Ducati Monster Forum

so i've de-registered my duke, knowing it needs a bit of decent work, and the time it will take to do this whilst we have our 3rd kid, i cant justify keeping it registered just to sit in the garage. After some late nights snooping about the forums, and weighing up some options, ive decided to do what many other illogical, moneywasting 750 owners do - polish their turd!

yes i know, buy a 900 engine at half the cost, blah blah. i dont want that. I like my turd.

so the list of mods i want/hope to do so far:

- FBF high comp pistons
- 620/800 heads to compliment
- new OEM clutch basket
- barnett clutch plate kit
- machine stock flywheel
- machine new OEM primary gear (worth doing at all? ive a new one with the new basket)
- rebuild mikuni carbs
- either pods or open airbox
- LIFO/lightweight battery, maybe relocate
- new tank, probably CA cycleworks
- new fuel/air lines etc, all rubber is old old old.
- new fork seals, respring and fresh oil whilst there.
- SS rims.... massive weight savings (ok so they were a bargain and i prefer the thinner three spoke look)

will add to this as I go, all i can think of at the moment.
this is to compliment what little mods ive got so far:

- ohlins rear shock.
- 900 adjustable front forks
- cycleworks exactfit coils
- K&N air filter
- remus low mount pipes.

im very limited by funds, so will be doing as much work myself/with friends, only limited by my poor spannering ability.

pics to follow throughout winter.

questions i have so far:

regarding the heads, from what ive read 800 heads will be slightly better than the 620? but apparently 620 are cheaper and easier to come by?
is there a particular year range i need to look out for with the heads?
do i need complete heads, or are my 750 components transferable, and its just different porting in the heads that im after?

the heads/pistons are going to be one of the more expensive components to the build, so im still up in the air about it.

What year turd are you polishing?

I've been very happy with the Factory Pro parts for the Mikunis.
I've not compared directly with Dynojet stuff...... but.....
The first FP kit I did was on my own M750, fuel mileage went up 25%, and it ran better *everywhere*.
Same results I've gotten on many carb sets since then with FP stuff.

620 heads have the same size valves you've got now, so not a lot better.
695 or 800 heads will have the bigger valves and better cams.

'06 and earlier are 8mm valve stems, at least here in the states.
That restricts it to 800 heads.
Not a huge deal, but they seem to hold up a bit better than the 7mm stuff.

You'll want the heads complete with valves, cams and cam end covers.
Your 750 cams and valves are shyte and don't fit straight up, and the end cover is different.
Valve covers and rockers and rocker shafts will swap over.

I've had limited exposure to Barnett wet-clutch plates.
That first exposure was completely unsatisfying, but that was an APTC pack in an S2R800.
So, YMMV on an early wet clutch.

your's is a 97 motor, and the 98 and later reversed the o-ring recess location.  so you'll need later cylinders as well.

i'd suggest you'd buy this: http://www.ebay.com.au/itm/Ducati-800SS-Engine-Motor-GUARANTEED-/140786212065?pt=Motorcycles_Parts_Accessories&hash=item20c7831ce1&_uhb=1 (http://www.ebay.com.au/itm/Ducati-800SS-Engine-Motor-GUARANTEED-/140786212065?pt=Motorcycles_Parts_Accessories&hash=item20c7831ce1&_uhb=1)

or this: http://www.ebay.com.au/itm/DUCATI-900-MOTOR-FUEL-INJECTED-98-TO-2004-SS-OR-MONSTER-ETC-GOOD-CONDITION-AS-IS-/120968251322?pt=AU_Motorcycle_Parts_Accessories&hash=item1c2a4507ba&_uhb=1 (http://www.ebay.com.au/itm/DUCATI-900-MOTOR-FUEL-INJECTED-98-TO-2004-SS-OR-MONSTER-ETC-GOOD-CONDITION-AS-IS-/120968251322?pt=AU_Motorcycle_Parts_Accessories&hash=item1c2a4507ba&_uhb=1)

but i see you're committed to doing it the hard way.

so if i get heads off something else, i'll need cylinders to match.

what is better with 620 heads, if the valves are the same?
other option which has been pointed out is keep the 750 heads, and fit bigger inlet valves with a bit of machining.

worth replacing the cylinder studs whilst doing any of this? currently perving on the Nichols website...

