Ducati Monster Forum

hope this is the correct section for this type of thing.

Figured I could start documenting the slow process of someone figuring out how to rebuild their Moto.
Im no mechanic. Im a downhill racer. I wrench on bicycles, same thing right?

Short backstory. Ive had this 900 for 7 years give or take. A friend looped it out back then, we fixed it up but then with the mountainbike racing the Moto just sat and sat and sat and sat. Now, quarantine. Being that I can't get on the slopes seemed like a good time to take on a new project to take all my money.
Bought a Haynes manual, a Ducati manual and went to work.

there's no timeline for this. who knows. forever.

did I mention it was outside all those years? covered for the most part but still. a lot of snow and summers and everything in-between. Based off the amount of rat shit and bones there were some things living in there. Also might notice the yellow writing on the tank. Been impounded for parking on the sidewalk once (its usually inside the gated area but have to move it when they redid the brick on my building haha)

to note: this bike would start and run when I started disassembling. I just figured if I was gonna go in and after sitting for so long Id go all the way into the case and do some engine refinishing.

(https://live.staticflickr.com/65535/49838226376_7df7964f96_k.jpg) (https://flic.kr/p/2iW2Wn7)IMG_7221 copy (https://flic.kr/p/2iW2Wn7) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

I'm pretty into this currently. Ill be uploading some pictures I've taken along the way so far and do a better job from here.

tear down.
Id say it went ok. The bike was gross. Like I said, things were living in there.

things had been eating on some of the plastic bits here and there as well. Looks like it mostly left the wires themselves alone but who knows.

(https://live.staticflickr.com/65535/49838226186_8df3509595_k.jpg) (https://flic.kr/p/2iW2WiQ)IMG_7225 copy (https://flic.kr/p/2iW2WiQ) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr


did the tear down outside out front

(https://live.staticflickr.com/65535/49838524477_c67f1cade0_k.jpg) (https://flic.kr/p/2iW4sYM)IMG_7226 (https://flic.kr/p/2iW4sYM) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

I only have these two stands. Made some little legs for the engine and can see had to get a little creative for holding the bike staple with some strap to the fences around me with nothing overhead.

(https://live.staticflickr.com/65535/49837680118_16d98ac1f4_k.jpg) (https://flic.kr/p/2iVZ8YS)IMG_7410 (https://flic.kr/p/2iVZ8YS) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

(https://live.staticflickr.com/65535/49838524097_8fd82bbfd2_k.jpg) (https://flic.kr/p/2iW4sSe)IMG_7413 (https://flic.kr/p/2iW4sSe) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

then the fun part. we moved it all inside my apt  [evil]

(https://live.staticflickr.com/65535/49838224961_2b500cd28d_k.jpg) (https://flic.kr/p/2iW2VWH)IMG_7576 (https://flic.kr/p/2iW2VWH) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

Can't see any pictures.

per standard I got 3 of these 4 nuts off and the 4th one was being a punk and rounded off. After a little more freeze off and some vice grips was able to make progress on it

(https://live.staticflickr.com/65535/49838224776_4f5609000c_k.jpg) (https://flic.kr/p/2iW2VTw)IMG_7631 (https://flic.kr/p/2iW2VTw) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

(https://live.staticflickr.com/65535/49837678528_1730511ac9_k.jpg) (https://flic.kr/p/2iVZ8vs)IMG_7650 (https://flic.kr/p/2iVZ8vs) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr



pulling the heads was fun. Vertical heads came off easy breezy. the two nuts down behind the oil cooler for the horizontal one though.... yeeeeesh.

(https://live.staticflickr.com/65535/49838522537_02fc64e114_k.jpg) (https://flic.kr/p/2iW4spk)IMG_7656 (https://flic.kr/p/2iW4spk) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

(https://live.staticflickr.com/65535/49837678128_4fc45f051c_k.jpg) (https://flic.kr/p/2iVZ8oy)IMG_7662 (https://flic.kr/p/2iVZ8oy) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

(https://live.staticflickr.com/65535/49838223916_097c84673b_k.jpg) (https://flic.kr/p/2iW2VCG)IMG_7663 (https://flic.kr/p/2iW2VCG) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

one of the lower studs on the horizontal head did come out from the wrong end even after so much freeze off spray. Guess Ill be replacing some cylinder head studs. Threads in the case look fine.

(https://live.staticflickr.com/65535/49837678193_d9920406ac_k.jpg) (https://flic.kr/p/2iVZ8pF)IMG_7660 (https://flic.kr/p/2iVZ8pF) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

oof thanks guess Ill have to figure out a different host

Can see them now. You have your work cut out for you with bike being out in the conditions.

cut up a socket to make a tool for the castle nuts on the pulley wheels

(https://live.staticflickr.com/65535/49837676983_7d662777a3_k.jpg) (https://flic.kr/p/2iVZ83P)IMG_8395 (https://flic.kr/p/2iVZ83P) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

do they always have red locktite on the washers??

