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Title: 999 Rebuild (warning, many pictures) Post by: Ronr on May 02, 2009, 05:04:58 PM 2003 999 Track Bike Rebuild
Had a Pre-Purchase Inspection (PPI) done at AMS Engine compression and leakdown looked good Reset cam timing Frame looked straight They told me the oil leak was coming from the clutch. (oops, didn't see the other leak on the left side....) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0612.jpg) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0736.jpg) Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 02, 2009, 05:05:28 PM Left Side
Fixed oil leak and got flywheel machined down Removing left side cover. Five dollar steering wheel remover works fine. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0769.jpg) Left cover off (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0770.jpg) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0775.jpg) Flywheel removed. Impact wrench got the big nut off easy. Starter gears in lower left. Water pump drive on top left. Top right is where the shifter drum gets turned by the shifter mechanism assembly. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0792.jpg) End of crankshaft (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0930.jpg) Flywheel and Alternator Rotor, outboard side (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0800.jpg) Flywheel/Rotor, inboard side (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0802.jpg) Flywheel/Rotor after having flywheel machined by the Ducshop in Georgia. Started out at 4lb 15oz, ended up at 1lb 11oz. Huge savings for rotating engine mass. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0884.jpg) Adjusted shifter and retorqued two shifter bolts with blue Loctite. Some people claim this is good to do to help prevent the shifter mechanism from slipping out of adjustment, especially from hard use. I'm already in there, so why not. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0781.jpg) Machined flywheel and rotor reinstalled (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0928.jpg) Cover reinstalled with water pump cover rewelded and repainted by RichD (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_1423.jpg) Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 02, 2009, 05:05:57 PM Right Side
Rebuilt clutch. Replaced every seal I could find to fix oil leak Removed old oily clutch plates (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0744.jpg) Removed clutch hub nut. Impact wrench. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0748.jpg) Removed clutch hub. Oil leaking into clutch via clutch basket bolts. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0750.jpg) Clutch hardware removed (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0751.jpg) Clutch cover off. This picture was actually taken later, right before I reinstalled the cover. You can see the Three Bond sealant where the cover attaches. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0861.jpg) Clutch gear removed. That's the oil pump down on the right. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0807.jpg) Clutch gear. That big seal is getting replaced. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0810.jpg) Clutch cover and big seal. That's a fun seal to replace. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0832.jpg) Pulled clutch hub apart due to some damage. Replaced one or two of the rubber bumpers. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0840.jpg) The roll pin had been mushed in the hub. Fortunately, I had a spare hub with a good pin. I could not get the bad pin out with hand tools. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0841.jpg) Cover with new seal installed (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0854.jpg) Cover back on (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0862.jpg) Torquing down clutch hub nut with tool provided by RichD (many thanks!!) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0864.jpg) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0867.jpg) Installed fresh Surflex clutch plate kit with stock pressure plate. Changed later to stainless steel springs and screws, and aluminum caps since I'm going with an open clutch cover now. (original parts will rust) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0868.jpg) New open clutch cover (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_1862.jpg) Also removed and cleaned the oil screen. Found a few aluminum particles in it. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0852.jpg) Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 02, 2009, 05:06:17 PM Front End
Ohlins fork kit, Ohlins steering damper, clip ons, grips, quarter turn throttle tube, axle Removed forks and had an Ohlins Piston Kit installed, had forks inspected and freshened up by AMS. Springs checked out okay for my weight. Replaced front axle, it was damaged on the threaded end. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0823.jpg) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0894.jpg) Old suspension parts that were replaced by kit parts (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0898.jpg) Replaced clip ons and grips. Left side had been damaged. Replaced stock throttle with a Yamaha R1 quarter turn throttle tube. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0896.jpg) Decided the original base model non-adjustable steering damper was not great for the track, I happened to have an Ohlins steering damper on my old ZX-6R. Sent it off to Ohlins for a rebuild. Bought the OEM 999S Ohlins damper clamp parts and a buddy made an adapter for me. It all fit up really nice. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0818.jpg) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_1431.jpg) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_1433.jpg) Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 02, 2009, 05:06:33 PM Rear End
Ohlins shock, new sprocket Changed out original shock with Ohlins shock with correct spring for my weight. Hanging the rear of the bike from the garage door structure worked out way better than using stands, which I've done before. Really unstable using stands. Also replaced rear sprocket. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_1237.jpg) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_1243.jpg) Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 02, 2009, 05:06:46 PM General
Replaced original smooth cast footpegs with new machined footpegs. Much grippier. Installed new frame sliders and axle sliders. Old frame slider had snapped off during crash and didn't protect the side of the bike real well. Also replaced various other seals, cleaned up the brake calipers and pads, and general inspection, cleanup, and retorquing of fasteners. Track bodywork has some issues, but I'm still working on that. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_1855.jpg) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_1850.jpg) Title: Re: 999 Rebuild (warning, many pictures) Post by: El Matador on May 02, 2009, 05:53:22 PM damn. Just damn.
