- Overhaul of the cylinder barrel/piston components
- Refitting the cylinder/piston assembly
-6.1 - Clutch assembly: clutch
- Description of the clutch assembly
- Removal of the clutch
- Checking and overhauling the components
- Reassembling the clutch
-6.2 - Clutch assembly: clutch cover
- Removal of the clutch-side crankcase cover
- Disassembly of the clutch cover
- Reassembly of the clutch-side crankcase cover
- Refitting the clutch-side crankcase cover
-6.3 - Clutch assembly: primary drive gears
- Removal of the primary drive gear
- Refitting the primary drive gears and checking backlash
-7.1 - Gearbox assembly: gearchange mechanism
- Removal of the gear selector lever
- Disassembly of gear interlock plunger and pawl assembly
- Refitting the gear interlock plunger and pawl assembly
- Refitting the gear selector lever
-7.2 - Gearbox assembly: gearbox shafts
- Removal of the gearbox assembly
- Disassembly of the gearbox shafts
- Overhaul of the gearbox
- Inspection of the gear selector forks
- Inspection of the gear selector drum
- Reassembly of the gearbox shafts
- Reassembly of the gearbox
-8 - Flywheel - alternator
- Removal of the generator cover
- Disassembly of the generator cover
- Removing the flywheel - generator assembly
- Overhaul of the flywheel-alternator assembly
- Refitting the flywheel-alternator assembly
- Refitting the alternator-side crankcase cover
-9.1 - Crankcase assembly: external components
- Removing outer components
- Refitting the external components
- Removal of the timing gears
- Refitting the timing gears
- Removal of the starter motor idler gear
- Refitting the starter motor gear
-9.2 - Crankcase assembly: crankcase halves
- Separation of the crankcase halves
- Overhaul of the crankcase halves
- Main bearings
- Reassembly of the crankcase halves
- Shimming the shafts
- Reassembly of the crankcase halves
-9.3 - Crankcase assembly: crankshaft/connecting rods assembly
- Removal of the crankshaft/connecting rods assembly
- Disassembly of the crankshaft/connecting rods assembly
- Overhaul of the connecting rods
- Reassembly of the connecting rods
- Refitting the crankshaft/connecting rod assembly