My M900 Project...

[ibanezlynx]

Hi all,
I was lucky enough to get my hands on a 94 M900 off of a friend who moved to America and couldn't import it. I have been riding it the past summer and it's been great fun and in total covered about 15k miles. I also managed to get a 04 zx6r which I plan on doing the miles on this coming summer. This will give me the time to restore the monster.
The bike:
http://i1358.photobucket.com/albums/q771/xcmaniac/duc_zps9de4278f.jpg
It's suffered from poor engine paint and knackered frame paint on the left hand side from the battery leaking. There is also a bit off damaged when the previous owners wife reversed into it. All in all a good bike though.
I plan on re-painting the frame, engine and wheels and also any other corroded bits. I don't really want to pimp it out or spend mega bucks on carbon and ohlins this and that. I just want to put the time in and make it a look wonderful and ride well... I want to utilise my skills as an engineer.
So I will be updating the forum with photos, problems and tips as I progress on.

Wish me luck...

[ibanezlynx]

So I have started stripping it:
http://i1358.photobucket.com/albums/q771/xcmaniac/IMG_0955_zps39be7a08.jpg
http://i1358.photobucket.com/albums/q771/xcmaniac/IMG_1028_zpsbc7635d4.jpg

I have also re-painted the belly pan. I will wait until the end and decide whether I want to use it or show off the new engine paint.....
http://i1358.photobucket.com/albums/q771/xcmaniac/IMG_0907_zpsc1c02d54.jpg
http://i1358.photobucket.com/albums/q771/xcmaniac/IMG_0906_zps44d37664.jpg
http://i1358.photobucket.com/albums/q771/xcmaniac/IMG_0949_zps81a911c8.jpg

[Dirty]

Hi all,
I don't really want to pimp it out or spend mega bucks on carbon and ohlins this and that. I just want to put the time in and make it a look wonderful and ride well...
..........
.........
.........

Wish me luck...

Good luck with that :woot: :)

[Mr Gazza]

That looks like a really nice original early Monster there.

Shame that you say the paint has suffered, but heartening to hear you say "restore".

All I would change personaly would be to ditch the belly pan and fairing...Possibly I might go for Gold wheels, but otherwise all the colours are just right, even down to the yellow hoop.

Good luck with the refit, keep us posted.

[BeePee]

oooh I like a good rebuild thread, might be me soon as well

[Flip]

.....that is restoration.

It's only original once remember and them there early ones are getting fewer and far-er between these days.

A nice patina paints a thousand words and all that.
Either way I'm not really into them being kept in Museums (unless there's an excuse to go to Bologna again) so have fun with the spanners!

One thing's for sure- whatever way you go with it you'll divide people's opinion.

[utopia]

A nice patina paints a thousand words and all that.


Well said, that man.

One comment on the bellypan.
I had one exactly like that, except the front section had a mesh-filled vent hole cut in it.
I found that, even with the added ventilation, the fact that the bellypan enclosed the front header pipe meant that it retained lots of heat.
Probably not a problem on the move, but stopping at traffic lights caused great waves of heat to rise off the motor.
I reckon they can contribute to overheating and I replaced mine with a short, Monza style pan, which leaves the header exposed and eliminates the problem.

Good luck with the rebuild.
I will watch with interest.

[ibanezlynx]

Yes that is well said.
Interesting point Utopia. I'm probably going to ditch it. After I put in the hard work on the engine repaint I will want to show it off. I also got ride of the headlight fairing a while ago.

The photo is on the good side. Most of the damage is the left hand side from the battery. Also the belt covers are cracked and the battery support. Exhaust are pretty messy too.

I have already powder coated the yellow hoop black. Hate it yellow but that's just personal!
Nearly finished sorting out the swing arm so will up date with pics soon...

[ibanezlynx]

Right, Finally got round to doing some more work...
The engine is out and the frame stripped of bits and pieces:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/IMG_1064_zpsa550dffb.jpg
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/IMG_1087_zps85f3055f.jpg

You can see the damage that the battery leak caused:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/IMG_1088_zps43008815.jpg

I'm not sure what to do about frame paint/powder coat and filling in the frame numbers? Any one had any experience with this?
I have cleaned the swing arm, shock, new rose joints, powder coated the ugly yellow brace and replaced with stainless bolts where necessary:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/IMG_1089_zpsab30b936.jpg

I have also disassembled the lock mechanism, painted and put nice shiny bolts in place. This is what it was like:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/IMG_1013_zpsc069d47e.jpg

And now:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/IMG_1090_zps5eba0690.jpg

Next to start cleaning bits and weld up an engine stand!

