Ducati Diavel Instruction manual

1 - General
file:///C|/Documents%20and%20Settings/Jairo/Escritorio/diavel/en/Diavel_Carbon_11_1.1.1.html[20/03/2013 19:25:04]
01 - General
02 - Information about the model
03 - Technical data
04 - Maintenance operations
05 - Fairings
06 - Electric system and engine control system
07 - Chassis
08 - Fuel/Exhaust System
09 - Engine
0GENERAL INDEX
Section 1
01 - General
1 - How to use this manual 3
How to use this manual 3
Layout of the manual 4
2 - Symbols - Abbreviations - References 5
Product specifications 6
3 - Hazardous Products - Warnings 8
General safety rules 8
General maintenance indications 10
Section 2
02 - Information about the model
1 - Identification data 3
Diavel identification data 3
Section 3
03 - Technical data
1.1 - Technical specifications 3
General 3
Colours 4
Transmission 4
Timing system/valves 5
Crankshaft 5
Cylinder/Piston 6
Gearbox 6
Cooling system 7
Front wheel 7
Front suspension (Diavel ABS) 7

1 - General
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Front suspension (Diavel Carbon ABS) 7
Rear wheel 7
Rear suspension (Diavel ABS) 8
Rear suspension (Diavel Carbon ABS) 8
Hydraulic brakes 8
Charging system/alternator 9
Injection-ignition system 9
Fuel system 9
Injection system 9
Lights/instrument panel 10
1.2 - Dimensions 11
2 - Fuel, lubricants and other fluids 12
3 - Torque settings 13
Frame torque settings 13
Engine torque settings 20
4 - Service tools 23
Specific tools for the engine 23
Specific tools for the frame 30
Appropriate diagnosis tools 33
Section 4
04 - Maintenance operations
1 - Vehicle pre-delivery 3
2 - Scheduled maintenance chart 4
Operations to be carried out by the dealer 4
List of operations to be performed at 1000 km 4
Operations to be carried out by the dealer 5
List of operations to be performed every 12000 km / year (first limit reached) 5
Operations to be carried out by the customer 5
List of operations to be performed every 1000 km 5
3 - Maintenance operations 6
Reading of the error memory with DDS on the engine control units, vehicle and ABS 6
Check engine oil level 6
Changing the engine oil and filter cartridge 7
Checking valve clearances 11
Change timing belts 14
Spark plugs replacement 15
Changing and cleaning the air filters 17
Checking the coolant level 20
Changing the coolant 21
Changing the brake fluid 23
Changing the clutch fluid 28
Draining the clutch hydraulic circuit 29
Filling the clutch circuit 32
Adjusting the steering head bearings 34
Adjusting the chain tension 35
Checking brake pad wear and changing brake pads 36

1 - General
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Adjusting the throttle cable 41
Adjusting the clutch lever and front brake lever 43
Adjusting the position of the gear change and rear brake pedals 44
Adjusting the front fork 45
Adjusting the rear shock absorber 47
Section 5
05 - Fairings
1 - Rear-view mirrors 3
Removal of the rear-view mirrors 4
Refitting the rear-view mirrors 4
2 - Fairings 5
Removal of the fuel tank fairings 6
Disassembly of the front half-fairings 9
Reassembly of the front half-fairings 10
Refitting the fuel tank fairings 12
3 - Seat 19
Removal of the seat 20
Disassembly of the seat 20
Reassembly of the seat 21
Refitting the seat 22
4 - Front and rear mudguard 23
Removal of the front mudguard 24
Refitting the front mudguard 26
Removing the rear mudguard 27
Refitting the rear mudguard 27
5 - Belly fairing 28
Removal of belly fairing 29
Reassembly of belly fairing 32
6 - Electrical components support 37
Removing the electrical components support 38
Reassembling the electrical components support 40
Section 6
06 - Electric system and engine control system
1 - Wiring diagram 6
Key to wiring diagram 7
Wiring diagram colour codes 8
Rear left fuse box (1) key 8
Rear right fuse box (2) key 8
Routing of wiring on frame 9
Table A 11
Table B 13
Table C 14

1 - General
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Table D 15
Table E 17
Table F 19
Table G 20
Table H 21
Table J 23
Table K 24
Table L 25
Table M 26
Table N 27
Table O 29
Table P 31
Table Q 32
Table R 33
Table S 38
Table T 39
Table U 42
Table V 43
Table W 44
Table X 46
2 - Battery charging system 49
Checking the battery charging system 49
Recharging the battery 50
Topping up the electrolyte 51
Battery 55
Alternator 59
Rectifier-regulator 62
3 - Electric starting system 64
Electric starting system 64
Starter motor 64
Solenoid starter 69
4 - Lights and indicating devices 71
Renewal of the headlight 71
Changing bulbs 75
Headlight aim 78
5 - Indicating devices 79
Checking the indicating devices 79
6 - Protection and safety devices 85
Checking protection and safety device components 85
Checking the fuses 86
7 - Instruments 87
Dashboard 87
Dashboard system 89
LCD unit functions 91
Vehicle speed indicator 92
Engine rpm indicator (RPM) 93
Clock 94
Coolant temperature 95
Dashboard on tank 96
TFT - Parameter setting/display 96
Total distance covered indicator: “Odometer“ 97