(https://live.staticflickr.com/65535/49838222666_449f449eca_k.jpg) (https://flic.kr/p/2iW2Vg9)IMG_8401 (https://flic.kr/p/2iW2Vg9) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

was excited to buy a new impact wrench to tackle the clutch  ;D

(https://live.staticflickr.com/65535/49837656893_7ce547b3b2_k.jpg) (https://flic.kr/p/2iVZ25r)IMG_8213 (https://flic.kr/p/2iVZ25r) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

(https://live.staticflickr.com/65535/49838521842_ab387c392c_k.jpg) (https://flic.kr/p/2iW4scm)IMG_8071 (https://flic.kr/p/2iW4scm) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

obviously the plates are in not the best shape. can I revive these somehow? or just have to bite the bullet and get a new set?

(https://live.staticflickr.com/65535/49838298766_e9238262b9_k.jpg) (https://flic.kr/p/2iW3iTd)IMG_8220 copy (https://flic.kr/p/2iW3iTd) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

(https://live.staticflickr.com/65535/49838521842_ab387c392c_k.jpg) (https://flic.kr/p/2iW4scm)IMG_8071 (https://flic.kr/p/2iW4scm) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

the clutch pieces themselves cleaned up nicely

(https://live.staticflickr.com/65535/49837677108_1909c28bc5_k.jpg) (https://flic.kr/p/2iVZ85Y)IMG_8217 (https://flic.kr/p/2iVZ85Y) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

bicycles remember...

used an old bicycle crank puller to modify a little for a crankcase puller

(https://live.staticflickr.com/65535/49838223801_cc380b65e6_k.jpg) (https://flic.kr/p/2iW2VAH)IMG_7727 (https://flic.kr/p/2iW2VAH) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

Moved this build tread to General.

The red loctite was put on the nut, and got pushed down to the washer.
Blue loctite is more appropriate.

Inspect that harness in excruciating detail to make sure no rodents have compromised it.

That is a top-shelf slipper clutch.
Inspect that spider spring for cracks.

piston heads came off, cleaned them up with a steam cleaner

(https://live.staticflickr.com/65535/49837677533_fed76d0592_k.jpg) (https://flic.kr/p/2iVZ8di)IMG_8156 (https://flic.kr/p/2iVZ8di) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

(https://live.staticflickr.com/65535/49838521502_1b7987e319_k.jpg) (https://flic.kr/p/2iW4s6u)IMG_8169 (https://flic.kr/p/2iW4s6u) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

thanks. Ive actually been crawling the forum for wiring harness threads. Im already this far outside of my comfort zone why not right

I will admit. Im currently stuck on the primary drive gear. Internet research tells me its a real PIA. Borrowing a hydraulic gear puller to see if I can use that and some heat to do the trick at home. But from reading it sounds like I might shouldn't get my hopes up without the Ducati tool for it so I might end up taking a trip with the case to my local dealer for a little help here.

this was a lot all at once but Ive been working on it for a couple weeks now ha. Don't expect this to be a fast one as I order things I need as I go so sometimes were waiting on the mail.

this slipper actually came from someone on this board back when the bike was crashed and had the original clutch badly damaged

bummer, the hydraulic gear puller I was able to snag is too large to get a grip on the primary drive gear.

Access to the edge of the gear is limited by the crankcases.

OEM Ducati tool is shaped to use all of the space.

I'd recommend using the OEM tool.

have one located. Hopefully can have an update in here sooner than later

‘00 900S with the floating rear caliper hanger, OE Öhlins rear shock.  Nice.  The 10mm engine mounting bolts aren’t great, but Nichols makes Titanium replacements.  Nice Nichols breather & 48T slipper clutch.

If it were my bike, high compression pistons would be in order and some fork internals...

+1 on that.

Perfect project for cabin fever.

What condition were the cylinders? Saddle?

Look up eBay for CCW heavy duty studs, they are about. Powerbarn are selling JE high comp pistons for a good price.

The stock loom is such a mess on this model as it travels over, under and around the air box. Corse Dynamics intake kit with cut down battery box opens up wiring options. That being said the air box has better volume than some models and with modifications and a PCIII can work well.

https://www.ebay.com.au/itm/California-Cycleworks-Cylinder-Head-Stud-Set-for-Ducati-916-900SS/183821280428?_trksid=p2485497.m4902.l9144&redirect=mobile


http://power-barn.com/ducati-900ss-standard-bore-high-compression-piston-kit-by-je-pistons/

oh wow thanks yall.