[Darren69]

From ugly to lovely in so many hours, time well spent though. Nice job!

[Mr Gazza]

Sorry you didn't like your yellow hoop. It's a nice original feature inherited from the 888...But it's your bike.

Shame the frame took all that acid..!! (sounds like my mis-spent youth!!_)

If you speak nicely to the powder coaters, it might be possible to mask the frame numbers up after grit blasting, using self adhesive aluminium tape, but it will need to be carefully cut away after the coating and that will expose the grit blasted surface again so it will require painting over...Best to discuss with the actual guy doing the coating.

Liking the attention to detail with the seat latch..Nice.. Keep up the good work.

[craigie]

Whilst you have it in bits I would recommend a jack up kit for the hoop. One of the best wee mods to my mind.

[Cobra88]

what's happened to the Like button on recent posts ?

Nice one Ibanezlynx :)

[Dukedesmo]

If you speak nicely to the powder coaters, it might be possible to mask the frame numbers up after grit blasting, using self adhesive aluminium tape, but it will need to be carefully cut away after the coating and that will expose the grit blasted surface again so it will require painting over...Best to discuss with the actual guy doing the coating.



When I had my frame powder coated they masked the small area around the frame number so that it was left bare, then used conventional paint over the area so that it is still legible.


I also had my black hoop done in yellow...

[Flip]

Sorry you didn't like your yellow hoop. It's a nice original feature inherited from the 888...But it's your bike.

Told you whatever you did would divide opinions!! I have to say I agree with Mr Gazza and DD on this one.

Whilst you have it in bits I would recommend a jack up kit for the hoop. One of the best wee mods to my mind.

Or you could just wind out the rose joints a couple of turns to raise the back up- craigie is spot on though, the cheapest single thing you can do to improve handling and stop it steering like a 'Chopper'.

Next best is junk the original shock- it is bound to be knackered and the spring too hard anyway.

[utopia]

Shame the frame took all that acid..!! (sounds like my mis-spent youth!!_)


Its important to dilute the acid with something.
Kool-Aid used to be the popular choice. :rolleyes:

[ibanezlynx]

Cheers for the heads up utopia...

[utopia]

I probably should have posted an explanatory link.
I was referring to the Kool-Aid Acid Tests organised by Ken Kesey's Merry Pranksters in late 60s San Francisco where the aforementioned childrens' drink, laced with LSD, was freely available and the Grateful Dead were the house band.

http://www.google.co.uk/url?sa=i&source=images&cd=&docid=2wHlDStNPwQrRM&tbnid=Nog2wT1uE7MvlM:&ved=0CAUQjBw4RQ&url=http%3A%2F%2F1.bp.blogspot.com%2F-FA8_VGQMa40%2FT7vG2jQ0bEI%2FAAAAAAAAAjo%2FNCqeJiSy V-8%2Fs320%2Felectric_kool-aid_acid_test-full.jpg&ei=aQ76UtnONejB7Ab0noGwDw&psig=AFQjCNGxXbPUB3pD4KsEEs_js37YeZLJKw&ust=1392205801959578

Dilution of battery acid is also important.
And neutralisation with a weak alkali. (washing soda?)

[Mr Gazza]

:chuckle::chuckle: I can just picture Ibanezlynx diligently washing down his frame with Kool-Aid.

All that talk about the Dead Heads has got me thinking about a tie dyed bike cover though..:idea:

[Dirty]

I didn't know about the merry pranksters and thought it was a reference to Jonestown!! So glad it wasn't :)

[ibanezlynx]

Haha very good! I was going to say give me some credit however I have just been a very silly TW*T!
Just tried to get the clutch nut off and snapped one of the spring posts....
Does anyone have a clutch basket/plate carrier left over??

[Mr Gazza]

Sorry to hear about your little accident Ibanezlynx.

Can you not just replace the post?. Do they press into, or bolt onto the drum?

I've never fished mine out, but I can't think that they are made all in one piece.

