SRV-TSB-19-012
Service Bulletin Details
Public Details for: SRV-TSB-19-012
Cr186 - rear brake hoses check and replace if req. - applicability: xdiavel model year 2016-2020 (all models). This technical service bulletin provides dealers and service managers information about an identified potential for the rear bra
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CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Date: To: From: December 6, 2019 Dealer Principal, General Manager, Service Manager, North American Dealer Network Richard Kenton, Technical Director Eric Bradley, Technical Training and Publications Manager Dear Dealers, Ongoing product quality testing and field reports have identified a potential for the rear brake application to soften over time as a consequence of use. To correct in cases of this occurrence, new rear brake hoses (ABS control unit to rear brake master cylinder - green - and ABS control unit to rear brake caliper - yellow) are now available for the above listed model. OLD NEW NOTE All XDiavel model versions currently produced and being shipped by DMH to all destinations have already been equipped with these new brake hoses 1/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Application You can find the precise list of VIN numbers involved in CR186 on the DCS, in sections: VIN HISTORY It is possible to search by individual frame number. CAMPAIGNS It is possible to search for all the frame numbers that you received from Ducati Motor Holding. Customer Impact All motorcycles in your inventory (to be registered or already registered) and to be delivered to final Customers must be updated during pre-delivery operations and always before delivery to the final Customer. All motorcycles already delivered to final Customers must undergo this inspection as soon as they come to your workshop. Note: this is NOT a safety recall. Parts Distribution If required, the following components required to carry out the upgrade under this Workshop Campaign must be ordered for each affected frame number. 61911361A: ABS control unit / rear brake master cylinder hose 61911341A: ABS control unit / rear brake caliper hose 85250241A: Copper washers (8pcs) The required self-locking ties (small (7 pcs) and large (3 pcs)) are easy to find consumables and should be sourced locally. 2/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Warranty Reimbursement Rules Reimbursement for work associated with this Service Campaign will be made through the regular warranty claim procedure using the “Vehicle History” section of the DCS. The warranty claim is pre-filled and is identified as CR186. Two operation types are provided and described below: Operation TYPE 1: Description TYPE 1 Check rear brake pedal travel Spare Parts No Parts Required Labor 12 minutes (2 LU) Operation TYPE 2: Description TYPE 2 Check rear brake pedal travel and replace rear brake lines Spare Parts Rear brake hoses and washers Labor 2h:54min (29 LU) Operation Type 2 includes reimbursement for the parts listed for the operation; copper washers (8) part no. 85250241A, ABS control unit / rear brake master cylinder hose Part no.61911361A, ABS control unit / rear brake caliper hose Part no.61911341A), the consumable ties and DOT 4 brake fluid; and labor for 2h:54min (29 labor units) that includes the time necessary for : Vehicle reception Check Rear Brake Pedal Travel Rear brake hose removal (ABS control unit / brake master cylinder and ABS control unit / brake caliper) Installation of new rear brake hose assembly (ABS control unit / brake master cylinder and ABS control unit / brake caliper) Filling and bleeding procedure of the rear brake system Soft cleaning of the vehicle 3/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Table of contents Introduction Page 1 Application 2 Customer Impact 2 Parts Distribution 2 Warranty Reimbursement Rules 3 Spare Parts 4 Service Solution Operation 1: Check Rear Brake Pedal Travel Operation 2: Rear Brake Line Replacement Part 1: Vehicle Preparation Part 2: Rear Brake Hose Removal Part 3: Rear Brake Hose Installation – Master Cyl. to ABS control Part 4: Rear Brake Hose Installation – ABS Control to Rear Caliper Part 5: Rear Brake System Filling and Bleeding Part 6: Vehicle Refitting 5 5 7 7 17 19 21 26 27 Spare Parts Part No. Description 61911361A ABS control unit / rear brake master cylinder hose 61911341A ABS control unit / rear brake caliper hose 85250241A Copper washers (8pcs) Picture (x8) 4/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Service Solution WARNING To ensure the correct execution of the operation within the provided labor time to carry out the updates, it is necessary to follow the sequence indicated in the following instructions Operation 1: Check rear brake pedal travel 1. Measure height (A) between rear brake lever lower end and load-bearing surface; brake lever must be in rest position (upper limit stop) 2. Slowly position the 8 kg weight onto rear brake lever; then measure height (B) between rear brake lever lower end and load-bearing surface 3. The difference between the measured heights (A) and (B) has to falls within the range: A - B = between 15 to 23 mm a) If the difference between the measured heights (A) and (B) falls within the above range, no further action is required. b) If the difference between the measured heights (A) and (B) is greater than 23 mm, proceed to the Operation 2: Rear Brake Line Replacement. 