Another build thread - Ducati 1000 - Page 11

PPuxley · 11-10-2021, 12:15 PM

Coming on Tony. Probably worth mentioning, that the special bolt is NOT found on the casings for the early Monsters before people start thinking theyve missed it.

I have just checked with Snell's. The Special bolt did not appear on a 900 Monster till the 900ie 2002, but was introduced in the 600 and 750 from 2000. Anyway a check of the SD fiches will confirm
Special bolt part no 77910292A

350TSS · 11-10-2021, 04:31 PM

Thank you - I was worrying that I had to strip off my alternator cover to check whether or not I had fitted it, knowing almost certainly that I hadn't.

PPuxley · 11-10-2021, 04:34 PM

I was next to certain I hadnt seen that bolt when dismantling and rebuilding, and hadnt read about it in either the relevant Factory or Haynes Manual but wanted to be certain.

buzzer · 12-10-2021, 02:08 PM

There is something satisfying about doing the hydraulics. I pulled everything apart and gave it all a good clean, bead blasted everything and put it all back together with a smear of rubber brake grease and brake fluid. I didn’t replace any of the rubbers on this build, all seems to be in nice condition, so they just got a quick wash in methylated spirits.

last update for a few days... I will be 66 tomorrow, and get my pension!! another milestone reached! My wife is treating me to a few days away and we have family things planned!

walkingpictures · 12-10-2021, 03:02 PM

Still loving this thread Tony.....Happy Birthday for tomorrow,just over a year older than me!!!! Have a good'un

Kimbo

buzzer · 17-10-2021, 09:45 AM

Quote:

Originally Posted by walkingpictures

Still loving this thread Tony.....Happy Birthday for tomorrow,just over a year older than me!!!! Have a good'un

Kimbo

thanks!

I took a good look at the forks, and while the sliders were perfect, the anodizing on the legs was past its best. I popped them in the lathe and used some 240 paper to remove the anodising, then followed it up with some 800, and then a polish. they came up a treat! I did consider re-anodizing them but there is so much to polish anyway! I fitted a couple of new seals, and some new oil. all in all not a difficult job!

utopia · 17-10-2021, 01:25 PM

They look great.
But like yourself, I'm a sucker for a bit of polished ally.
Mind you, if the original finish on the legs is anything like that on mine (Showas) then the machining marks look to be fairly deep.
They probably look deeper than they actually are but I would still think it would take quite a bit of effort to remove them.
More to the point, I would be nervous that removal of that much material might compromise their fit in the yokes.
Did you perchance take any before and after measurements of their diameter ? ...and/or have you yet tried them in the yokes ?
Given your usual attention to detail, I'm quite sure none of this has escaped your consideration but I remain curious.

And I hope you had a very happy birthday the other day.

buzzer · 18-10-2021, 06:34 PM

Quote:

Originally Posted by utopia

They look great.
But like yourself, I'm a sucker for a bit of polished ally.
Mind you, if the original finish on the legs is anything like that on mine (Showas) then the machining marks look to be fairly deep.
They probably look deeper than they actually are but I would still think it would take quite a bit of effort to remove them.
More to the point, I would be nervous that removal of that much material might compromise their fit in the yokes.
Did you perchance take any before and after measurements of their diameter ? ...and/or have you yet tried them in the yokes ?
Given your usual attention to detail, I'm quite sure none of this has escaped your consideration but I remain curious.

And I hope you had a very happy birthday the other day.

the machining marks were not as deep as they look... I took less than 2 thou off in total

Started the rebuild of the engine… a tip I picked up years ago is its sometimes best to pop the piston in the bore with a ring clamp from the top, and then push it down far enough so you can get the piston pin in from the side… this saves broken rings and that’s important when a set for one piston is over £200! Put some rag in the open crankcase before putting the circlip in though!

350TSS · 18-10-2021, 07:38 PM

Good tip re the piston I struggled for ages with a ring clamp underneath the barrel to get the rings engaged (there is barely any room there for a clamp) and then had a second struggle to get the ring clamp off the connecting rod.

Dukedesmo · 19-10-2021, 12:32 PM

I've always fitted the piston to the rod first - to avoid struggling with the circlip in the confined space under the cylinder.