Have you priced up a new one from Moto Rapido with Club discount? Trouble with nearly all of the secondhand ones is that they are already cream crackered..

[ibanezlynx]

Yeh bit of a bummer.
They look like an crappy cast which has been post machined. I need to get the thing off and have a proper look. I might end up machining a new post and the carrier and bolt it from the back with loctite. I guess because it's a crappy cast it's brittle and weak, however I am annoyed I did what I did. Guess we learn from our mistakes.
The clutch doesn't look to healthy so I'm going to have to get new plates to. Will have a measure first though!

[ibanezlynx]

Update time...
Been pretty slow for a while as I am waiting for a mate to help me weld up an engine frame.
I have however completely stripped the frame, wheels for powder coat and various other parts.
Can anyone suggest a way in removing the sprocket rubber dampers from the rear wheel? Its being a right pain!

[ibanezlynx]

Finally had some progress...
I haven't posted anything in a while as I have been getting stuck into the project.
I have had the frame back from the powder coaters and I am pleased:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/IMG_1288_zpse34c0bc4.jpg
I have started building the frame up and have slotted the front end in (which I have stripped, cleaned and put stainless fasteners where I can):
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/IMG_1320_zps19755980.jpg?t=1399197933
I have also rebuilt the footrests of which the hangars were powder coated and I have stripped the top end of the motor.....

[spacemonkey]

How did your 2 engine mount bolts come out? Mine are stuck solid so I'd be interested to hear how yours were and what you did...

[ibanezlynx]

The bolt's were fine to come out. Once out I could see that they are pretty corroded and will probably try and source replacements.
Have you used penetrating oil?
You could also try tightening and loosening it to encourage the threads to "break" and move?
Is the engine hanging in the frame or is it supported underneath?

[spacemonkey]

Engine supported underneath, and yes tried penetrating oil. See my thread in this section.

[slob]

...Can anyone suggest a way in removing the sprocket rubber dampers from the rear wheel? Its being a right pain!

Use the search function on the top menu for CUSH you'll find loads of advice on the same problem, you are not alone ;-)

[ibanezlynx]

Thanks for the heads up Slob...

[NattyBoy]

Nice work mate - sounds a bit like mine !

Nice to see the frame hasnt been hacksawed at the back :>)

[ibanezlynx]

Bit more progress...

Managed to pull the rear wheel cush drive bushes out with a homemade puller. Was a faf and I had to cut one out...

Also heads are off and stripped. Barrels off and pistons out. Just inspecting them at the moment!

http://rs1358.pbsrc.com/albums/q771/xcmaniac/Ducati/IMG_1366_zpsfa81df61.jpg~c100

[Mikemostro]

What a nice project you are managing ibanezlynx ;)
This is really somthing I would like to do once in my life :hail:

[ibanezlynx]

Finally got round to the forum again.
got all the engine parts checked. I need new exhaust guides but bores are good, valves are good, pistons and rings are also good.
Loom is back on the frame with the front end. Just stripped and painted the starter motor. All looking good so far. Will post pics soon!
Next is getting the motor soda blasted and painting a few bits. Whilst also getting the wheels powder coated....

[ibanezlynx]

Hello guys,
Firstly let me apologise for not posting much in a while. I have been super busy with various other ventures. However, the spark is re-ignited and I am hammering on with the project. I thought I would show some of my recent progress...
The heads are back. I had new exhaust guides put in, the valves were dressed and the seats re-done. I am very happy with the job:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150323_184622_zps7dkjjikt.jpg

I have spent some time scrubbing the exhausts. The underside was pretty pitted but they didn't turn out too bad:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150315_135442_zps5y5javby.jpg

I repainted the exhaust clamps. I took them to work and blasted them, then re-painted with hi-temp exhaust paint. Hopefully they stand up ok:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150324_181332_zpsjimw3hx4.jpg

I then stripped, cleaned and re-painted the starter motor:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150324_181232_zpskzgz7gqv.jpg

The footrest hangars have been stripped, powder coated and re-built with new fasteners etc:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150324_181040_zpsaynsowdf.jpg

The mirrors were a rusty mess. I stripped them, blasted and re-painted. They are not great but I have spent a lot of money recently and it will save me a few bob. It is also nice to have the original mirrors on:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150313_155147_zpsggqleptz.jpg

Front end rebuilt:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150315_135800_zpspndhuyih.jpg?t=1427142383

Whole bike so far:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150315_135332_zpszdrkcpmg.jpg

The engine will be soda blasted within the next 3 weeks and then I can paint it.
Should be getting the wheels back this week from powder coat. I can then crack on and build them up...
At the moment I am making new starter wiring and just trying to get everything super clean.
I haven't spent any money on bling parts, trying to keep it classy and understated.