5/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 WARNING Before measuring the heights (A) and (B), check always that the free travel of the rear brake lever is correct (between 2 to 5 mm). Remember that the idle stroke refers to the stroke performed by the brake cylinder control rod before operating the pump. If the idle stroke is outside the specified values, it must be adjusted again using the adjustment screw on the control rod; 6/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Operation 2 Part 1: Vehicle preparation 1. Position the bike on the rear paddock stand 2. Drain all the oil contained inside the rear brake system 3. Remove the seat 4. Remove the M6x20 screw (1) with washer (2) retaining fuel tank 5. Slightly lift the fuel tank, disconnect the fuel supply hose (3), the ground cable (4) and the fuel pump connector (5) 7/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 NOTE To disconnect the fuel supply hose (3) press on the flange in point (6) and at the same time tighten the outer ring (7) in the indicated points 6. Disconnect the fuel level sensor connector (8) 7. Lift the fuel tank by pulling out the 2 pins (9) from the relevant supports (X) 8/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 8. Pull out the drain hose (10) and the canister filter breather tube (11) from the fuel tank 9. Remove the 2 M6x22 screws (12) with the relevant spacers (13) fastening RH cover (14) and LH cover (15) of the engine 10. Remove the filter cover (16) by unscrewing the 4 self-tapping screws (17) 11. Disconnect the air temperature sensor connector (18) 9/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 12. Remove the self-tapping screw (19) securing the coolant filling plug support 13. Working on vehicle LH side: 13.1 Remove the 2 M6x10 screws (20) securing the connector support 13.2 Remove the 2 M6x25 screws (21) securing ignition coil (22) and disconnect the relevant connector (23) 13.3 Disconnect secondary air (AIS) connector (24) 10/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 13.4 Remove the 2 spring retainers (25) and pull out the horizontal head secondary air pipe (26) and the vertical head secondary air pipe 13.5 Disconnect vertical cylinder ETV (28), injection (29) and horizontal cylinder ETV (30) connectors 13.6 Remove tie (31) and pull out Airbox drain hose (32) 11/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 14. Working on vehicle RH side: 14.1 Pull out horizontal cylinder head pressure sensor pipe (33) acting on clamp (34) 14.2 Disconnect horizontal cylinder head pressure sensor connector (35) 14.3 Pull out blow-by hose (36) from the Airbox by loosening tie (37) 12/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 15. Working on vehicle LH side, loosen tie (38) positioned on the horizontal cylinder head and tie (39) positioned on the vertical cylinder head 15.1 Remove the Airbox from the vehicle 15.2 Protect the engine with a cloth near the ABS control unit and cover the intake manifolds as shown in the figure to avoid the possible penetration of brake fluid or impurities inside the manifolds. WARNING Remember that the brake fluid could damage the paint or parts of the motorcycle. Wash the affected area with plenty of water in case of accidental contact. 16. Remove the rear wheel (See Sec. 7: "Chassis – Rear wheel" of the Workshop Manual) 17. Remove the rear mudguard (See Sec.5: "Fairing installation – Rear and front mudguard" of the Workshop Manual) 13/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 18. Before carrying out the removal of: hose (40) connecting the ABS control unit to the rear brake master cylinder, hose (41) connecting the ABS control unit to the rear brake caliper it is necessary to perform the following: 19. Pull out the brake hose (40) from the relevant tabs (42) present on the coolant radiator 14/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 20. Pull out the brake hose (41) from cable guide (43) 21. Remove 3 L.39mm button ties (44) joining the brake hose (41) to the speed sensor cable and rear turn indicator cable\ 22. Remove 3 small self-locking ties (45) joining the brake hose (41) to the speed sensor cable and rear turn indicator cable 23. Pull out the brake hose (41) from the 2 teeth (46) present on the rear shock absorber reservoir support View of inner side 15/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 24. Remove the 2 hose grommets (47) on swinging arm 25. Remove 4 small self-locking ties (48) joining the brake hose (41), the speed sensor cable and rear turn indicator cable 26. Remove 3 big self-locking ties (49) joining the brake hose (41), the speed sensor cable and rear turn indicator cable 27. Remove the 3 M6x18 screws (50) securing the air conveyor to the horizontal belt cover NOTE It is recommended to remove the air conveyor on horizontal belt cover to make the removal and installation operation of the brake hose connecting the ABS control unit to the rear brake master cylinder easier. 16/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Part 2: Rear brake hose removal 1. Working on the ABS control unit, remove the special screw (51) with the 2 copper washers (52) securing brake hose (40) to ABS control unit. ATTENTION Remember that the brake fluid could damage the paint or parts of the motorcycle. Wash the affected area with plenty of water in case of accidental contact. 