srv-tsb-18-001 starter clutch and flywheel replacement

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move drain ca

move the 2 sc

move the 2 sc

move the 3 sc



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crews M6x4

crews M4x1

crews M6x16



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6 (8) securin

Flywheer 2016-2

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USA

tand.

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ng the gear s

ng the clutch

el Replac017 XDi

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oil sump and

6x16 (4) secu

sensor (7).

h actuator (9

cement avel (all

d drain the f

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9).

model a

fluid.

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and

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6) Rem

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move screw M

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move clutch p

move the screlever out.



M6x16 (10) a

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ew M6x18 (1



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Flywheer 2016-2

-TSB-18

USA

washer (11)

ave cylinderc band as sh

the gear sh

el Replac017 XDi

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securing th

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hift lever to t

cement avel (all

he engine rp

engine rpm figure.

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pm sensor (1

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10) Rem

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Flywheer 2016-2

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USA

ver out, mat timing for

ng the wirin

el Replac017 XDi

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ke a mark othe subsequ

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cement avel (all

on it and onuent reasse

).

model a

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11) Rem

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move generaspecial scrthe 2 specthe 9 screwscrew M6x

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tor cover (21rew M6x35 (cial screws Mws M6x30 (1x35 (20).

crews M6x14

ew M6x1 (24



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4 (22) secur

4) securing t

Flywheer 2016-2

-TSB-18

USA

ing:

ing the timi

the side stan

el Replac017 XDi

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ng inspectio

nd switch.

cement avel (all

on cover (23

model a

3).

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14) Rem

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move the 2 sc

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Flywheer 2016-2

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USA

ing the LH f

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front heel gu

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ontal head e.

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Flywheer 2016-2

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USA

d the gearcith a cloth.

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positioned

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Flywheer 2016-2

-TSB-18

USA

the driven ti

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el Replac017 XDi

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iming gear t

cement avel (all

timed with t

model a

the engrave

and

ed points of

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17) Instahole

18) Rem

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ate the remo

tool Part no

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Flywheer 2016-2

-TSB-18

USA

driving the 2he 2 screws

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el Replac017 XDi

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ol Part no.88king flange es on the flycrankshaft p

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remove th

33931

Flywheer 2016-2

-TSB-18

USA

wheel driving

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ear, flange,

cement avel (all

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22) Rem

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bearing cage

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o. 887133931

e (31) and bu

of the rolleem gear in o

aces (33) ofr to remov

Flywheer 2016-2

-TSB-18

USA

.

ushing (32).

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el Replac017 XDi

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age and of id loosing t

rator cover dues of the

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25) Thor

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move the 8 sc



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crews M6x2



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Flywheer 2016-2

-TSB-18

USA

haft and nu

ng the rotor

el Replac017 XDi

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t (28) from t

r (35) to the

cement avel (all

the Loctite

flywheel so

model a

648 previou

as to recove

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usly applied.

er the rotor.

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ation of the

lywheel assegned with t

Flywheer 2016-2

-TSB-18

USA

no. 6992831

flywheel ass

embly of kithe engrave

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el Replac017 XDi

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12A and rem

sembly pres

t Part no. 6ed point (37

NEW

ication groov

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move the ser

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ves

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vice screw.

art no.69928

orienting it ywheel, as s

and

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tion of kit P

TTENTION efore instalriven timingthe figure.



ws M6x25 (Afollowing th

Part no. 6992

ling the flyw gear are tim



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wheel assemmed with th

Flywheer 2016-2

-TSB-18

USA

in the kit Pashown in th

mbly, check he engraved

el Replac017 XDi

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art no.69928he figure.

that the 2d points of t

cement avel (all

8312A and ti

2 engraved the primary

model a

ighten them

points prestiming gear

and

m to a torque

ent on the r, as shown

e

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all the flywhned with the

rt the coppeper washer m



eel assembly

ushing with S

heel assembe lowered to

er washer smust be use



y and install

Shell Gadus

ly on the crooth (38) on

supplied wited ONLY to

Flywheer 2016-2

-TSB-18

USA

l roller bear

S2 V220 gr

ankshaft mathe cranksh

h special to insert the

el Replac017 XDi

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ing cage (31

rease.

aking sure thaft.

ool Part no. flywheel co

cement avel (all

1) and bushi

that the hol

887133931 mpletely on

model a

ing (32) as s

e (37) on th

on the crann the cranks

and

shown in the

e flywheel i

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e

s

e e

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hammer, dri

make sure gear teeth.