Will keep you all updated...

[slob]

nice work.

[DrD]

Its interesting how different people rebuild their monsters in different sequences..there are about four rebuilds on the forum at the moment and all are going about it in different order.

[ibanezlynx]

If I did this again I would have prioritised the engine and not had a couple of months fiddling with only the smaller components.

[ChrisC2925]

Showing your age there Utopia, were you on the bus at the time or had it parked up? I believe the original 'Further' is in Ken Kesey's son's shed!

[ibanezlynx]

This came in the post today. Thanks to motorapido:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150330_165545_zps7jvfk5yn.jpg[/URL][/IMG]

[Dookbob]

looking good, wont be long before your,e on it and rolling.

[ibanezlynx]

Had some more progress...
Wheels came back from powdercoat. Just need to build them up at work:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150411_110046_zpsifzoxvq2.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20150411_110046_zpsifzoxvq2.jpg.html)

Frame bolts were a state. Decided to have them zinc plated again by Collings in Milton Keynes. I would really recommend them. Really pleased with the result.
Before:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150329_160824_zpsp8qz9n3g.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20150329_160824_zpsp8qz9n3g.jpg.html)
After:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150401_165136_zps7q3enz7d.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20150401_165136_zps7q3enz7d.jpg.html)
Also tidied up the rad with a ali cover:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150404_171030_zps0knwjsik.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20150404_171030_zps0knwjsik.jpg.html)

[Yorkie]

Nice build and a good steady progress.

Yorkie

[utopia]

Showing your age there Utopia, were you on the bus at the time or had it parked up? I believe the original 'Further' is in Ken Kesey's son's shed!

The bus came by and I got on and that's where it all began. ;)

But no, not literally, I was here in England.
We didn't have Kool-Aid !! :rolleyes:


Apologies for the sidetrack.

[albert12]

Good luck with it.

[ibanezlynx]

I picked up the engine from soda blast the other day and was pleased with the results:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150415_182341_zpsevnih6ar.jpg
After cleaning, degreasing and masking I hit it with primer:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150416_191904_zpsftnqul5i.jpg
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150416_191907_zpsphnscn5r.jpg
Then colour:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150419_163422_zpskdw007us.jpg
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150419_163619_zpsg3ncosh1.jpg
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150419_163754_zpsahmk1kar.jpg

I used VHT primer and paint. The main silver is an aluminium silver and the barrels are satin black.
I am really pleased with the results.
If I did it again I would consider brush painting the barrels as the fins are a pain. I would also consider sanding some of the cast flash marks on the cases back as they really show up.

[Dirty]

Looks great

[Nottsbiker]

Looking good there mate can't wait to see the next instalment

[Dookbob]

That is quite obviously going to be the dogs whatsits when it,s finished. Nice one.

[ALCOENTRE]

great job budie... Well done... good luck

[HongKongPhooey]

Inspirational stuff!

Learning lots from this rebuild.

[ibanezlynx]

Hello everyone. Bit more progress. I finished building the heads up tonight:

http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150615_181801_zpssum80aua.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20150615_181801_zpssum80aua.jpg.html)

Everything went pretty smoothly. Although I used cable ties to close the springs whilst I assemble the rockers as I didn't have the tool. Doing this nicked and damaged the valve stem seals which I had to replace again. I would recommend buying the proper tool and putting the stem seals on after the lower rockers are assembled.

Keep you all posted....

[utopia]

Engine should look good when its built up, with the black barrels, cam plates and rocker covers.
Nice ....and looks immaculately done too.

[stevie babe]

It's looking good. Can't wait to see pictures of the finished Article.

[Darkness]

I'm liking the coffee table with the crank cases built into it: are you going into competition with Albie by producing monster based furniture?

I'm also liking the rebuild. Keep up the good work, and please keep posting the photo's

[ibanezlynx]

Got round to building the engine. Just got to get the belt tension right and the bike can be built!

