8 -
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
 Spare 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 generator cover
Note
This operation is described for an engine removed from the frame since all reassembly procedures are easier with the engine on the bench.
 
Disconnect the alternator cable connector from the main wiring (A).
Unscrew the two retaining screws (7) of the centre cap (6) over the end of the crankshaft.
Unscrew the screws (1), (11), (12) and (13) securing the alternator-side crankcase cover (29).
Fit the tool 88713.1749 to the holes of the screws (7) that have just been removed.
Turn the tool shaft slowly to separate the cover (29) from the LH crankcase half.
There is a sealing ring (4) on the cover (29) in correspondence with the gearchange shaft that may be damaged when removing the alternator cover.
Always check the condition of this sealing ring and renew it if damaged.
Disassembly of the alternator-side crankcase cover
Undo the three stator retaining screws (25) and the retaining screws (32) of the two cable guide brackets (31) from inside the crankcase cover.
Remove the stator (33) and the cable guide (31).
The alternator-side crankcase cover is fitted with a bearing (27), held in place by circlip (28), which locates on the end of the crank­shaft.
Remove the circlip (28) with circlip pliers.
Remove the bearing (27) using a universal puller.
Be careful when fitting the new bearing (27) to ensure it is positioned with the shielded side facing away from the cover.
Secure the bearing with the circlip (28), ensuring that it is correctly fitted in its seat in the crankcase cover (29).
Unscrew the horizontal and vertical cylinder coolant inlet unions (2).
Upon assembly of new components apply prescribed sealant and tighten to a torque of 25 Nm (Min. 23 Nm - Max. 27 Nm) (Sect. 3 - 3, Engine torque settings).
Important
The unions (2) may also be removed without removing the alternator-side crankcase cover (29) from the engine.
 
Refit the water pump components (B) as described in Sect. 9 - 3.3, Removal of the water pump.
Removing the flywheel - generator assembly
Use the tool 88713.3367 fixed to the M10 side stand fixing holes (D).
Secure the tool to the flywheel with the screws (E).
Unscrew the alternator-flywheel retaining nut (15).
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 (15), the washer (16) and the flywheel assembly (23) with the driven gear (21) from the crankshaft.
Remove the inner race (19), the needle roller bearing (20) and the washer (18).
Important
Check the race (19), the needle roller bearing (20) and the inner washer (18) for wear. Renew if worn.
Overhaul of the flywheel-alternator assembly
Examine the inner part of alternator rotor (24) 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.
Disassembling the generator flywheel
Unscrew the 8 screws (26) and remove the rotor (24) from the flywheel.
Insert two of the screws (26) just removed from the flywheel rotor-side in their holes in order to remove the flange (14) and the starter clutch (22) from the flywheel (17).
The starter clutch is a slight interference fit on the flange. To remove it, use a suitable drift.
Reassembling the flywheel - generator assembly
Install the starter clutch (22) in the flange (14) to bring the edge (A) of the clutch up against the flange.
Important
Assemble the components (starter clutch and flange) so that the edge (A) of the starter clutch is positioned on side of the flange with the bevelled edge (B).
Seat the flange (14) with the starter clutch (22) in the flywheel (17), aligning the flange locating hole (C) with the flywheel locating hole (D).
Note
The flange locating hole (C) is the hole with the countersunk lead-in (E).
Note
The locating hole (D) of the flywheel can be either one of the two holes (F).
Note
Use suitable tools to align the locating holes.
 
Important
Assemble the components (flange and flywheel) so that edge (A) of the starter clutch (22) is enclosed between the flange and flywheel.
Install the rotor (24) on the flywheel (17), aligning one of the flywheel locating holes (D) with the rotor locating hole (G).
Note
The rotor locating hole (G) is the hole positioned on the same diameter as the fixing holes (H).
Note
Use suitable tools to align the locating holes.
 
Apply threadlocker to the rotor-flywheel fixing screws (26) and start them in their threads.
Tighten the screws (26) to a torque of 13 Nm (Min. 11 Nm - Max. 15 Nm) (Sect. 3 - 3, Engine torque settings) following the se­quence above.
Lubricate the surface (L) of the driven gear (21) with engine oil.
Install the driven gear on the starter clutch, ensuring it is properly seated.
Note
To facilitate installation, rotate the driven gear in the direction of the green arrow.
 
Hold the flywheel (17) with one hand and 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 roller cage unit (20) with washer (18) and internal ring (19), applying prescribed grease on the washer (18).
Install the roller cage assembly (20) with the washer (18) and inner race (19).
Install the flywheel assembly (23) with the gear (21), aligning the notches as shown in the photo.
Fit the washer (16) on the end of the crankshaft.
Apply the recommended threadlocker to the thread on the end of the crankshaft and the nut (15).
Start the nut (15) on the crankshaft.
Lock the flywheel rotation by means of tool number 88713.3367 and tighten the nut (15) to a torque of 330 Nm (Min. 313 Nm - Max. 346 Nm) (Sect. 3 - 3, Engine torque settings).
Refitting the alternator-side crankcase cover
Make sure that the following parts are installed in the alternator-side crankcase cover (29) before refitting it:
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Install the water pump unit (Sec. 9 - 3.3, Refitting the water pump).
Remove any scale and grease from the mating surfaces of the left-hand crankcase half and the crankcase half cover.
Fit the two locating bushes (30).
Spread a continuous uniform bead of DUCATI liquid gasket on the cover mating surface, ensuring continuity around the holes for the retaining screws and bushes.
Grease the end of the crankshaft and the gearchange shaft to facilitate installation of the cover and to prevent the sealing ring (4) from being damaged, if already installed in the cover.
While positioning the cover (29) on the crankcase half, slightly turn the timing belt drive shaft pulleys to facilitate insertion of the pump control shaft.
The notch (M) on the alternator cover must be inserted on the starter motor gear pin (P).
Tap the cover at different positions with a rubber mallet to facilitate its location on the shafts and locating bushes.
Note
Should it be necessary to remove the cover again, fit the puller 88713.1749 located in the threaded holes in correspondence with the crankshaft.
Insert the fixing screws in their holes following the indications given in the table.
M6x25 mm screws
M6x20 mm screws
M6x30 mm screws
M6x25 mm banjo bolt
M6x30 mm banjo bolt
Tighten the retaining screws to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm) (Sect. 3 - 3, Engine torque settings).
Damp the sealing ring (4) with alcohol and install it in the alternator-side crankcase cover (29), in correspondence with the gearch­ange shaft.
Make sure that the O-ring (5) is installed in the cover (6).
Apply threadlocker to the screws (7).
Tighten the two screws (7) that retain cover (6) with the engine crankcase to the torque of 5 Nm (Min. 4.5 Nm - Max. 5.5 Nm) (Sect. 3 - 3, Engine torque settings).
Reconnect the alternator wiring to the main wiring loom (A).
 
 
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