I then use a home-made ring compressor which is basically a strip of shim (wide enough to cover all the rings) and a large jubilee clip - loosen the clip enough so it'll slide on the piston and then gently tap the cylinder down onto the piston using the flat of my hand. Being thin it'll then easily pull out from under the cylinder.

Done it many times on different bikes and never a problem.

PPuxley · 19-10-2021, 01:19 PM

Ive always used the piston in the cylinder first method if I possibly can.

buzzer · 22-10-2021, 01:59 PM

I couldn’t resist modifying the clutch cover… I guess that the clutch is going to be even more noisy now!

buzzer · 23-10-2021, 09:33 AM

Next job has been to make the plate and trigger wheel for the hall sensors for the ignition. I have made some modifications from the last couple I made, the trigger wheel bigger and i have fitted a heat sink to the plate. I tried to order the same hall sensors as I used the last few times, but everyone seemed to be out of stock, with a delivery date of sept 2022! Fortunately a good friend found me some in Germany, so they are on the way!

The hall sensors are triggered by two tiny magnets in the rim of the trigger wheel, south pole turns the hall on, north off.

Darren69 · 23-10-2021, 10:06 AM

Great work as usual. I noticed this one, thinking ahead for your next project?: -

https://www.ebay.co.uk/itm/265364799...torefresh=true

And was thinking you could do something very cool with it. I made a couple of offers around £1200 but they were rejected. And since the most obvious choices of cafe racer have been done to death, and badly in most cases ii had in mind a kind of Supermono rep thing with a single 4V head liike half a 916 engine. Like the original one, keep the inj and get rid of the ugly Terblanche body kit and make it look cool.

As it's local to me I'm more than happy to go and check it over if you are interested? I mean it's super cheap but maybe its blown up but still clean low miles?

buzzer · 23-10-2021, 05:41 PM

Quote:

Originally Posted by Darren69

Great work as usual. I noticed this one, thinking ahead for your next project?: -

https://www.ebay.co.uk/itm/265364799...torefresh=true

And was thinking you could do something very cool with it. I made a couple of offers around £1200 but they were rejected. And since the most obvious choices of cafe racer have been done to death, and badly in most cases ii had in mind a kind of Supermono rep thing with a single 4V head liike half a 916 engine. Like the original one, keep the inj and get rid of the ugly Terblanche body kit and make it look cool.

As it's local to me I'm more than happy to go and check it over if you are interested? I mean it's super cheap but maybe its blown up but still clean low miles?

Thanks for that! I am SO tempted! timing is a bit out for me though... I wonder what's up with the engine?

11-10-2021, 12:15 PM	#151
PPuxley Registered User Join Date: Apr 2021 Location: Reading Bike: M900 Posts: 600	Coming on Tony. Probably worth mentioning, that the special bolt is NOT found on the casings for the early Monsters before people start thinking theyve missed it. I have just checked with Snell's. The Special bolt did not appear on a 900 Monster till the 900ie 2002, but was introduced in the 600 and 750 from 2000. Anyway a check of the SD fiches will confirm Special bolt part no 77910292A __________________ Golf-My favourite game. While my wife plays I'm in the workshop. Last edited by PPuxley; 11-10-2021 at 01:02 PM..

11-10-2021, 04:34 PM	#153
PPuxley Registered User Join Date: Apr 2021 Location: Reading Bike: M900 Posts: 600	I was next to certain I hadnt seen that bolt when dismantling and rebuilding, and hadnt read about it in either the relevant Factory or Haynes Manual but wanted to be certain. __________________ Golf-My favourite game. While my wife plays I'm in the workshop.

12-10-2021, 02:08 PM	#154
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	There is something satisfying about doing the hydraulics. I pulled everything apart and gave it all a good clean, bead blasted everything and put it all back together with a smear of rubber brake grease and brake fluid. I didn’t replace any of the rubbers on this build, all seems to be in nice condition, so they just got a quick wash in methylated spirits. last update for a few days... I will be 66 tomorrow, and get my pension!! another milestone reached! My wife is treating me to a few days away and we have family things planned! Last edited by buzzer; 12-10-2021 at 02:43 PM..