[Yorkie]

Great build.

Yorkie

[ibanezlynx]

Pic of engine:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150801_161401_zpskhxld8cz.jpg

[Albie]

Looking good. Jealous comes to mind.

[utopia]

Off topic ...its just clicked ...."Ibanez" .,...you're a guitar player, yes ?

On the VHT paint ..I've used some of Halfords own brand, which is satin black with a small-grain metallic glint to it.
I have no idea how durable it is as I've only used it on a reg/rec so far, but it looks really good.
What brand did you use ?
Also, I found that, despite an extended length oven cure, the paint still needed some time in service before it fully hardened off.
Might be worth being extra careful in the first few weeks.

[ibanezlynx]

You've got it. Been a guitar player for many years. Time is just the issue as I get older... Used to gig a lot and was lead guitarist in a pink floyd tribute band.

I used the VHT paint. If you type in VHT paint in ebay it comes up. If you want colour specifics I can get you them. http://www.vhtpaint.com/
I baked the heads, covers and barrels in the oven at work but as you say little bits have chipped off where I've knocked them with a spanner or something. As careful as I have been it's inevitable.
This bike will be so looked after bit will be ridden also (in the dry). Hard to keep things perfect with UK roads... I have a Yamaha XT660X which I do my miles on and to play about.

[ibanezlynx]

Had some good progress today. Engine in frame with front and back ends on. Not long now...



http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150814_174458_zpsrzkixnrh.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20150814_174458_zpsrzkixnrh.jpg.html)

[Nottsbiker]

Looks like you are making some great progress there mate :)

Is the silver frame made to look like aluminium or is it the camera?

[ibanezlynx]

Thanks mate. The frame was shot blasted, dipped and powder coated. It's like a metallic silver but quite subtle. I found it very difficult to match a colour similar enough to the stock colour.

[Albie]

Mine gets done next Wednesday in bronze powder. Going to be worrying of how close to original but looks close. Yours is looking great in silver. Mine was silver but had a hint of something.

[Nottsbiker]

Makes me think of getting mine done ally style by Aerocoat for a Spondon / Martek look farme

[ibanezlynx]

Spent some time today getting on. Carbs and fuel lines assembled. Brakes and clutch bleed and feeling good. Pretty much all done apart from the airbox and I need to solder up the heavy gauge battery wires. Hopefully try and start in on Tuesday...
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20150829_140537_zps1ntgvdcy.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20150829_140537_zps1ntgvdcy.jpg.html)

[Yorkie]

Lovely looking project.

Yorkie

[Darren69]

Looks sweet. Nice job!

[Pedro]

Nice looking bike you have there, can't beat the original!

[squarehead]

Great work.

[Davy]

Nothing in the world to match these original 900 works of art.

[Albie]

I finally discovered what I needed regards the rectifier mounting looking at one of your pictures. Thanks for that and its what I thought as in mine has obviously had a replacement one as yours has angular top and bottom and mine is rectangular and the hole centres are out hence mine has a bracket and triangulated fitting method. This is why threads need photos to help others out. You have my thanks.
Need to see the correct fitment of fusebox type screws to frame now.

[ibanezlynx]

No worries mate. Thanks for all the nice comments. Will post some detailed pics soon.
If you need any pics or info just let me know Albie...

[Darren69]

I finally discovered what I needed regards the rectifier mounting looking at one of your pictures. Thanks for that and its what I thought as in mine has obviously had a replacement one as yours has angular top and bottom and mine is rectangular and the hole centres are out hence mine has a bracket and triangulated fitting method. This is why threads need photos to help others out. You have my thanks.
Need to see the correct fitment of fusebox type screws to frame now.

Some of the older posts seem to have lost the pictures. Have they been moved or deleted?

[ibanezlynx]

They were moved when I moved around some photos. If anyone wants any specific pics I can put them up. Will probably do some before/after photos of various bits once I know it's running...