Flywheer 2016-2

-TSB-18

USA

final tightenhase

ve the flywh

that the d

el Replac017 XDi

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ning use the

heel assemb

driven gear

cement avel (all

e washer (29

bly fully hom

teeth are

model a

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me on the cra

NOT overla

and

n the engine

ankshaft.

aid on the

e

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4) Instahole

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tighten nunecessary

remove nu

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ut (28) with to tighten t

ut (28) and c

t no.8871333



887133367 dtart the 2 sc

he instructio

copper washe 2 screws

copper wash

3367

Flywheer 2016-2

-TSB-18

USA

driving the 2crews (27).

ons below:

sher to a tos (27) progre

er;

el Replac017 XDi

-001

2 pins (26) f

orque of 330ssively;

cement avel (all

ully home in

0 Nm ± 5%

model a

n correspond

; during thi

and

dence of the

s phase it i

e

s

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insert the

apply 3 be

apply LOC

ATTDo

Perform th

NOTho



steel washe

ads of LOCT

TITE 648 th

TENTION not exceed

he final tight

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er (29) previo

TITE 648 on

hroughout n

the quantity

tening of nu

an the nut t

Flywheer 2016-2

-TSB-18

USA

ously remov

the cranksh

ut (28) first

y of LOCTIT

ut (28) to a t

top side from

el Replac017 XDi

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ved;

haft thread,

3 threads a

TE 648 requi

torque of 33

m LOCTITE 6

cement avel (all

as shown in

s shown in t

ired and sho

30 Nm ± 5%.

648 residue

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n the figure.

the figure.

own in the p

.

s.

and

icture.

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6) Rem

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move special

reassembly

ly a bead ofkcase couple

ATTENTIBefore ap there there the su

all the genehe crankcase

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tool Part no

y

f ThreeBonded with the

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urface is wel

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eeBond 1207any type insany type onl dry and if n

(21) within

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Flywheer 2016-2

-TSB-18

USA

7.

ck sealing cover.

7B black seaside the cra

n the sealantnot run a cle

5 minutes o

ning rubber.

el Replac017 XDi

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compound a

aling compounkcase; t application

ean cloth ove

of applying

r element (3

cement avel (all

along the en

und check th

n surface; er it again.

the sealant

39) is correct

model a

ntire surface

hat:

t and drive i

tly fitted in t

and

e (34) of the

t fully home

the relevant

e

e

t

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3) Startscrew

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4) Fit ti

5) Fit tstan

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t special scw M6x35 (20

ten all the s

iming inspec

the side stad. Tighten t



rew M6X350).

screws to a t

ction cover (

nd switch bthe retaining



(17), the 2

torque of 13

23) by tighte

by inserting g screw M6X

Flywheer 2016-2

-TSB-18

USA

special scre

Nm ± 10% f

ening the 2 s

the timing X1 (24) to a t

el Replac017 XDi

-001

ews M6X30

following the

screws M6x1

pin (40) oftorque of 5

cement avel (all

0 (18), the 9

e sequence

14 (22) to a to

f the switchNm ± 10%.

model a

screws M6

shown in th

orque of 5 N

in the hole

and

x30 (19) and

e figure.

m ± 10%.

e (41) of the

d

e

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6) Fit t

7) Insermark

8) Appl

9) Fix L

10) Rele

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rt the gear ked.

ly Loctite 22

LH front hee

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over (16) by t

shift lever

22 on the th

el guard by t

lave cylinde



tightening t

on the gea

read of scre

tightening th

er, engine rp

Flywheer 2016-2

-TSB-18

USA

the 3 screws

rbox selecto

w M6x18 (14

he 2 screws

m sensor an

el Replac017 XDi

-001

s M5x12 (15)

or shaft foll

4) and tight

M5X10 (25)

nd gear sens

cement avel (all

to a torque

lowing the

en to a torq

) to a torque

sor from the

model a

e of 4 Nm ± 1

initial timin

ue of 10 Nm

e of 5 Nm ±

e elastic ban

and

10%.

g previously

m ± 10%.