620 cams are a more modern design, and higher lift, compared to the 750.
Ports may be better, but I've not compared side by side.

Given the amount of work involved, IMO it's worth the extra cost of the 695/800 heads.
You're not on a tight time schedule, so availability isn't such an issue, yes?

I'm not aware of the small motors having stud issues.
California Cycleworks has their own studs at ~1/3 the price of the Nichols units.

Edit: So the whole shebang top end for early 750s then.
I 'spose it all depends on what parts you can scrounge up cheap. A friendly machinist might make 900 inlet valves fit and you might find cheap 900V cams.

Brad, your 750 motor still for sale?

yes.

the pre 98 heads have the o-rings in the heads.  so you could get the later heads machined to take o-rings.  get pete smith at epicycle to do them.

don't use 620 heads.  they have a short duration inlet cam which works well in a 620, and apparantly quite good in  big bore 620/750 (ask nick).  otherwise they're much as you have now.

800 heads have a bigger chamber to take the 900 valves, so you'll need very high comp 750 pistons to make them high comp.

i found a 696 motor on ebay germany for 650 euro that they'll send to au for 45 euro. [laugh]  put 696 heads and cylinders on it.

Your 750 motor is very well developed, maybe Nibor should sell his motor and buy that ? ;D

i did notice that for sale comment in one of brad's writeups  :P but then i'd miss out on all the fun haha.

im guessing the machining just the heads for o-rings would be comparable if not cheaper compared with sourcing cylinders too. FBF make 11:1 and 12:1 piston kits for the 750, so the 12:1 would suit with the 800 chamber, still achieving a decent ratio yeah?

is it any 800 head? so S2R 800, 800SS, 800M all the same engine, on different setups?

PM sent

The following alternator cover gasket for a pantah engine should fit I think. Anyone can confirm?
I know the CA Cycleworks alternator cover gasket doesn't fit, that's 98 spec onwards (with external clutch slave cylinder)
http://ducati-gowanloch.com/catalog/ducati-pantah-alternator-gasket-p-2387.html (http://ducati-gowanloch.com/catalog/ducati-pantah-alternator-gasket-p-2387.html)(http://ducati-gowanloch.com/catalog/images/ducati_gasket_066049135.jpg)

Others will confirm, but surely that's the correct gasket? Dealer have any left?

Polish away Nibor ;D

yes, pre 97 is same as pantah.

Thanks Brad!

Places where turds were polished until they were nuggets of gold.

Hordpower (JD Hord)
http//www.hordpower.com/gallery/album07
"750SS cam comparison"


Mosperformanceservices (Doug Lofgren)
http://www.visi.com/~mpoerfserv/750SS.htm (http://www.visi.com/~mpoerfserv/750SS.htm)

bikeboy.org (Brad Black)
"750M Brads 600 gets a bigger engine and played with"

Once the mods are done, I shall forever dub my 750, "Nugget".
 [Dolph]

 [laugh] [clap]

so this is where I'm at so far. airbox/carbs/ignition are off with guidance from Koko64, then i just dived into it. wiring harness is off, everywhere except a couple of pickups. rear tail section stripped to the frame, even the rubber grommets are out.

bars will be removed shortly, helpful i can keep everything attached to the bars except the clutch line, dont need to try and find my preferred positions when reinstalling everything on the bars. left the forks on as i think i need to loosen the top bolts or something before they come out of the triples, to aid in rebuild.

i should probably drop the oil now eh? :P engine case covers will be off next, along with the swingarm and everything attached. thats after i work out how im going to support the engine, either use a engine centre stand and something else at the front, or hopefully a mate can fab up a decent engine workstand. then the front end can come off too, lastly the frame off the block.