[ibanezlynx]

Hi all.
So its been a while since i've posted, been so busy. Anyway, it passed the MOT with flying colours and I have done about 200 miles since with absoltely no problems. The only issue was a little oil mist but I nipped the oil hoses a bit more and now its fine.
Here are a few more pics:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20151004_171712_zps3tr1ajfz.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20151004_171712_zps3tr1ajfz.jpg.html)
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20151004_171738_zpskvdyw2lo.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20151004_171738_zpskvdyw2lo.jpg.html)
One of the best things I changed was upgrading the starter cables. I did it very cheaply buying the bits myself and soldering it all up. Another was the oil cooler cover. I bought some ali mesh which I cut up and formed around the rad, then secured with lock wire.
I also machined some tophat components so I didnt have to fork out on footrest bolts:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20151004_171825_zpsquur6wyz.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20151004_171825_zpsquur6wyz.jpg.html)
I also sanded the writting off of the reservoir caps and powder coated them which turned out good:
http://i1358.photobucket.com/albums/q771/xcmaniac/Ducati/20151004_171954_zps6sematf2.jpg (http://s1358.photobucket.com/user/xcmaniac/media/Ducati/20151004_171954_zps6sematf2.jpg.html)

Another thing I would say is that dont give up on clutch slave cylinders. You could replace yours with an aftermarket unit which is bling and requires less force or you could refurb the old one. I wasnt worried about the force as I have strong hands. Mine leaked badly but I stripped it and gently polished the corrosion out of the bore. I bought a new seal for £3, rebuilt it and it works fine now.

So thanks for everyones help. This is such a great forum and I'm glad to be a part of it. I hope to make it to one of the rideouts and meet some of you. Please feel free to pm me with any questions, I would be more than happy to help...

[Albie]

Looks stunning. Very envious right now. Enjoy the rest of the nice weather. Top marks.

Just a question you saying about footrest fittings. So easy and cheap to clean up and replate. I don't blame you though making some.

Can I ask whether the tyres are Michelin pr2 or 3 or just pr and is the rear if so a 180/55

PS I think your tank clip is 180 degrees out of rotation. Curve should go with tank. Just saying ;-)

[Davy]

There's the reason why I love Ducati monsters.. Fantastic looking well done

[Darren69]

Great job, looks very nice. I think the furry thing on your handlebars is non standard though! :)

[ibanezlynx]

Yeh the foot rest bolts were such a mess. I knackered a few getting them off as they had seized... I had the tools available so I just made some.

The tyre is just a 170 pilot which was on it when I picked it up. Still nice and tacky and I did'nt want to buy a new set as I the rebuild may not have come together quite as well.

Haha good spot on the tank clip. I reverse engineered and had the middle section of the bracket andhad it grown out of nylon as the old one fell apart. I wasnt sure which orientation was correct!

Thanks for all the nice comments...

[ibanezlynx]

Thats my little good luck charm, courtesy of my mum. Had one on every bikes so far...

[slob]

That looks really tidy, good work.

[Darren69]

Thats my little good luck charm, courtesy of my mum. Had one on every bikes so far...

Must be lucky then if from Mum! I can't help but think the footrest bolts would look that little bit better as polished stainless dome heads, maybe that's just me being picky though.

Otherwise a very nice build very sympathetic to the original with some sensible mods, its nice to see one that's not been choppered to bits.

I didn't realise until I read somewhere the other day that the original Monster was the first mass production bike to actually have proper 'real' carbon parts fitted as standard.

[Mr Gazza]

I can't help but think the footrest bolts would look that little bit better as polished stainless dome heads,

It says A2-70 on the bolt heads so I guess that makes them Stainless already.

I put most of my S/S bolts in my cordless drill and presented the heads to my sanding disc, with both spinning.
Once the letter stamps were gone i put them to the polishing mop, still spinning in the drill....worked a treat.

Oh yeah...very nice build Ibanezlynx..:thumbsup:

[Darren69]

And what Gary doesn't know about polishing isn't worth polishing really. He knows his stuff but with domeheads they probably won't be stamped, I don't think. So won't need more than a light buff with your linishing wheel, more's the shame. He knows I'm joking of course! I'm actually in the process of getting stainless replaced with Titanium so I' one to talk? :)

[Mr Gazza]

Hex head bolts don't usually come with a dome head, but there are dome nuts which, as you say are not stamped.
Some of the more decorative bolt heads, such as button heads, don't always have stamps, or sometimes they may have extra small discreet stamps

Those flanged head bolts would grind to a slightly domed face, or rather a very slight radius on the otherwise flat face of the head, once the stamps have been removed.