I knew it wouldn't take long for this thread to get talking dirty to me.
I had not considered this mod but when's the next time Ill be this far into things. Not crazy expensive either  [thumbsup]

what kind of other mods does upgrading to these pistons require? any Dif fuel mapping or anything to go along with it?

If you are going the heavy modification route do consider making your own harness.  There are a few threads about making one on this forum.  Not so bad on a carbie.  I couldn't agree more with koko64 about the factory harness.

I will definitely be watching this thread.

this is great to hear. something I have the idea Id really like to tackle but its pretty intimidating. I have been searching the forum for all the good threads, collected a couple so far.

FYI this ones fuel injected not carbed, not sure if that changes the opinion of it being not so bad ha

Yes, more work, but still doable.  Lotsa pins in the connector for the ECU.

Just raising the compression means higher octane fuel but that's about it, all else being equal. The tuning consequences start with open airboxes or intake kits that remove and replace the air box with pods, then you have to look at Powercommanders, dynotuning or ECU reflashing. Unfortunately, removing the air box, or cutting it off the battery holder, frees up how you can reroute and tidy up the loom in that area without chopping it up. It's the worst part of the loom on that model imo. The easier path of tidying up rather than cutting up the loom is much easier with the air box gone or modified. My brother and I considered a separate airbox to battery/ignition holder made from two whole components in order to reroute the loom and make servicing easier, quicker (and cheaper). This would keep the airbox operating with its benefits.
FWIW, the WASP intake kit people over here did not fit their velocity stacks and pods to your model but modified the air box and tuned it with a PCIII on a dyno. I noted that with interest. Just some food for thought.

That model, the 900ie imo, is the best of the 900 models. The motor comes with hot cams from the factory and better ports (don't make them any bigger), a bigger air box, lighter wheels (a bit), a stronger charging system and EFI. You get the S model goodies too. The motor just needs more compression and a good tune to wake up. You won't recognize the performance.

 https://ca-cycleworks.com/cs900d.html

https://ca-cycleworks.com/chnut.html

Back in stock with Chris, a loyal sponsor


And also,
https://www.bellissimoto.com/parts/airboxes-intakes/tpo-beast-high-flow-air-intake-kit-1
https://www.bellissimoto.com/parts/airboxes-intakes/tpo-outerwears-filter-covers-for-beast-and-beast-r-kits-1

Wow so cool to hear they are still around.


Still remember buying all the parts from them back on my first experiences with my first m750

http://www.ducatimonsterforum.org/index.php?topic=6291.0

Hahaha amazingly excited when taught how to change a chain... 

OK. update.

Got my hands on a primary gear puller. But talk to me about how this fits on here...
that probably sounds like a weird question. But this doesn't just slide on easily for me? Are there different sizes? If I look at mine the bottom part is kinda cut in more than half a circle seems weird to slide over a gear ha. When I compare to other images online it seems most flatten out here so you can actually slide it over the gear.
Im close to taking the dremel to it just to hit those corners flat but figured id ask first.

(https://live.staticflickr.com/65535/49875167107_24a8fda986_k.jpg) (https://flic.kr/p/2iZigyg)IMG_9244 copy (https://flic.kr/p/2iZigyg) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

Remove oil pump.  Remove transmission input gear.  Slide puller over crank gear after removing the nut (of course)...

All of that has been done. It just doesn’t seem to fit. The ears on the bottom cut out seem to not clear the smaller back part of the drive gear when try to slide it on from the side. I’m pretty sure that if I bust the grinder out it’ll slide on after but it’s such an expensive tool to be modifying

Can you post a photo?

so here is a flick trying to slide it on. and trying to circle where the tool starts to catch on the teeth. sorry reallllly difficult to get light back there ha


(https://live.staticflickr.com/65535/49877148042_411f9bc46b_k.jpg) (https://flic.kr/p/2iZtqqj)fitissue (https://flic.kr/p/2iZtqqj) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr


and thinking grinding these ears off might potentially solve

(https://live.staticflickr.com/65535/49876305463_57dcaf97f3_k.jpg) (https://flic.kr/p/2iZp6X6)cuteats (https://flic.kr/p/2iZp6X6) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

when I google image search it looks like they should be flat...

(https://cdn.shopify.com/s/files/1/2139/6487/products/01fb8db4fca451c094a4cb0f58883241_grande.jpg?v=1513385617)

(https://live.staticflickr.com/65535/49404809106_7815b2b1fa_o.jpg) (https://flic.kr/p/2igJyvy)

Pic doesn't show it well on mine, but yes you can grind those flat.

Put the nut back on, but with a noticeable gap to the gear.

That way when it comes off with a BANG it won't hop off and crush your foot.