(https://scontent-a-hkg.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/p180x540/10565011_10152303018734912_2140675749602751924_n.jpg?oh=b9348dfc0238e4f5a10ae5c174d3a03d&oe=5442C5B3)

 just ordered a new chain and sprockets, and looking at the pistons. looks like I will be keeping the 750 heads, just adding 900 inlet valves, and doing some light porting to keep the cost down. with this in mind, 11:1 or 12:1 high comp pistons? any reason to go or not go a particular compression?

i really should have taken more photos of the wiring installation, ive forgot most of it already  ;D

It depends on whether the advertised compression of the pistons is the compression acheived with your combustion chamber. Worth emailing the vendor with details of your planned mods to the heads. If the valves are unshrouded you might need the higher compression version. Which pistons you looking at? Someone here may have experience with them.

Not sure what you get there, but at those compression ratios pump gas may not work for you.

We have premium 95 and 98 RON gas. Iirc, Brad ran 95 on his hi comp 750. I'm not sure if it had 11:1 or 12:1 comp ratio. On a 900 with 11:1 JEs I run 98 and retarded adv. Iirc, Brad noted that the 750 liked/handled more adv and handled 95 fuel. Suppose the 88 bore and smaller combustion chamber helps.

I'm sure you're way smarter than me, and took LOTS of photos as well as put all the hardware and misc parts in labeled baggies...

I like Chinese food containers. ;D

progress!

just bought some of these  [drool]

http://www.ferracci.com/fast-by-ferracci-parts/engine-parts/piston-kit/piston-kit-88mm-750-12-1.html (http://www.ferracci.com/fast-by-ferracci-parts/engine-parts/piston-kit/piston-kit-88mm-750-12-1.html)

super awesome bonus is FBF have 25% off on Mondays currently, which i randomly discovered! $420 USD parts, had for less than $400AUD. im stoked!!  [Dolph]

no idea how long this is for, but if anyone else is keen to blow some dosh on some pistons or whatever else, now is the time to do it!!

This is going to be a hot 750, I'm looking forward to it. I've always regretted swapping that turd of a 900 motor into my ultra fun, (and ultra reliable  [bang] ) 750 instead of going the route you are and keeping it forever.

You wont regret that 944 when you twist the throttle.
Nibors 750 should be a sweet little motor.

Thanks?!?  I just lightened my wallet for a set.

 [laugh]

Gettin ready to pack these bad boys up and send em across the pond for Nibor's build. :D

(http://i1008.photobucket.com/albums/af202/johnnyblaze19761/2014-12-15%2018.38.19_zpsxmz1vnv0.jpg) (http://s1008.photobucket.com/user/johnnyblaze19761/media/2014-12-15%2018.38.19_zpsxmz1vnv0.jpg.html)

I can't like this, as it's not facebook. Bacon will have to do!!

 [bacon] [bacon] [bacon] [drool]

the slow march of progression...

(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10891733_10152643293314912_7313287699480142813_n.jpg?oh=68de412592efbc05529fb24ee8ef9a15&oe=554307C0&__gda__=1430036629_58c773c3015922d54cdb552ee6fd8457)
(https://scontent-b-hkg.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10885257_10152643293529912_5247975965065070977_n.jpg?oh=5e6e62b3fa5b167e9fa4270ad7f7f975&oe=54FD02D7)

whilst removing in the process of removing the swingarm, I noticed im missing two of three bolts on the lower chain guide. this may or may not have contributed to what looks like the chain having slapped and gouged the left side swingarm pivot pinch bolt. Hard to see, but too a bit of reshaping with a chisel to get the hex bit in to allow for slackening.

once slackened, I began to drift out the pivot. this revealed itself as more worn than thought! the bearings arent looking too crash hot, and the bolt itself has a nice rust patch complete with mild pitting, complimenting the rusty inner pivot bolt housing/hollow.