It does tend to make the hex part shallower, so greater care must be taken with the spanner/socket...This is no good if a highish torque is required. In which case another head style should be used.

Come to think of it button heads would look rather nice on the footrest hangers with those nice top hats.

http://www.westfieldfasteners.co.uk/A2_ScrewBolt_SHBtn_M8.html

Don't use these for disc bolts though, they won't take the torque required.....As I found out..!!

[Darren69]

You need something like these for disc bolts:-

http://www.ebay.co.uk/itm/DUCATI-916-748-Brake-Disc-Rotor-bolts-Stainless-Steel-Low-Head-12Front-4Rear-/131611033748?hash=item1ea4a10094

I have similar sets on both bikes.

[Mr Gazza]

Ibanezlynx, Please don't be offended by our comments about your bolt heads..:mand:
It's a smashing re-build in every way...I think we've been quite rude..:rolleyes: Sorry.

Apologies also for hijack.
I personally wouldn't use those A2-70 bolts Darren. I tried A2-70 button heads on my discs, but chewed the heads out before I reached 25nm.
I asked the supplier if I had chosen the wrong bolts for the job.
They said this;

"Hi Gary

Thanks for your email and I'm sorry about the problems you appear to be encountering with the A2-70 bolts.

Firstly, may I express a word of caution in using stainless steel bolts for strength-critical applications such as motorcycle brake discs.
As I'll outline below, the tensile strength of standard stainless fasteners is significantly inferior to carbon steel fasteners.

I've just looked up the torque settings for M8 A2-70 bolts which is 17Nm, so you would be very likely to round off the sockets if torqing up to 25Nm.

There is also a common misconception that A4 stainless fasteners are stronger than their A2 equivalent and have a similar strength to 8.8 carbon fasteners.

The difference between A2 and A4 stainless is not its mechanical properties but its chemical composition. A4 is generally for marine applications where its extra corrosion resistance is required for the constant splashing of corrosive salt water. A2 provides sufficient corrosion resistance for most applications.

Our A2 fasteners are A2-70 grade. The 70 signifies that the Ultimate Tensile Strength is at least 700 N/mm^2. More importantly: the stress at which A2-70 begins to yield is at least 450N/mm^2. A4-70 has exactly the same ultimate tensile strength and yield stress.

Standard carbon steel fasteners are generally 8.8 grade. The first figure signifies that the Ultimate Tensile Strength is at least 800N/mm^2. The second figure signifies that the fastener will begin to yield at 80% of the Ultimate Tensile Strength, ie at least 640N/mm^2.

To get similar strength stainless fasteners you would require A2-80 or A4-80 where the yield stress is 600N/mm^2. There are significantly fewer of these on the market as A2-70 are sufficient for the majority of applications. In practice fasteners generally fail due to the excess load applied to them when they are assembled not when used in operation.

So, if you are replacing 8.8 carbon steel fasteners and you are certain you want to use stainless products, then I would recommend that you purchase our A4-80 fasteners for your disc bolts.

I hope that this makes the situation clear. Please email me if you have any further questions.

Many thanks

Matt Naish "

I couldn't find A2-80 button heads. He came back with this;

"Hi Gary

No problem at all.

I guess that's the main problem you'll face:- socket button screws are the best fastener type for the job but they're very hard to come by in A4-80 (A2-80 is almost impossible to find).

As you suggest, this leaves you with cap screws as the only real option from us (I'm not sure if the heads will clear the fork/brake assembly on rotation?) or you can risk using A2-70 or A4-70 as many other motorcyclists do!

I'm certainly extremely scepticle of doing this (hence my previous email!) and I'm not going to recommend doing this, but it's not at all uncommon.
In fact Inox Fasteners advertise A2-70 specifically as brake disc bolts!

My best suggestion would be to try specialist motorcycle fastener suppliers to see if they have sources of the less common bits like A2 or A4-80 button heads, or order the cap heads from us to test them as you can always return them for a full refund if they're no good.

I'm sorry that I'm not able to help more.

Many thanks

Matt Naish

Westfield Fasteners Ltd
www.westfieldfasteners.co.uk
enquiries@westfieldfasteners.co.uk
01844 201133"

In the end I used high tensile steel 10.9 BZP button heads.
With a light polish they look like s/s.