1 - General
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“Trip 1“ meter 98
“Trip 2“ meter 99
Distance travelled on fuel reserve: “TRIP FUEL“ 99
Indicator “CONS. AVG“ - Average fuel consumption 100
Indicator “CONS.“ - Instantaneous fuel consumption 100
Indicator “SPEED AVG” - Average speed 101
Indicator “TRIP TIME“ - Trip time 101
Indicator “AIR” - Air temperature 102
Engaged gear indicator 102
“Riding Mode set“ indication 103
Indication if the “LAP” function is active/not active 103
“Riding Style” function (riding style change) 104
Maintenance indicator 105
First warning - OIL SERVICE 1000 Km 105
Residual range indication when the SERVICE is due 106
Indication of range reached for SERVICE 106
Warning indication (Alarms/Signals) 107
“Low” battery level 108
Traction Control (DTC) deactivated 108
Hands Free key (HF) not recognised 109
“Low“ Hands Free key (HF) battery level 109
“High“ engine coolant temperature 110
Steering release error - Steering still locked 110
Dashboard diagnosis 111
“Setting” menu 113
“Riding Mode” customisation 115
DTC (Ducati Traction Control) setting function 117
Tips on how to select the sensitivity level 118
ENGINE setting function (Engine Power Control) 119
DEFAULT function (Resetting Ducati default parameters) 120
Menu 2 On/Off function 121
Background setting function for the dashboard on tank - DASHBOARD 1 122
Backlighting setting function for the dashboard on handlebar - DASHBOARD 2 123
Digital RPM indication function 124
LAP Activation/Deactivation function (lap time) 125
LAP registration function 126
Stored LAP display function 128
Stored LAP erase function 129
Battery voltage indicator (BATTERY) 130
Clock setting function 131
Units of measurement modification function 132
ABS disabling function 134
Immobilizer override procedure 135
PIN CODE change function 136
8 - The Hands Free system 138
Introduction to the “Hands Free“ system 138
Operating principle 138
How to turn the motorcycle on 139
How to switch the dashboard on 139
How to start the engine 140
How to start the motorcycle if the active key is not working 141
How to start the motorcycle without keys 141
How to turn the motorcycle off 142
Recovery and emergency procedures 144
Recovery procedure with no key 144
Recovery in the event of flat active key battery 145

1 - General
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Recovery procedure in the event of electric steering lock fault 145
Recovery procedure in the event of Hands Free system fault 146
Start procedure with PIN code (no keys) 146
How to enable engine start with PIN code 147
How to enable the PIN code 147
How to reset the PIN code 147
Wiring diagram of the Hands Free system 148
Possible faults of the Hands Free system components 152
The Hands Free module 152
Communication antenna 154
On/off switch on handlebar 156
The Hands free relay 158
Active key 159
Passive key 162
Programming/reprogramming keys 163
9 - Introduction to the engine control system 164
Specific operating strategies 164
Inputs and outputs of engine control unit and connection to CAN network 165
Layout of engine control system and other components 166
Removal of the control unit 167
Reassembly of the control unit 168
Fuel system circuit 170
Injection and ignition 173
Operating principle and characteristics of the ride-by-wire system 177
Explanation of the function of the ride-by-wire system 182
Anti-pollution system and auto-adaptive strategy 184
Ignition coils 189
Injectors 193
Throttle valve operation engine 195
Engine start button 197
Clutch lever button 199
Side stand button 201
Injection relay 203
Throttle valve actuator motor relay 205
Starter motor relay 207
Radiator fan relay 209
Engine speed-timing sensor 211
Accelerator position sensor (throttle grip) 213
Throttle valve position sensor 215
Component assembling position 215
Air temperature sensor 217
Engine temperature sensor 219
Absolute pressure sensors 221
Oxygen sensors 223
On-board computers and the CAN line 227
Fault indication 228
Operating principle of DTC 229
Riding Modes 230
The battery charging circuit and power distribution 231
Ground connection locations 232
Electrical power for lighting and signalling devices 232
Location of elements on motorcycle 234
High beam lights not working 236
Low beam lights not working 238
Horn not working 240
Turn indicators not working 242