time fore new bearings all round, and most likely a new pivot bolt.... anyone make this in Ti?  :P

(https://scontent-b-hkg.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/1526395_10152643293674912_5673075095720735152_n.jpg?oh=911ee6e66bf051753887a3b4d2d95d62&oe=553135FF)
(https://scontent-b-hkg.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10888477_10152643293739912_5516391366785878449_n.jpg?oh=0584f3b2d0e0b169a08ccc3984e8544f&oe=5533125D)
(https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/1525331_10152643293874912_1922791724195068090_n.jpg?oh=92ad0adcfe7cf416a94d52b14711aec7&oe=553310EC&__gda__=1428936838_de23a38c36b6e81afb3d461ee745488c)

TPO might.

I've looked for swingarm pivot bolts in Ti for our bikes and come up short. TPO doesn't have em and it's unfortunate because the ones they sell for other bikes include a gorgeous Ti nut that replaces the ugly circlip + rubber cap.

They are bloody expensive anyway...we're better off. :) wish I'd known you needed one Nibor, I have several extras.

the collection so far. big shout out to Rudemouthsky and Valtermotousa, my parts suppliers!


Fast By Ferracci (Wiseco) 12.5:1 high comp pistons. these things are beautiful! and so cute, they come in their own little bag like a helmet bag haha. slight gain from stock 9:1 compression [Dolph]

(https://scontent-a-sjc.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/1533743_10152712174029912_6326798778700957010_n.jpg?oh=e587b23e8dab7b30e32c9cdddf0ea63b&oe=55681EB0)


NOS cush drive rubbers for the new-to-me rims I picked up too. these are buried in a box under some stuff so no good pics yet.

(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10730983_10152712174144912_7148072768654640776_n.jpg?oh=d51632a14e56f7fd6c3d9ad6d32bc394&oe=5521E3A2&__gda__=1432291508_e604216abb70eee571cdb1b5c20551f2)


NOS cluster with DP tacho. stoked to pick this up, complete with LED mod done for me already ;D I just need to source a KM/H faceplace for the speedo, hopefully in grey to match. stock is white.

(https://scontent-a-sjc.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10957689_10152712174279912_1515185909465452773_n.jpg?oh=56d41103a95cd62474573b85724d0afc&oe=555AFF2F)


some FCR39's. 2nd hand from Germany, but looks like they've been cleaned up already. not gonna pretend I have any idea how to tune these, luckily I know one of the best at it!

(https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10926414_10152712174369912_4101631160489404631_n.jpg?oh=de59609faf34034ad3eada0fc93f5e32&oe=555CBDA0&__gda__=1431660277_a6da71413ee242fa65fe2a402aad3b3c)


NOS clutch basket and drive gear, to go with the Barnett plate kit I picked up a couple of years ago.

(https://scontent-b-sjc.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10941216_10152712174474912_437346527952044524_n.jpg?oh=cf65854d1dbedadc455efb261e9bc7e2&oe=555C20B9)


IMA Mod1 Triple Clamp set with risers. these are the newer Mod1's in 7075, not 6082 T6. I assume this is a good thing haha. so stoked to have these in my hot little hands, I have been lusting over them for years.

(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10409033_10152712174559912_6329248903476611556_n.jpg?oh=ccb076f6e070ecffc0d7c32f22e38755&oe=556332FF&__gda__=1431103104_f4ba271d4c709662a1b065bb149ab2e5)


freshly painted gloss black steel swingarm. its so shiny! mucch better than stock silver IMO. good encouragement for the semi blackout plans too. now the rearsets and frame need to match...

(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10920949_10152712174644912_4304752339752868162_n.jpg?oh=cde3bce982592559932503e4114d3254&oe=5552CCFE&__gda__=1431811816_9c28caf4e2290302a51b19f3a22c225c)

so in my infinite wisdom, I need to get the flywheel off for machining, after removing virtually everything that can assist with its removal. the head studs are cracked loose too, so not sure if there will be any compression left to assist.

