Ducati Scrambler 800 - Service manual > Crankcase: external components

Refitting the starter motor

Start retaining screws (2) with specified threadlocker.

Tighten the screws (3) to a torque of 10 Nm (min. 9 Nm. - max. 11 Nm).

Connect the connector (1).

Removing the starter motor

Remove the generator cover (Removing the generator cover).

Remove starter motor connector (1).

Loosen screw (3) and the two screws (2).

Remove starter motor (4).

Refitting the starter motor idler gear

Refitting is the reverse of removal.

Apply indicated threadlocker to screw (5) of pin (6) and tighten it to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm).

Removing the starter motor idler gear

Remove the snap ring (1) and washer (2).

Remove the starter motor idler gear (3) and washer (4).

Loosen screw (5) securing pin (6) and remove the latter.

Refitting the timing gears

Important The two timing gears must always be replaced as a pair.

Check the presence of the timing layshaft key (4) and the crankshaft key (6).

Refitting is the reverse of removal.

Align the two references of the timing layshaft gears with the camshaft reference.

On completion of the refitting operations, check that washer (2) is staked against nut (3) in such a way to prevent the nut from working loose.

Removing the timing gears

Slide out the driving gear (1) of the timing gears.

Straighten out the lock washer (2) of timing gear lock nut (3).

Restrain the timing gear by inserting a pin in one of the holes, and unscrew the locking nut (3).

Slide out nut (3), washer (2) and driven timing gear (4).

Refitting the external components

Check the condition of O-rings (3) and replace them if necessary.

Install the blow-by valve (2) in the crankcase along with O-rings (3), previously lubricated.

Tighten screw (1) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm).

Fit nuts (5) on nipples (4).

Apply recommended threadlocker to the plug thread (4). Tighten nipples (4) to a torque of 32 Nm (Min. 29 Nm - Max. 35 Nm).

Apply the recommended threadlocker on nipple (6).

Tighten oil filter cartridge support nipple (6) to a torque of 42 Nm (Min. 38 Nm - Max. 46 Nm).

Screw the drain plug (12) with seal (13) to a torque of 20 Nm (Min. 18 Nm - Max. 22 Nm) after applying the specified product.

Refit the neutral switch (14) and the relevant seal (15) by tightening to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm).

Apply threadlocker to plug (10), start it with the relevant gasket (11) and tighten the plug to a torque of 25 Nm (Min. 22 Nm - Max. 28 Nm).

Refit the mesh filter (9).

If previously removed, refit the stud bolts (16) on the crankcase halves, applying sealant on the thread and tightening to a torque of 30 Nm (Min. 28 Nm - Max. 32 Nm).

Make sure that the O-rings (20) are fitted on the crankcase.

Fit the pick-up sensor (17) in its seat in the crankcase half.

Start the screw (18) with the washer (19) and tighten to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm).

Use a feeler gauge to check the clearance between the engine sensor (17) and the timing gear (23).

The value must be between 0.6 and 0.8 mm.

Fit on the casing the ball (25), spring (26), pad (24) and tighten bush (21) with gasket (22) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm).

Refit the cylinder/piston assembly (Refitting the cylinder/piston assembly).

Refit the cylinder heads (Refitting the cylinder heads).

Refit the generator cover (Refitting the generator cover).

Refit the oil pump (Refitting the oil pump).

Refit the clutch cover (Refitting the clutch cover).

Refit the engine in the frame (Refitting the engine).

Removing outer components

Remove the engine from the frame (Removing the engine).

Remove the clutch cover (Removing the clutch cover).

Remove the complete clutch unit (Removing the clutch).

Remove the oil pump (Removing the oil pump).

Remove the generator cover (Removing the generator cover).

Remove the heads (Removing the engine heads).

Remove the cylinder (Removing the cylinder/piston assembly).

Undo screw (1) and remove the blow-by valve (2) from the engine.

Check the condition of the O-rings (3) located in the casing and replace them if necessary.

Loosen and remove the two nipples (4) from the clutch crankcase half and collect washers (5).

Loosen and remove the oil filter cartridge.

Loosen and remove oil filter supporting nipple (6).

Loosen plug (7) and remove seal (8).

Remove the mesh filter (9) from the clutch-side crankcase half.

Loosen plug (10), taking care not to damage seal (11).

Remove the drain plug (12) with its seal (13).

Remove the neutral switch (14) and the relevant seal (15).

Remove the cylinder head stud bolts (16) with the aid of the appropriate tool.

To remove the engine sensor (17), undo the screw (18) and collect the washer (19).

Check the condition of O-rings (20) on the crankcase half and replace them if necessary.

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