19-10-2021, 12:32 PM	#160
Dukedesmo Registered User Join Date: Sep 2010 Location: Leics Bike: M900 Posts: 2,842	I've always fitted the piston to the rod first - to avoid struggling with the circlip in the confined space under the cylinder. I then use a home-made ring compressor which is basically a strip of shim (wide enough to cover all the rings) and a large jubilee clip - loosen the clip enough so it'll slide on the piston and then gently tap the cylinder down onto the piston using the flat of my hand. Being thin it'll then easily pull out from under the cylinder. Done it many times on different bikes and never a problem. __________________ M900, 916, LeMans II.

19-10-2021, 01:19 PM	#161
PPuxley Registered User Join Date: Apr 2021 Location: Reading Bike: M900 Posts: 600	Ive always used the piston in the cylinder first method if I possibly can. __________________ Golf-My favourite game. While my wife plays I'm in the workshop.

11-10-2021, 04:31 PM	#152
350TSS Too much time on my hands member Join Date: Jan 2013 Location: Shipbourne Bike: M900 Posts: 1,419	Thank you - I was worrying that I had to strip off my alternator cover to check whether or not I had fitted it, knowing almost certainly that I hadn't.

12-10-2021, 03:02 PM	#155
walkingpictures preneolithic frebie Join Date: Sep 2002 Location: Cambridge Bike: S4Rs Posts: 319	Still loving this thread Tony.....Happy Birthday for tomorrow,just over a year older than me!!!! Have a good'un Kimbo

17-10-2021, 01:25 PM	#157
utopia No turn left unstoned Join Date: Jun 2010 Location: leicester Bike: M750 Posts: 4,545	They look great. But like yourself, I'm a sucker for a bit of polished ally. Mind you, if the original finish on the legs is anything like that on mine (Showas) then the machining marks look to be fairly deep. They probably look deeper than they actually are but I would still think it would take quite a bit of effort to remove them. More to the point, I would be nervous that removal of that much material might compromise their fit in the yokes. Did you perchance take any before and after measurements of their diameter ? ...and/or have you yet tried them in the yokes ? Given your usual attention to detail, I'm quite sure none of this has escaped your consideration but I remain curious. And I hope you had a very happy birthday the other day.

18-10-2021, 07:38 PM	#159
350TSS Too much time on my hands member Join Date: Jan 2013 Location: Shipbourne Bike: M900 Posts: 1,419	Good tip re the piston I struggled for ages with a ring clamp underneath the barrel to get the rings engaged (there is barely any room there for a clamp) and then had a second struggle to get the ring clamp off the connecting rod.

22-10-2021, 01:59 PM	#162
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	I couldn’t resist modifying the clutch cover… I guess that the clutch is going to be even more noisy now!

23-10-2021, 09:33 AM	#163
buzzer Registered User Join Date: Jun 2018 Location: Wolverhampton Bike: M900 Posts: 392	Next job has been to make the plate and trigger wheel for the hall sensors for the ignition. I have made some modifications from the last couple I made, the trigger wheel bigger and i have fitted a heat sink to the plate. I tried to order the same hall sensors as I used the last few times, but everyone seemed to be out of stock, with a delivery date of sept 2022! Fortunately a good friend found me some in Germany, so they are on the way! The hall sensors are triggered by two tiny magnets in the rim of the trigger wheel, south pole turns the hall on, north off.

23-10-2021, 10:06 AM	#164
Darren69 Transmaniacon MOC Join Date: Sep 2013 Location: Sutton In Ashfield Bike: Multiple Monsters Posts: 6,022	Great work as usual. I noticed this one, thinking ahead for your next project?: - https://www.ebay.co.uk/itm/265364799...torefresh=true And was thinking you could do something very cool with it. I made a couple of offers around £1200 but they were rejected. And since the most obvious choices of cafe racer have been done to death, and badly in most cases ii had in mind a kind of Supermono rep thing with a single 4V head liike half a 916 engine. Like the original one, keep the inj and get rid of the ugly Terblanche body kit and make it look cool. As it's local to me I'm more than happy to go and check it over if you are interested? I mean it's super cheap but maybe its blown up but still clean low miles? __________________ Roast Beef Monster! Termignoni and Bucci - Italian for pipe and slippers! S4 Fogarty, S4R 07T, 748, Series 1 Mirage