Hold the body carefully with a wrench so it doesn't slap up against the cases.

perfect. tomorrow we do battle

took the dremel and cut the ears off the tool

(https://live.staticflickr.com/65535/49883711528_ffd8bee070_h.jpg) (https://flic.kr/p/2j144vS)toolfix (https://flic.kr/p/2j144vS) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr


amazing how much easier things can get with the right tool. Put it on applied a good amount of pressure on it then put heat to the gear and it popped off when it was ready. Loud

(https://live.staticflickr.com/65535/49884229521_6093583a6e_h.jpg) (https://flic.kr/p/2j16HuM)drivegear (https://flic.kr/p/2j16HuM) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

(https://live.staticflickr.com/65535/49885246006_3a27b99d03_b.jpg) (https://flic.kr/p/2j1bVEo)IMG_9320 (https://flic.kr/p/2j1bVEo) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

bolts out, few different sizes used.

(https://live.staticflickr.com/65535/49885555687_1f49a72466_b.jpg) (https://flic.kr/p/2j1dvHH)IMG_9319 (https://flic.kr/p/2j1dvHH) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

was definitely surprised how much oil was still in there ha. Spilled a good bit on the floor flipping the case over the couple of times to take the bolts out then flip it to take it apart.

(https://live.staticflickr.com/65535/49884722928_d741017b8a_b.jpg) (https://flic.kr/p/2j19faN)IMG_9322 (https://flic.kr/p/2j19faN) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

and here's about where I left off for the day

(https://live.staticflickr.com/65535/49884722878_1a67e8b9a6_h.jpg) (https://flic.kr/p/2j19f9W)IMG_9329 (https://flic.kr/p/2j19f9W) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

 [thumbsup]
You can buy a stainless bolt kit for the cases.

There are loose shims on the end of the crank, inside behind the clutch and inside behind the countershaft.
Shims both ends of shift drum as well.

And well worth it.

My wife would shit a brick (possibly two) if I dragged a bike engine in the house and split the cases.  :D  [laugh]

I'd be dead with one foot still on the doorsill.

 ;D

maybe this is insightful on why I don't have one of those yet... hmmm 

so Ive been in touch with a media blasting company here in town and sounds like Im gonna just need to remove all the bearings and stuff which I was hoping I could avoid but oh well.

"We wash and degrees all parts prior to media blasting and also out gas. This is all to maintain the integrity of our media. Your bearing would need to be removed due to the washing and out gassing process"
womp womp

One thing I dont see in any manual, can I remove the sight glasses from the engine cases for the blasting?
also... not sure Im seeing how the bearings in the back of the case where the swingarm connects come out?

changed plans a little.
IDK if lazy or save money whatever. All the bearings feel perfect so just didn't wanna mess with them. Instead of getting the case and covers blasted I just removed the paint and corrosion myself on the outsides. Ive done my fair share of paintstripping and sanding so what's one more.

I still plan to get the cylinder heads and barrels blasted cause what else would I do with all those fins.

(https://live.staticflickr.com/65535/49927294007_c8d0318e65_k.jpg) (https://flic.kr/p/2j4Ur4V)IMG_9409 copy (https://flic.kr/p/2j4Ur4V) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

(https://live.staticflickr.com/65535/49926477408_eb028aa8d7_k.jpg) (https://flic.kr/p/2j4QfjC)IMG_0029 (https://flic.kr/p/2j4QfjC) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

(https://live.staticflickr.com/65535/49927293857_6cc4cd4ca5_k.jpg) (https://flic.kr/p/2j4Ur2k)IMG_9662 copy (https://flic.kr/p/2j4Ur2k) by rsoffar (https://www.flickr.com/photos/92398865@N05/), on Flickr

getting the seal out of the clutch side case cover is being a punk


plug some of my previous paint stripping and metal finishing work.... thank god the Moto pieces are getting painted and don't need a consistent grain finish like this past one.

(https://ep1.pinkbike.org/p6pb17157790/p6pb17157790.jpg)

(https://ep1.pinkbike.org/p6pb17157794/p6pb17157794.jpg)


maybe the Duc will need some engine turned gold leaf too? so many ideas spinning

think I'm going to have my painter flip my factory colors here on the engine. move the gold color to the case covers and do the lighter silver gold Ducati uses on the engine for the case this time.

using the same painter on all this as I always have a buddy of mine down in Philly
Heres our last project together.

Candy purple over flake. whole bike is one transparent color layered to make the logo and its actually a gradual fade to darker (more layers) to the back of the bike.
excited to see where we can take the Duc, been working on some basic photoshops but haven't super gotten into the paint yet, maybe will post some of those later

(https://ep1.pinkbike.org/p6pb16132813/p6pb16132813.jpg)

 [thumbsup]

WAO, I thought I had moto issues  [beer]
Glad to see progress.
G luck

Any progress since the last post?      [popcorn]