(https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10358563_10152712174749912_7502829349626269477_n.jpg?oh=8825c32fb624ee24ca31e85fa6e071af&oe=555B0E63&__gda__=1432233782_4ec4fc63a114170f2c11b0d899c82ff1)

so I'm thinking of buying bought one of these: https://www.motionpro.com/motorcycle/partno/08-0427/ (https://www.motionpro.com/motorcycle/partno/08-0427/)
anyone used one before? with a little googling, not a lot comes up, but some people seem to love them, others hate them and swear they break. I'd rather this break than a gear tooth though!

some target mods have changed too:

- no longer going to change the heads, and potentially wont increase the inlet valve size. just some light porting, and pistons for the heads. simply the amount of time this project is taking (and lack of time I have to give to it), I just really miss riding and want to be back on the bike!
- picked up some FCR39's as mentioned, so no need to rebuild the mikunis.
- no pods, as much as I like the look, the performance is missing. Koko64 has some interesting plans for my Airbox...  ;D
- paintjobs on most parts, to compliment the new swing arm, and the frame will need repainting anyway with the weld to be done, and acid damage to clean up
- I'd love to find some 860 GT finned valve covers to put on. blame Rudemouthsky for that one!

IMO, don't use that gear-tooth-jammer on the timing gears, only on the primary gears.

Those are tall domes on those slugs.
I forget, do you have different cams in a box for this motor?

If you want mine I'd consider selling em; because I sorta wish I'd gone with the Corse Dynamics pair in anodized red. Getting an oil cooler mount made has become more of a hassle than I'm happy about simply because I don't have the time.

May damage the timing gears?




Nope stock cams. Will be looking at smoothing some of the edges on top as Brad did, to avoid hotspots. Also ceramic coating, simply as I will be getting the exhaust done too so bundle it up.

When it comes to black, you can't beat super wet black powder coat. It doesn't scratch like paint and it can be buffed out with some cut and polish paste and a buffer.

Polish away neighbour, polish away. [thumbsup]
So Nichols flywheel with $ saved from not buying cams and inlet valves? [evil]

Curious how things have been going so far ? Been going back through some of these looking for ideas. Got the mod bug again.

So how is Nugget?

the nugget is very stationary  :(

no progress for a while, at least whilst I part out the 900.

been cleaning up the headers, might just leave them brushed/polished steel rather than ceramic coat. we shall see!

Pmed you.
Got an update on Nugget?

Been speaking with Nibor,  this case may hopefully be wrapped up soon.

Hopefully!!

We shall polish the Nugget to a high lustre. [evil]

Have prepared an enlarged airbox, opened inlet manifolds and some ported velocity stacks for the FCR39s. Hoping to emulate the M750ie power curve with its better intake tract/airbox.

man I am itching to open the throttle!

...instead of just your wallet.   [thumbsup]

Nibor did some more polishing of Nugget today. I mainly watched and offered moral support while eating Mrs Nibor's chocolate brownies. Frame is on the motor and the swingarm is on with new bearings. [thumbsup]

oi! who's thread is this?  :P

I got shit on my hands too from polishing. :P

Make no mistake, it's all yours.

 [laugh] [laugh]

so an official update  ;)

Progress!

(https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xft1/v/t1.0-9/12472793_10153614406014912_7595578246105157392_n.jpg?oh=96f8de163bfa0ee32fda067c59d62e73&oe=5778E3CD&__gda__=1467173695_35c924d404ed88e8379328997e4ec035)

first the frame went on. I replaced my missing frame spacers that I carefully archived with my lost odd socks, with that from the 900 I bought. I knew there was a reason I dropped $3500 - for spall pieces of aluminium.

after much dicking around, we discovered the 17mm front axle is the perfect tool to drift in the swingarm seal retainer, seals, and bearings. this was only after grinding down one of my sockets on Koko64's benchgrinder, after I nearly got it stuck in the swingarm bore inside the engine  [laugh]

