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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
 Parts catalogue
 Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removal of the alternator-side crankcase cover
 
 Notes
For clarity, the figures show the engine block removed from the frame.
 
Unscrew the bolts (11) and remove the chain guard (1).
Unscrew the two retaining bolts (6) of the centre cap (5) over the end of the crankshaft.
Unscrew the left-hand crankcase cover bolts (10), (11) and (12).
Recover the spacers (8), the washers (15) and the hose guides (9) and (14).
 
Fix service tool no. 88713.1749 to the holes left vacant by the two bolts (6) you have just removed.
Turn the tool shaft slowly to separate the cover (28) from the LH crankcase half.
Disassembly of the alternator-side crankcase cover
Undo the three stator retaining bolts (24) and the two bolts (31) securing the cable guide bracket (30) from inside the alternator‑side crankcase cover.
Remove the stator (32) and the cable guide (30).
The alternator-side crankcase cover is fitted with a bearing (26), held in place by circlip (27), which locates on the end of the crankshaft.
Remove the circlip (27) with circlip pliers.
Remove the bearing (26) using a universal puller.
Removal of the flywheel-alternator assembly
Use service tool no. 88713.2036 fixed to the M10 sidestand fixing holes (D).
Secure the tool to the flywheel with the bolt (E).
Unscrew the alternator/flywheel nut (34), heating it with a hot air gun; do not use a naked flame as this could damage the starting system components.
 Warning
While unscrewing the nut, apply axial pressure to the socket to avoid damage or injury in the event of the wrench suddenly slipping off the nut.
Remove the nut (34), the Belleville washer (33) and the flywheel assembly (22) complete with the gear (20).
Remove the inner race (18), the needle roller bearing (19) and the washer (17).
 Important
Examine the inner race (18), needle roller bearing (19) and internal washer (17) for wear.
 Notes
The hole in the inner race (18) allows the passage of oil for lubrication of needle roller bearing (19).
Checking the flywheel/alternator assembly
Examine the inner part of alternator rotor (23) for signs of damage.
Check that the starter clutch is working properly and that the needle races do not show signs of wear or damage of any kind.
If there is any malfunction, remove the whole assembly.
Disassembly of the flywheel-alternator assembly.
Unscrew the eight bolts (25) and remove the alternator rotor (23) from the flywheel.
Insert two of the bolts (25) just removed from flywheel rotor-side in their holes in order to remove the flange (13) and the starter clutch (21) from the flywheel (16).
The starter clutch is a slight interference fit on the flange. To remove it, use a suitable drift.
Reassembly of the flywheel-alternator assembly
Install the starter clutch (21) in the flange (13), making sure it is properly seated.
 Important
Orient the flange so that the side with the bevelled edge (A) faces the starter clutch.
Seat the flange (13) with the starter clutch in the flywheel (16), aligning the flange locating hole (B) with the flywheel locating hole (C).
When refitting the flange to flywheel, insert a pin or a wrench inside the hole (C) for the rotor flywheel locating dowel in order to line up the flywheel holes with the flange threads. This is a useful tip, as the holes cannot be aligned after having fitted the flange to the flywheel due to the interference fit.
Orient the flange so that the side with the bevelled edge faces the flywheel.
Install the rotor (23) on the flywheel (16), aligning the flywheel locating hole (E) with the rotor locating hole (D).
 
Apply threadlocker to the rotor/flywheel fixing bolts (25) and start them in their threads.
Tighten the bolts (25) to the specified torque (Sect. C 3, Engine torque settings).
Install the driven gear (20) on the starter clutch, ensuring it is properly seated.
 
Check that the driven gear can rotate freely in the direction of the green arrow but not in the direction of the red arrow.
If either of these two conditions is not met, this means that the starter clutch has not been installed correctly.
 
Refitting the flywheel-alternator assembly
Fit the washer (17) (suitably lubricated), needle roller bearing (19), and inner race (18) to the crankshaft. Make sure the inner race is centred relative to the washer.
Install the flywheel-rotor-driven gear assembly on the crankshaft, taking care not to alter the position of the inner race (18) relative to the washer (17).
The flywheel reference mark must be aligned with the groove on the crankshaft, in correspondence with the keyway.
 
Lubricate the contact surfaces of Belleville washer (33) with engine oil.
Fit the Belleville washer (33) on the end of the crankshaft.
Apply the recommended threadlocker to the threads of the crankshaft and the flywheel nut (34).
Restrain the rotation of the flywheel with the holding tool 88713.2036.
 Important
Tighten the nut (34) to the specified torque (Sect. C 3, Engine torque settings).
 
Remove all traces of Loctite from the threads of the nut (34) and the crankshaft (A).
Reassembly of the alternator-side crankcase cover
Fit the stator (32) to the crankcase cover, routing the cable through the notch in the cover.
Apply threadlocker to the stator fixing bolts (24) and tighten to the specified torque (Sect. C 3, Engine torque settings).
Fit the cable clamp (30) and fix it to the cover with the two bolts (31).
Before refitting, make sure that the crankshaft end bearing (26) and relative retaining ring (27) are installed in the alternator-side crankcase cover (28).
Refitting the alternator-side crankcase cover
Remove any scale and grease from the mating surfaces of the left-hand crankcase half and the crankcase cover.
Fit the two locating bushes (29).
Spread a continuous uniform bead of DUCATI liquid gasket on the mating surface of the cover (28), ensuring continuity around the holes for the retaining bolts and locating bushes.
Tap the cover at different positions with a rubber mallet to facilitate its location on the shafts and locating bushes.
Insert the retaining bolts in their holes following the indications given in the table.
 
M6x20 mm bolts
M6x25 mm bolts
M6x30 mm bolts
Under the screw (12), located in correspondence with the starter motor, fit the spacers (8), hose clips (9) and (14), and washers (15).
Tighten the fixing bolts to the specified torque (Sect. C 3, Engine torque settings).
Dampen the oil seal (3) with alcohol and install it in the alternator-side crankcase cover, in correspondence with the gearchange shaft (Sect. F 5, Refitting the gearchange control), using the specific installation tool 88713.1411.
Make sure that the O-ring (4) is installed in the cover (5).
Apply threadlocker to the bolts (6).
Tighten the two retaining bolts (6) of the inspection cover (5) over the end of the crankshaft to the specified torque (Sect. C 3, Engine torque settings).
Refit the chain guard (1) and tighten the bolts (11).