1 - General
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High beam flash not working - start/stop lap function not working 244
Number plate light not working 245
Running lights not working 246
Dashboard menu option scrolling not possible 247
Resetting turn indicators not possible - accessing dashboard menu not possible 248
Gear indicator display on dashboard shows dashes, engaged gear not displayed correctly, idle speed irregular
with gearbox in neutral. 249
Dashes shown instead of speed indication or indicated speed is incorrect. 252
ABS fault indicator not working 255
ABS disabled information not displayed. 255
Wiring diagram 255
Stop light not working 256
Exhaust By-pass valve not working correctly 258
11 - Diagnostic instruments 260
Using a multimeter to check the electrical systems 260
Description of the diagnosis instrument (DDS) 262
Tester power supply 264
DDS diagnosis instrument 267
Checking and adjusting timing belt tension 268
Checking the idle speed 272
Check the idle and the CO amount with warm engine 272
Check the engine oil pressure 273
Cylinder compression test 277
Fuel pressure test 281
Guided diagnosis 285
Testing the battery charging system 288
Deactivating the “service” indication on the dashboard 291
ABS diagnosis 294
Icons table 295
Section 7
07 - Chassis
1 - Front wheel 5
Removal of the front wheel 6
Overhauling the front wheel 9
Refitting the front wheel 12
2 - Rear wheel 15
Removing of the rear wheel 16
Overhauling the rear wheel 16
Refitting the rear wheel 18
3 - Front brake control 19
Removal of the front brake master cylinder 21
Refitting the front brake master cylinder 22
Maintenance operations 24
Removal of the front brake system 24
Removal of the brake discs 26
Overhauling the front brake components 26
Refitting the brake disks 26
Refitting the front brake system 27

1 - General
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4 - Rear brake
30
Removing of the rear brake control 32
Disassembly of the rear brake control 34
Refitting the rear brake control 35
Removal of the rear brake calliper 39
Removal of the rear brake disc 40
Refitting the rear brake calliper 41
5 - ABS system information 42
Operating principle 42
ABS system operating information 43
ABS system deactivation 45
6 - System components 46
Replacing the front phonic wheel sensor 47
Replacing the rear phonic wheel sensor 49
Removing of the ABS control unit 51
Refitting the ABS control unit 52
Flexible wiring/hoses positioning 54
Table A 55
Table B 57
Table C 62
7 - ABS components maintenance 68
Adjusting of the AIR-GAP phonic wheel sensor 68
Bleeding of the ABS hydraulic system 71
8.1 - Handlebar unit: Throttle twistgrip 72
Removal of the handlebar 73
Refitting the handlebar 74
Adjusting the throttle cable 75
Removal of the throttle twistgrip 75
Refitting the throttle twistgrip 76
8.2 - Handlebar unit: Hydraulic clutch control 77
Removal of the clutch master cylinder assembly 78
Refitting the clutch master cylinder assembly 79
Removal of the clutch transmission unit 81
Refitting the clutch transmission unit 82
8.3 - Handlebar unit: Hands free 89
Removing the Hands Free 90
Refitting the Hands Free 91
9 - Gearchange mechanism 92
Removal of the gearchange control 93
Disassembly of the gearchange mechanism 93
Refitting the gearchange mechanism 94
10.1 - Fork - Steering head: front fork 95
Removal of the front forks 96
Overhauling the front forks 97
Refitting the front forks 105
10.3 - Fork - steering head: Steering 107
Adjusting the steering head bearings 108

1 - General
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Steering angle adjustment 109
Removal of the steering head components 110
Refitting the steering head components 114
12 - Rear shock absorber assembly 120
Rear suspension system 121
Removal of the rear shock absorber 122
Overhauling the rear shock absorber 123
Disassembly of rear shock absorber - rocker arm - linkage assembly 123
Reassembly of rear shock absorber - rocker arm - linkage assembly 124
Refitting the rear suspension 128
Removal of the shock absorber support 130
Refitting the shock absorber support 131
13 - Swingarm 138
Removal of the rear wheel eccentric hub and rear wheel shaft 140
Refitting the rear wheel eccentric hub and rear wheel shaft 142
Removal of the swingarm 146
Inspecting the swingarm pivot 149
Overhauling the rear swingarm 150
Refitting the swingarm 154
14 - Final drive 157
Inspecting the final drive 158
Removing of the front sprocket 159
Refitting the front sprocket 161
Replacing of the rear sprocket 163
Refitting the rear sprocket 164
Washing the chain 165
Lubricating the chain 165
15 - Footrest brackets 166
Removal of the front footrests 167
Refitting the front footrests 168
Removing the front footrest brackets 170
Reassembling the front footrest brackets 171
Removing of the rear footrests 172
Refitting the rear footrests 173
16 - Stands 176
Removing of the side stand 177
Refitting the side stand 180
17 - Frame inspection 181
Disassembly of structural components and the frame 183
Removal of the tool tray 185
Removing the frame and the lateral footrests 186
Checking the frame 187
Reassembly of structural components and the frame 188
Reassembling the frame and the lateral footrests 196
Reassembly of the tool tray 199
18 - Tail light - number plate holder 201
Removal of the licence plate holder 202
Refitting the number plate holder 203
Removal of the tail light 206
Refitting the tail light 207