I think the first seal took 30min to get in. with one side done, the other side's retainer, 2x seals and 2x bearings took barely 10min, with the newly discovered multi-tool. the axle pin fit well in the first bearing, to act as a guide for the rest of them, whilst the larger headstock which gets clamped in the front fork does the drifting contact, with 0.5mm to clear all around. perfect  [thumbsup]

we also pumped 5L of grease into the cavity between the two bearing sets, to avoid the reason I had to replace this swingarm pivot pin in the first place - water penetration, causing rust and bearing failure. this may or may not have been done with a syringe stolen from my son's medical supplies. good thing Mrs Nibor doesnt frequent the forums  ;D as a bonus my increased top speed should allow Nugget to outrun even a greased scotsman!

(http://vignette4.wikia.nocookie.net/springfieldbound/images/b/b2/The_Greased_Scotsman_%28Official_Image%29.png/revision/latest?cb=20120318040757)

 [thumbsup]

as always, after much dicking around, I now have the delicious billet that is IMA triples, firmly mounted upon my frame, with some All Balls tapered roller bearings carrying them. they were going to be complimented with some shiney stainless bolts, but one decided to shear off at less than 19nm of torque  :o no thanks. out they go, all new 12.9 zinc plated to replace!

big shout out to Technico Racing (whom im trying to convince to make some billet parts like the S&P rear hoop, and other nice things), who managed to remove the shank I'd left buried in the triple, without too much fuss.

(https://scontent-syd1-1.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/12998528_10153644718624912_6936046758428324927_n.jpg?oh=890be71e2362b89881054cdcf6abb4f9&oe=577F1C83)
(https://scontent-syd1-1.xx.fbcdn.net/v/t1.0-9/12936686_10153642715079912_2606433863894593139_n.jpg?oh=87444638816d3e0a0830d949f66f8470&oe=5785C92C)

Lookin' good Nibor!

so I've slowly been slugging away at little bits and pieces. lots of prepping (some good some lazy), lots of rattlecan painting (with results reflecting the prep effort!), lots of pissing off the missus by cooking smelly painte parts in her oven  ;D

collected most of the bolts I need to replace nearly everything. stoked to find the footpeg racket bolts were relatively cheap, whilst being rather particular/specialist. disappointed to find it's damn near impossible to locally source low and ultra-low profile socket head cap screws in silver zinc, what little they had was all black steel. these are for the swingarm/rear hoop bolts, and the headlight mount bolts.

also, the dash/meter mounting bolts, with their thread on the half nearest to the head, whilst having an unthreaded skinny pin section on the tail, are super special with no-one knowing them. and stock $17 a bolt is hard to swallow!

lastly bolt related, I'm sick of taking a variety of bolts or even just a list to my local shop, and having the bloke there "match" them to replace my corroded old stuff. his version of matching is +- 5-10mm, which is ridiculous, and not a match. /rant.

SO! I just cleaned up my rose joints for the hoop, keeping them. fitted the rear hoop, and shock linkage (except 1 bolt to be replaced still, as my replacement bolt supplied was 5mm shorter than requested, so the nut doesnt have a quality purchase). this means I'm nearly up for mounting wheels!! [Dolph]

the bars are on, the brake lines need replacing with longer ones that fit/can be routed correctly and aesthetically. FCRs fitted to my painted inlet manifolds (still need throttle and fuel lines). speaking of fuel, my pump is painted too, ready for the rebuild kit.

the list goes on!

time for some sleep, need to get up and earn some more money to pay for more bits  [thumbsup]



P.S. pics to follow, when my phone is not dead [beer]

Cool!  Looking forward to the results... 

AFAIK:
The swingarm/hoop bolts and dash/meter bolts are specials, exclusive to Ducati.
Headlight mount bolts are standard low-head configuration, available in Stainless.

Looking good, keep up the strong work!

(https://scontent-syd1-1.xx.fbcdn.net/v/t1.0-9/13227076_10153706227839912_2444615416629349456_n.jpg?oh=96faebf7541d5d826f5345a3f29c3c48&oe=57E734DD)
painting all the bits!


