Closing the crankcase
Install O-ring (34) in its seat (35) in the crankcase half. Fit the hose (11) in the crankcase half, by inserting the end (36) fully in the O-ring.
Align the hole (37) of the hose with the threaded hole (38) in the crankcase half.
Position bushing under crankcase half jet (11), on generator side.
Apply threadlocker to the screw (10) and start it in the threaded hole (38).
Tighten the screw to a torque of 8 Nm (Min. 7 Nm - Max. 9 Nm).
If previously removed, apply specified threadlocker on dowel thread (39), and tighten to a torque of 20 Nm (Min. 18 Nm - Max. 22 Nm).
Install the timing layshaft (8) in the roller bearing (19) of the clutch-side crankcase half.
To avoid damaging the sealing ring (24) on the timing layshaft, protect the threaded end of the shaft with the special protective cap part no. 88713.3520.
Dampen sealing ring (24) with alcohol and fit it on the timing layshaft. Push seal until it is against the roller bearing (19).
The inner races (41) of gearbox shaft end bearings are installed on bearings.
Note
When refitting used components, before installing the gearbox assembly in the crankcase half, make sure that the inner races of the gearbox shaft bearings are fitted into the correct bearings and have not been left on the shafts.
Match gearbox shafts (4), fit the shim suitable for the gearbox secondary shaft, and fit shafts to the clutch-side crankcase half.
Insert the 1st-4th and 2nd-3rd speed selector forks (42) in their respective channels in the driven gears of the secondary shaft.
Note
The two selector forks are identical.
Insert the 5th-6th speed selector fork (43) in the driven gear of the primary shaft.
Install the selector drum (5) in the crankcase with calculated shim thickness.
Fit the pins (44) in the previously installed selector forks.
Fit the shimmed crankshaft (6) into the clutch-side crankcase half bearing, positioning the connecting rods (45) in correspondence with the relative cylinder barrel seats.
Check that the two centring bushes (30) are correctly fitted.
Grease the O-ring (9) to hold it in position and install it on the oil way connecting the two crankcase halves.
Make sure that the connecting rods (45) are correctly positioned in the respective cylinder seats.
Incorrect positioning of the connecting rods at this stage will inevitably lead to the need to re-open the crankcase half.
Apply a uniform and continuous bead of DUCATI sealing compound to the mating surfaces of the crankcase halves, going around all the holes as shown.
Bring the crankcase halves (12) and (13) together, tapping with a rubber mallet in the area of the shafts, if necessary.
Prepare the crankcase bolts and insert them in the alternator-side crankcase half (12); note that the bolts are of different lengths.
 
Ref.
 
Q.ty
 
Description
 
1
 
7
 
screws M8 x 75 mm
 
2
 
2
 
screws M6 x 75 mm
 
3
 
7
 
screws M6 x 35 mm
Progressively tighten the crankcase bolts until fully seated, starting with the bolts of the largest diameter (M8).
Insert two M8 bolts (1) in the clutch-side crankcase half (12).
Tighten all screws to the torque specified below:
-
screws (1) first to a snug torque of 19 Nm (Min. 17 Nm - Max. 21 Nm), then tighten to 25 Nm (Min. 22 Nm - Max. 28 Nm);
-
screws(2) and (3) to a tightening torque of 10 Nm (Min. 9 Nm - Max. 11 Nm).
Check that the crankshaft can be turned with a certain amount of interference with the main bearings (the crankshaft should have a pre-load of 0.15 to 0.20 mm); also check that all the parts you have fitted are free to rotate or move correctly.
Fit the sealing ring (23) on the gearbox secondary shaft using the suitable tool (T).
Refit the mesh filter (Changing engine oil and filter cartridge).
Refit the primary drive gear (Refitting the primary drive gear and checking the backlash).
Refit the oil pump (Refitting the oil pump).
Refit the clutch unit (Refitting the clutch).
Refit the clutch cover (Refitting the clutch cover).
Refit the starter motor (Refitting the starter motor).
Refit the complete generator (Refitting the flywheel/generator unit) and the generator side cover (Refitting the generator cover).
Refit the cylinder/piston assembly (Refitting the cylinder/piston assembly).
Refit the complete cylinder head unit (Refitting the cylinder head assemblies).
Refit the timing belt pulleys (Refitting the head pulleys/idler pulleys).
Refit the timing belts (Refitting the timing belts).
Refit the timing outer covers (Refitting the timing outer covers).
Refit the engine on the frame (Refitting the engine).