[ibanezlynx]

No offence taken...
I'm quite happy with the bolts to be honest. If at some point I'm twiddling my thumbs I might remove the marking. But I have other things to sort out. Next on the list is tidying up the front mudguard and the underside of the tank (little spots of surface rust).
I'm just pleased with the lovely comments.
In terms of this rebuild, any braking or suspension replacement fasteners have been high tensile BZP... Not worth risking it...

[Darren69]

Ibanezlynx, Please don't be offended by our comments about your bolt heads..:mand:
It's a smashing re-build in every way...I think we've been quite rude..:rolleyes: Sorry.

Apologies also for hijack.
I personally wouldn't use those A2-70 bolts Darren. I tried A2-70 button heads on my discs, but chewed the heads out before I reached 25nm.
I asked the supplier if I had chosen the wrong bolts for the job.
They said this;

[
In the end I used high tensile steel 10.9 BZP button heads.
With a light polish they look like s/s.

Thanks for the heads up on this. Its worrying that the seller has specifically stated that these are a direct replacment for OEM if the OEM are 8.8 carbon steel. I was looking to upgrade to titanium when I do my brake upgrades so if I went for titanium what grade would I need? Would these be more suitable?

http://www.ebay.co.uk/itm/NEW-DUCATI-748-916-996-998-TITANIUM-FRONT-BRAKE-DISC-BOLTS-/181121132134?hash=item2a2ba92666

[Darren69]

Actually the spec in the S4 workshop manual allows for a +/- 5% tolerance of 24nm so maybe they would be ok at the lower end 22.8nm?

[Mr Gazza]

Sorry, but quoting from my emails doesn't make me an expert....You just read the extent of my knowledge..:rolleyes:

Westfield's Matt Naish said that the M8 x 16 A2-70 bolt would torque to 17nm, and that's a long way short of the 25nm that my manual states.
I made my own decision not to use A2-70 for that application based on his trusted advise.

Look at the numbers and make your own mind up.

Those Titanium,Torx socket, button heads bolts look the absolute last word. Sorry I haven't a clue what the grades mean for Ti bolts, but at least the vendor states the grade clearly. Unlike the vendor of the Stainless ones...I had to zoom in on the picture to read the stamps on the heads.
Perhaps Kato, Capo or Garry could throw some light on the grades?

Just discovered that i have 18 x A4-80 Stainless M8 16mm Socket Head Cap Screws.
Up for grabs for £8 + £3 postage if anyone wants them....They are as bought , un-polished.!

[Darren69]

Sorry, but quoting from my emails doesn't make me an expert....You just read the extent of my knowledge..:rolleyes:

Westfield's Matt Naish said that the M8 x 16 A2-70 bolt would torque to 17nm, and that's a long way short of the 25nm that my manual states.
I made my own decision not to use A2-70 for that application based on his trusted advise.

Look at the numbers and make your own mind up.

Those Titanium,Torx socket, button heads bolts look the absolute last word. Sorry I haven't a clue what the grades mean for Ti bolts, but at least the vendor states the grade clearly. Unlike the vendor of the Stainless ones...I had to zoom in on the picture to read the stamps on the heads.
Perhaps Kato, Capo or Garry could throw some light on the grades?

Just discovered that i have 18 x A4-80 Stainless M8 16mm Socket Head Cap Screws.
Up for grabs for £8 + £3 postage if anyone wants them....They are as bought , un-polished.!

I'm no expert either more well informed after reading your post and well if I don't get the titanium ones they sound ideal. I will ask Durhamducs if they can withstand 24nm +5% and then I will be happier.

[ibanezlynx]

Done a fair few runs on the monster now and it's going great. Forgot how fun these are. Out of curiosity what do you think this monster is worth? Full service history, 15k miles, engine re-work and condition etc? Obviously depends on what someone is willing to pay...
I'm not sure and wondered what the guru's thought...

[Albie]

Done a fair few runs on the monster now and it's going great. Forgot how fun these are. Out of curiosity what do you think this monster is worth? Full service history, 15k miles, engine re-work and condition etc? Obviously depends on what someone is willing to pay...
I'm not sure and wondered what the guru's thought...

It's a buyers market but the older and nicer condition can command 2500 plus. I won't be selling mine but I would want 3000 plus because it will not need anything repaired or refinished and will be looking as good as new.