2. Working on the rear brake master cylinder, remove the special screw (53) with the 2 copper washers (54) securing brake hose (40) to rear brake master cylinder 3. Pull out brake hose (40) starting from the rear brake master cylinder fitting Pull out the hose starting from the brake master cylinder fitting 4. Working on the ABS control unit, remove the special screw (55) with the 2 copper washers (56) securing brake hose (41) to ABS control unit 17/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 5. Working on the rear brake caliper, remove the special screw (57) with the 2 copper washers (58) securing brake hose (41) to rear brake master cylinder 6. Pull out brake hose (41) by first routing the ABS control unit fitting below the rear subframe jointing bracket and then pulling it out starting from the ABS control unit fitting Pull out the hose starting from the ABS control unit 18/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Part 3: New rear brake hose installation - Brake hose connecting the ABS control unit to the rear brake master cylinder 1. Take the new brake hose (A) connecting the ABS control unit to the rear brake master cylinder NOTE The new brake hose can be identified by the different chamfering that characterizes the end part of the fittings. OLD NEW 2. Insert the ABS control unit fitting of the brake hose (A) between the coolant radiator and the horizontal head cover and route it inside the frame until reaching the ABS control unit, as shown in the figure 19/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 3. Route hose (A) between the 2 tabs (42) present on the coolant radiator 4. Position the seal (59) inside hose grommet (60) present on frame 5. Fasten the ABS control unit fitting to the control unit as shown in the figure, using 2 new copper washers (B) and tighten the special screw (51) to 25 Nm ± 5% with certification 6. Fasten the rear brake caliper fitting as shown in the figure using 2 new copper washers (C) and tighten the special screw (53) to 25 Nm ± 5% with certification 20/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Part 4: New rear brake hose installation - Brake hose connecting the ABS control unit to the rear brake caliper 1. Take the new brake hose (D) connecting the ABS control unit to the rear brake caliper. NOTE The new brake hose can be recognized by the different chamfering that characterizes the end part of the fittings. OLD NEW 2. Install the brake hose (D) as indicated below: 2.1 Route the ABS control unit fitting below the rear subframe jointing bracket 2.2 Insert the rear brake caliper fitting of the brake hose (D) between the rear subframe and the vertical head exhaust manifold 2.3 Route the brake hose (D) between the footrest holder plate and the swinging arm 21/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 3. Fasten the fitting to the ABS control unit as shown in the figure, using 2 new copper washers (E) and tighten the special screw (55) to 25 Nm ± 5% with certification 4. Fasten the rear brake master cylinder fitting as shown in the figure using 2 new copper washers (F) and tighten the special screw (57) to 25 Nm ± 5% with certification WARNING Make sure that brake hose (A) and brake hose (D) fittings are aimed on the ABS control unit as shown in the figure and check also that there are no interferences. 22/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 WARNING Make sure that brake hose (A) and brake hose (D) fittings are respectively aimed on the brake master cylinder and brake caliper as shown in the figure. 23/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 5. Fasten the new brake hose (D) connecting the ABS control unit to the rear brake caliper, as shown below: 5.1 Insert brake hose (D) inside the cable guide (43) 5.2 Join the brake hose (D) to the speed sensor cable and the rear turn indicator cable using the 2 L.39mm button ties (44) 5.3 Join the brake hose (D) to the speed sensor cable connector and the rear turn indicator wiring branch using the L.39mm button tie (63) 5.4 Join the brake hose (D) to the speed sensor cable and the rear turn indicator cable using the 3 small self-locking ties (64) 5.5 Insert the brake hose (D) inside the 2 teeth (46) present on the rear shock absorber reservoir support View of inner side 24/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 5.6 Fasten brake hose (D) to the swinging arm using 2 hose grommets (47) and tighten the relevant retaining screws to 8 Nm ± 10% 5.7 Install 4 small self-locking ties (65) joining the brake hose (D), the speed sensor cable and rear turn indicator cable 5.8 Install 3 big self-locking ties (66) joining the brake hose (D), the speed sensor cable and rear turn indicator cable in the following two locations: the tie (66A) in correspondence of the clip on the swinging arm; the tie (66B) in correspondence of the drive belt protection. NOTE Install the tie (66B) ONLY AFTER filling and bleeding the brake system to allow actuating the rear brake caliper. 