8 - | Flywheel - alternator

1 | Clip

2 | Pick-up sensor inspection screw

3 | Seal

4 | O-ring

5 | Cover

6 | Screw

7 | Washer

8 | Spacer

9 | Cable guide

10 | Screw

11 | Screw

12 | Screw

13 | Flange

14 | Locating dowel

15 | Circlip

16 | Flywheel

17 | Washer

18 | Inner race

19 | Needle roller bearing

20 | Electric starter driven gear

21 | Starter clutch

22 | Flywheel-starter clutch assembly

23 | Alternator rotor

24 | Screw

25 | Screw

26 | Bearing

27 | Circlip

28 | Alternator-side crankcase cover

29 | Locating bush

30 | Bracket

31 | Screw

32 | Alternator stator

33 | Belleville washer

34 | Flanged nut

35 | Washer

36 | Breather hose cover

37 | Screw

Parts catalogue

Alternator-side crankcase cover
Electric starting and ignition
Air intake - oil breather

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

Operation | Section reference
Drain the engine oil | D 4, Changing the engine oil and filter cartridge
Remove the gearchange mechanism | F 5, Removal of the gearchange mechanism
Remoe the clutch slave cylinder | F 2, Removal of the clutch slave cylinder
Remove the front sprocket cover | G 8, Removal of the front sprocket

Notes
For clarity, the figures show the engine block removed from the frame.
Unscrew the two retaining screws (6) of the centre cap (5) over the end of the crankshaft.
Unscrew the screws (10), (11), (12) and (37) securing the alternator-side crankcase cover (36).
Recover the spacer (8), the Belleville washer (35) and the cable guide (9).
Fix service tool no. 88713.1749 to the holes left vacant by the two screws (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 screws (24) and the two screws (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 screw (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
Undo the eight screwss (25) and remove the alternator rotor (23) from the flywheel.
Slide out locating dowel (14) and circlip (15).
Insert two of the screws (25) just removed from flywheel rotor-side in their holes in order to remove the flange (13) and the starter clutch (21).
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 (14) in order to line up the flywheel holes with 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.
Fit the locating dowel (14) with the circlip (15) in the flywheel locating hole (C).
Install the rotor (23) on the flywheel (16), aligning the flywheel locating dowel (14) with the rotor locating hole (D).
Apply threadlocker to the rotor/flywheel fixing screws (25) and start them in their threads.
Tighten the screws (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 screws (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 screws (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 screws 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 fixing screws in their holes following the indications given in the table.

Ref | Qty | Description
10 | 2 | M6x20 mm screws
11 | 8 | M6x25 mm screws
12 | 2 | M6x30 mm screws
37 | 1 | M6x30 mm screws

Install under the screw (12), in correspondence with the starter motor, the spacer (8), the guide (9), the washer (35) and install the cover (36) under screw (11) in correspondence with the alternator lead: for instructions on the positioning of the wiring under the cover (36) see below.
Tighten the fixing screws to the specified torque (Sect. C 3, Engine torque settings).
Check that the fuel tank drain hose (T) and the airbox drain hose (U) are positioned in the lower slot of the cover (36) as shown.
Offer the cover (36) up to the alternator-side crankcase cover and position the fuel tank breather hose (T) and the airbox drain hose (U), the sidestand cable (R), alternator cable (S) and the starter motor cable (Q) as shown.
Important
The starter motor cable (Q) is the only cable that should be routed outside the cover (36).
Position the fuel tank drain hose (T), inserting it in the guide (9).
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 mechanism), using the specific installation tool 88713.1411.
Make sure that the O-ring (4) is installed in the cover (5).
Apply threadlocker to the screws (6).
Tighten the two retaining screws (6) of the inspection cover (5) over the end of the crankshaft to the specified torque (Sect C 3, Engine torque settings).

Operation | Section reference
Refit the sprocket cover | G 8, Refitting the front sprocket
Refit the clutch slave cylinder | F 2, Refitting the clutch slave cylinder
Refit the gearchange mechanism | F 5, Refitting the gearchange mechanism
Top up the engine oil | D 4, Changing the engine oil and filter cartridge

Positioning of cables/hoses under the breather hose cover mounted on the alternator-side crankcase cover