10%.

d.

y

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11) Inser

12) Fix c

time

13) Tigh

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rt clutch pus

clutch actuaed by insertin

ten the 3 sc



shrod (13) al

ator (9), whing anti-rota

crews M6x16



ligning anti-

ch includes ation pin (42

6 (8) to a tor

Flywheer 2016-2

-TSB-18

USA

-rotation pi

the anti-rot2) into the se

rque of 10 N

el Replac017 XDi

-001

n (42) with h

tation insereats (44) on

Nm ± 10%, fo

cement avel (all

holes (43), a

t, on the clun the anti-ro

ollowing seq

model a

as shown in t

utch pushrootation inser

uence 1 – 2

and

the figure.

od previouslyrt.

– 3 – 1.

y

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14) Fix esprin

15) Positthe f

Appl

16) To in

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engine rpmng washer (1

tion gear sefigure.

ly Loctite 243

nstall the dr

clean the threadlock



m sensor (1211) to a torqu

ensor (7) on

3 on the thre

iving pulley

threads ofker previousl



2) on generaue of 10 Nm

the generat

eads of the 2

cover (5) it

f the 2 scrly applied;

Flywheer 2016-2

-TSB-18

USA

ator cover bm ± 10%.

tor cover ma

2 screw M4x

is necessary

ews M6x25

el Replac017 XDi

-001

by tightenin

aking sure t

x16 (6) and tig

y to:

5 (3)and of

cement avel (all

ng screw M

that the lab

ghten to a to

screw M6

model a

M6x16 (10) w

el is visible,

orque of 2.5

6x16 (4) to

and

with relevan

as shown in

Nm ± 10%.

remove the

t

n

e

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17) Befo

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apply Loct

tighten th

ore inserting

clean the e

apply Thre

tighten th



tite 243 alon

e 2 screws M

g drain cap (1

entire thread

eeBond 1215

e drain cap



ng the threa

M6x45 (3) an

1) with relev

d of the cap

5 grey along

(1) to a torq

Flywheer 2016-2

-TSB-18

USA

ds of the 2 s

nd screw M6

vant washer

;

the whole t

ue of 20 Nm

el Replac017 XDi

-001

screws M6x

6x16 (4) to a

(2), it is nec

thread of th

m ± 10%.

cement avel (all

x25 (3) and o

a torque of 6

cessary to:

e cap.

model a

of screw M6x

6 Nm ± 10%.

and

x16 (4);

.

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18) RemTigh

19) Ens

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6992

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move the filleten the fille

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t no.

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heel and sta

Flywheer 2016-2

-TSB-18

USA

the oil previoNm ± 5%.

ly and check

update is as

tion

rter clutch k

el Replac017 XDi

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ously draine

k the correct

follows:

kit

cement avel (all

ed until it rea

t operation o

Q.ty

1

model a

aches the re

of the safety

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and

equired level

y switch.

ge

l.

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Warranty Reimbursewarranty c The warra You will be

for 150

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the re

Warranty Audits.

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Service DeDucati No

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ement for wclaim proced

nty claim is

e reimbursed

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levant comp

Claims filled

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epartment rth America



work associadure using th

pre-filled an

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of labor timeeption; on of the flyt the warran

ponent requ

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operation.

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nd is identif

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ywheel and snty claim.

uired to carry

fferent way

Flywheer 2016-2

-TSB-18

USA

this Service ns section o

ied as CR145

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y might be c

el Replac017 XDi

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Campaign of the DCS.

5.

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