25/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Part 5: Rear brake system filling and bleeding 1. Proceed with the DOT4 fluid filling inside the rear brake system and bleed the system following the procedure indicated in the bulletin SRV-TTB-17-001 valid for the XDiavel model. The video of the bleeding procedure can be watched at the following link: https://youtu.be/hQo1FHPA6-U. ATTENTION Remember that the brake fluid could damage the paint or parts of the motorcycle. Wash the affected area with plenty of water in case of accidental contact. NOTE Install the big self-locking tie (66B) in correspondence of the drive belt protection. 26/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 Part 6: Vehicle refitting 4. Fit the rear mudguard (See Sec.5: “Fairing installation - Front and rear mudguard”) 5. Refit the rear wheel (See Sec. 7: "Chassis – Rear wheel" of the Workshop Manual) 6. Fit the air conveyor on the horizontal belt cover and tighten the 3 M6x18 screws (50) to Nm ± 10% 7. Remove the adhesive tape from the intake manifolds and apply soapy water on the rubber profile for intake manifold connection at the bottom of the Airbox 8. Install the Airbox on the vehicle making sure that the two intake manifolds are perfectly fitted inside it 27/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 9. Working on vehicle LH side, fasten the Airbox using tie (38) at the horizontal cylinder head and tie (39) positioned on the vertical cylinder head and tighten to 2.5 Nm ± 10% 10. Working on vehicle RH side: 10.1 install horizontal cylinder head pressure sensor pipe (33) and secure it with clamp (34) 10.2 connect horizontal cylinder head pressure sensor connector (35) 28/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 10.3 connect Airbox blow-by hose (35) and secure it with tie (36) 11. Working on vehicle LH side 11.1 Connect secondary air (AIS) connector (24) 11.2 Connect the ignition coil connector (23) and fasten the coil (22) to the relevant support by tightening the 2 M6x25 screws (21) to 9 Nm ±10% 11.3Install the connector support tightening 2 M6x10 screws (20) to 6 Nm ± 10% with LOCTITE 243 applied along the threading 29/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 11.4 Install horizontal head secondary air pipe (26) and vertical head secondary air pipe (27) in correspondence of the actuator and fasten them using 2 spring retainers (25) 11.5Connect vertical cylinder ETV (28), injection (29) and horizontal cylinder ETV (30) connectors 11.6Connect the Airbox drain hose (32) and secure it with tie (31) 30/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 11.7Install RH cover (14) and LH cover (15) with relevant spacers (13) tightening the 2 M6x22 screws (12) to 1 Nm ± 10% 11.8 Connect the air temperature sensor connector (18) 11.9Fit the filter cover (16) and tighten the 4 self-tapping screws (17) to 3 Nm ± 10% NOTE Before carrying on with the tightening, start the self-tapping screws (17) taking care to start them in the original thread already present. 31/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 12. Install the coolant filling plug support and tighten the retaining self-tapping screw (19) to 3 Nm ± 10% NOTE Before carrying on with the tightening, start the self-tapping screw (18) taking care to start it in the original thread already present. 13. Install the fuel tank by inserting the 2 pins (9) in the relevant supports (X) 32/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 14. Connect the drain hose (10) and the breather tube of the canister filter (11) 15. Connect the fuel level sensor connector (8) 16. Connect the fuel supply hose (3), the ground cable (4) and the fuel pump connector (5) 17. Fasten the fuel tank and tighten the M6x20 screw (1) with the relevant washer (2) 10 Nm ± 10% 18. Start the engine and keep it at idle until reaching the fan activation condition 19. Connect the DDS 2.0 diagnosis instrument and run a Global Scan 20. Mount the seat 21. Measure height (A1) between rear brake lever lower end and load-bearing surface; brake lever must be in rest position (upper limit stop) 22. Slowly position the 8 kg weight onto rear brake lever; then measure height (B1) between rear brake lever lower end and load-bearing surface 33/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 23. Note the difference between the measured heights (A1) and (B1) Rear brake lever stroke 1 = (A1) – (B1) 24. Road test the vehicle on the road at a speed of about 50 Km/h and, by operating only the rear brake, brake until the ABS is engaged at least 10 times 25. Measure again the rear brake lever stroke as referred to under section (19) WARNING The measurement of the rear brake lever stroke required in point (25) must be taken with the same temperature conditions of point (21). Therefore, if the measurement was taken with cold engine it will be necessary to wait for 2 hours before proceeding. 26. Note the difference between the measured heights (A2) and (B2) Rear brake lever stroke 2 = (A2) – (B2) 27. Compare the 2 stroke values of the rear brake lever 28. If a stroke increase of the rear brake lever is detected, repeat the whole bleed procedure from section 1 to section 17 34/35 CR186 - Rear Brake Hoses Check and Replace if req. XDiavel Model Year 2016-2020 (all models) Technical Service Bulletin SRV-TSB-19-012 29. Once the new bleeding procedure is completed, check that the stroke of the rear brake lever has not increased 30. Perform a soft cleaning of the bike before delivering it to the Customer For questions or information on this Workshop Campaign, please contact your Service Area Manager 35/35