(https://scontent-syd1-1.xx.fbcdn.net/v/t1.0-9/13177554_10153706227809912_2076735028372023849_n.jpg?oh=76ce418c7c6a7619e4d167b256733078&oe=57A1BAAA)
inlet manifolds and FCRs are mounted.



(https://scontent-syd1-1.xx.fbcdn.net/v/t1.0-9/13174189_10153706227734912_5693206962259404175_n.jpg?oh=ef5e38e07b0cd3a5b0935859bd752526&oe=57A426DD)
modified (expanded) airbox fitted. will take another pic of the front, easier to  see the mod.



(https://scontent-syd1-1.xx.fbcdn.net/v/t1.0-9/13178917_10153706227684912_2628911401451610917_n.jpg?oh=560f5c5414d9300993bb72399ab1b5a5&oe=57D95585)
hard to see with the contrast/bad lighting, but the painted linkage, hoop, and ohlins are all fitted. will decide on a home for the remote reservoir later.

available in some countries  [thumbsdown]

I can't believe how hard it is to source components here. yet to find anyone local with low-profile silver zinc bolts, they're only in black steel. let alone stainless!

Just came across this thread, nice job I hope the best for you and Nugget!

just an FYI to keep an eye on the 97 monster in the US had weak engine cases that were prone to cracking at the layshaft. stock they would be fine with the power but if you start to make power the lifespan is shortened. i have personally killed two sets of 97 cases. the first set was a street bike that I turned into a track bike.  I beat that motor hard but outside of a light flywheel and a little port clean up it was a65hp stock motor at best. It lasted me about 7-8 seasons of about 1000-2000 track miles a season.

second set of cases were from a friend and they were a complete motor with pistons,cams and lots of little bits. I never ran it myself with these parts as I knew of the 97 cases. I swapped all my first engines parts into the newer set of cases and ran it also as a pretty stock motor. I cracked that one last fall after about a year and a half, so I think the time as a built motor shortened its life for sure.

When at the dealership we had a bunch of very built 750ss racers that broke cases after about 4-5 years at the expert level, when the 97 came out we built them on the 97 cases and often did not get a season. Sorry to be the bearer of bad news but you should know to keep an eye on the engine casting on the right side under the layshaft pulley. It will often start as an oil leak as there is an oil passageway the crack will spread to.

If you are NOT in the US I have no idea if these are the same cases we had, they certainly are the same style (early).

I just built a 750 from a 02 620 monster to get away from the 97, the 98 and later cases are MUCH better with little issues but there are a number of parts different than you have on the 97 so you cannot just swap your 97 parts into the 98+ motors. You pretty much have it done so just enjoy the bike. As a road bike it may last forever and if it does go you could source the earlier cases which were stronger or swap some of your parts to a newer block.

so the issue was specific to 1997 cases for the 750?

will keep my eyes peeled, for both the crack/leak, and for a spare case. I think I saw a NOS case floating around somewhere a while back!

that didnt take long. found a NOS case within 5min! just need to determine what year it is. combine that with NOS vertical and horizontal heads, as mine look shit with age and acid damage, add in my existing barrels (the barrel paint is bulletproof!) and all internals, and I have an virtually NOS engine!

 [drool]

First I would verify your 97 750 motor is the same as the us models (where are you?).

I would see little benefit in having a second set of the same case as they will end the same .... some day.  Earlier cases were stronger based on our experience, 98 and later were different but better still. Yes it was one year in the US where the 750 came back after being gone from the US market for a couple years, 1997 monster 750 is the only one in the US.

I do not know if it is true but was told the 97 was built up from the 400 when they ran out of the old castings in the early 90's. The 98 came with completely new cases and though I have seen them break they are super rare. This is why I built my replacement from a 620.

Your 97 cylinders will not mate up with later cases as the tensioners are on the cylinders on the 98 and later motors, your heads will.  If you have your existiting motor together and do not mind the work get the spare cases and hold on to them until you need them. Run it as you have it and if they break change them then. The cracks are NOT catastrophic as it shows itself as a oil leak first.  picture in link.

https://www.instagram.com/p/BE1wMdmoAOq/?taken-by=clubhouse_motorsports (https://www.instagram.com/p/BE1wMdmoAOq/?taken-by=clubhouse_motorsports)

I was bummed as I really preferred the look of the earlier motor and there was no other benefit to change for me. Some would take it as a sign to build the motor more (6 speed,slipper clutch,  or dropping in an 800 motor) but I was shooting for a 60hp motor and am at 59.9 on my dyno. Yes that missing  .1 bugs me!

Nibour, I did this for dash mount bolts ... You can modify two stainless m8x50 button bolts, just remove the lower 25mm of thread.

Btw this thread needs a like button, those FCR look sweet bud [thumbsup]

thanks mate! I'm hoping to have them looking even better in the future, but it's not a priority now unless they need a rebuild anyway. Hydroblasting!

(http://3.bp.blogspot.com/-vdFq-WJKDC8/UYZEHf1FyzI/AAAAAAAAAOw/2HzcBOINhXU/s1600/Keihin+B%2526A.jpg)

thanks for the tip on the stainless. I spoke to a mate about machining a hardened steel bolt, as I'm using silver zinc metric 12.9 bolts for most of my replacements. but the issues there are damaging his tooling with the toguh steel, and still needing to plate the machined surface. hopefully SS will be easier for him, as there's no need for me to finish it afterwards!  [thumbsup]

so an update of sorts.

not a lot of progress, as life has generally got in the way. combine that with me working on 4 or 5 sections of the build at once, with most of them having only 90% of the parts, leaves not much actually completed.

waiting for some bolts from Italy, as well as other parts from the USA, UK, and China/HK. rearsets are nearly complete and mounted, as goes for the front and rear ends. just need to get the wheels painted!!

painting the sprocket carrier and a new sprocket and Ti sprocket nuts (in the mail), and the rear looks sweet. also 90% complete with adding the floating caliper bracket and rod from the 900 partout, but this mounts with the rearsets which are waiting on bolts.

front end needs painted wheels, and waiting on a NOS speedo drive to replace my broken unit. Koko I have your spare, spare! decided NOS to avoid any issues for a while yet. then its all good to mount and I'll have a rolling bike!

rolling.... but not stopping! need to measure up and order the front and rear lines still, but will do this once the above is complete.

painted some more bits, and tried painting my oem beer tray. this caliper paint likes to be cooked though, but the beer tray didnt! its rather warped now haha. looks good though!! this was after trying RIT dye, which failed miserably. maybe I didnt use enough dye? maybe the plastics didnt want to take it. either way, two components came out exactly the same, except for the beer tray which actually came out slightly whiter/grey courtesy of the heat or maybe some colour bleed. hence the painting attempt. now I have justified a carbon/aluminium tray if I can find one :P

have been enjoying pulling apart a lot of smaller components to clean/paint, like the seat lock mechanism (both ends). they've ended up looking so much better, but all this has really eaten up what little time ive spent on the bike, so the big picture doesnt look much different to the pics above.

when I pull my finger out, I'll load some more pics, and even one day go back and fix all the broken pics so this can be a proper thread not an unpolished turd  ;D

I'll pop by this week if I can to have a look. Cam has a carbon tray. Make him an offer. It might need a recoat so I'd try and get it as is. I'll send you his number.

if I removed the wiring harness nearly last, it should go on nearly first. why am I trying to fit it last??  [bang] [laugh]

Pics Nibor pics!

I need to find a decent free image host, and go through and fix all the old pics. And upload new ones!

Got my wheels painted, wiring 90% complete, time to mount the tank and sort all the plumbing, and measure up some brake and clutch lines!

I'm using Photobucket. It's slow but solid.

Photobucket ftw! 👍🏻