Maybe I should break my shoulder, That way I might be able to get some shit done. And here I was, feeling proud that I put on pods and a new taillight on the 695 Title: Re: 999 Rebuild (warning, many pictures) Post by: rob lay on May 02, 2009, 06:19:19 PM Great job Ron.
I think one of your other girlfriends (the black one) from Maranello is jealous and wants you to caress her like the 999. [beer] Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 02, 2009, 06:20:53 PM Great job Ron. I think one of your other girlfriends (the black one) from Maranello is jealous and wants you to caress her like the 999. [beer] Thanks man, she just moved up on the list [thumbsup] Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 02, 2009, 06:26:14 PM damn. Just damn. Maybe I should break my shoulder, That way I might be able to get some shit done. And here I was, feeling proud that I put on pods and a new taillight on the 695 Nothing wrong with that. Nothing makes me happier than bolting on a new goody to the bike [moto] Title: Re: 999 Rebuild (warning, many pictures) Post by: Duc L'Smart on May 02, 2009, 06:41:21 PM Just AWESOME, RonR [thumbsup]
Can't wait to see you at the track... ;D How's the shoulder?!? Title: Re: 999 Rebuild (warning, many pictures) Post by: caffeinejunkee on May 02, 2009, 06:51:27 PM Too cool, man--congrats on the re-build and thnx for letting us see 'er nekid [beer]
Nice step-by-step pics [thumbsup] Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 02, 2009, 06:59:35 PM Just AWESOME, RonR [thumbsup] Can't wait to see you at the track... ;D How's the shoulder?!? Can't wait to take it to the track. [evil] Got fresh x-rays yesterday. Getting nice bone growth now, so the Doc is going to let me start doing strength exercises with some weights. Just been doing range of motion type stuff so far. Title: Re: 999 Rebuild (warning, many pictures) Post by: dallas2r on May 02, 2009, 07:52:04 PM Badass.
The synchronous healing of one 999 and one shoulder. Cool stuff. Thanks for the pics. [thumbsup] Title: Re: 999 Rebuild (warning, many pictures) Post by: fastwin on May 02, 2009, 08:03:11 PM Noticed the through the bodywork slider on the right side and the Speedymoto under bodywork right side slider in the next pic. Are those Rhinomoto front axle sliders? They make swingarm sliders too for the 999/749. Very nice, thorough work. Great pictures! I hear those 999s are nice bikes. [thumbsup] Hope you are up and riding again sooner than later. [clap]
Title: Re: 999 Rebuild (warning, many pictures) Post by: Cher on May 03, 2009, 04:32:42 AM Holy smokes, Ron!!! That is some awesome stuff :o Love the step by step pix... think I may be starting to understand how a multi-plate clutch works. Nah, maybe not! [laugh] You're going to have one fine SBK when it's all said and done - looks better than new. And that's great news about your shoulder! Go man, GO [thumbsup] Title: Re: 999 Rebuild (warning, many pictures) Post by: Cher on May 03, 2009, 05:26:39 AM Great job Ron. I think one of your other girlfriends (the black one) from Maranello is jealous and wants you to caress her like the 999. [beer] Hey there Rob. Sneakin' in under the radar are ya'?! Welcome to the local DFWM madness [thumbsup] Now does this mean you've gone and bought a Duc? [evil] Lisa Title: Re: 999 Rebuild (warning, many pictures) Post by: Duc L'Smart on May 03, 2009, 06:01:59 AM Great job Ron. I think one of your other girlfriends (the black one) from Maranello is jealous and wants you to caress her like the 999. [beer] Much-O Welcome-O, Rob! I didn't see it in your sig... Which Duc are you riding?!?!?!? ;D Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 03, 2009, 06:13:26 AM Noticed the through the bodywork slider on the right side and the Speedymoto under bodywork right side slider in the next pic. Are those Rhinomoto front axle sliders? They make swingarm sliders too for the 999/749. Very nice, thorough work. Great pictures! I hear those 999s are nice bikes. [thumbsup] Hope you are up and riding again sooner than later. [clap] For ease of storytelling, I organized the photos by bike section, not in order of doing all the work. I was pretty much doing things all over the bike at once - a little here, a little there. So you may see things in later pictures that aren't done, that I already showed complete in a previous section of pics. I ended up with the Speedymoto under body frame sliders (both sides!) and Rhino axle sliders on front and back. Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 03, 2009, 06:54:37 AM Holy smokes, Ron!!! That is some awesome stuff :o Love the step by step pix... think I may be starting to understand how a multi-plate clutch works. I hope so! The main reason for taking and posting the pictures was so y'all could see the mysterious inner goings-on under those covers. All the marbles fell out when I took the covers off, so I didn't get any shots of the Ducati rattle-generating technology. Title: Re: 999 Rebuild (warning, many pictures) Post by: rob lay on May 03, 2009, 08:08:15 AM Hey there Rob. Sneakin' in under the radar are ya'?! Welcome to the local DFWM madness [thumbsup] Now does this mean you've gone and bought a Duc? [evil] Lisa Much-O Welcome-O, Rob! I didn't see it in your sig... Which Duc are you riding?!?!?!? ;D Howdy, last thing I need, but up there on what I want. :) I might go surprise myself and take the safety course, slippery slope from there though. Title: Re: 999 Rebuild (warning, many pictures) Post by: DrDesmo on May 03, 2009, 08:10:29 AM Ron -
Great work ;D [thumbsup] Adam Title: Re: 999 Rebuild (warning, many pictures) Post by: fastwin on May 03, 2009, 11:30:50 AM For ease of storytelling, I organized the photos by bike section, not in order of doing all the work. I was pretty much doing things all over the bike at once - a little here, a little there. So you may see things in later pictures that aren't done, that I already showed complete in a previous section of pics. I ended up with the Speedymoto under body frame sliders (both sides!) and Rhino axle sliders on front and back. Good call. I've got the same set up on the 999 and 996S and feel real warm and IZ_ about it. Hope I never have to test it... but it's there if I do. [thumbsup] Speedymoto makes a nice, durable water pump housing too. Have thought about it but have never followed through. Nice to see James' 999 living on within the group. [moto] Title: Re: 999 Rebuild (warning, many pictures) Post by: Giannis on May 03, 2009, 08:24:45 PM Nice rebuild!!!! but please loose this ugly whale tail.. stock size mono tails look so much better!!! :-X ;D
(http://farm4.static.flickr.com/3206/3122214988_6d063d0283_o.jpg) Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 03, 2009, 08:32:08 PM Nice rebuild!!!! but please loose this ugly whale tail.. stock size mono tails look so much better!!! :-X ;D (http://farm4.static.flickr.com/3206/3122214988_6d063d0283_o.jpg) I agree. Mine has the biggest arse of any other I've seen. I'm sure it's an aerodynamic advantage though ;D Title: Re: 999 Rebuild (warning, many pictures) Post by: hiero on May 04, 2009, 05:13:19 AM hey ron, what exactly's involved with 'adjusting the shifter' stuff?
Title: Re: 999 Rebuild (warning, many pictures) Post by: Duc L'Smart on May 04, 2009, 05:26:31 AM hey ron, what exactly's involved with 'adjusting the shifter' stuff? quite a lot of beer... ;D Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 04, 2009, 06:45:48 PM hey ron, what exactly's involved with 'adjusting the shifter' stuff? Yes, this project required massive quantities of beer. [beer] There is a special Ducati tool that would normally be used to adjust the shifter properly. You select second gear and put the little tool on the little shifter nubs. The edge of the tool should line up with that line on the lever. Well, I didn't want to spend $80+ bucks on a single use tool, so Mark at the Ducshop explained that if I selected neutral, that nub in the photo should be centered on the indicator line. To make any needed adjustments, those two screws in the lower photo can be loosened slightly, enough that the internal shift lever on the right side of the third photo can be moved to put the indicator in the first photo in proper alignment with the aforementioned nubbin. Before tightening the two hold-down screws, I swabbed out their holes with brake cleaner to remove oil out of the threads, and put some blue loctite on the cleaned screws, and torqued them to spec. Mine needed some adjustment, otherwise I would have just removed one screw at a time, loctited and retorqued. Just for peace of mind. (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_1418.jpg) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0781.jpg) (http://i254.photobucket.com/albums/hh96/ronr84/999%20Rebuild/IMG_0930.jpg) Title: Re: 999 Rebuild (warning, many pictures) Post by: hiero on May 04, 2009, 07:01:09 PM ah, seems simple enough! I'll have to put it on the list of things to do when I'm in there! [thumbsup] thanks!
Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 04, 2009, 07:11:27 PM You bet!
Another thing I wanted to do while in there was send the big gears out and have giant lightening holes machined into them. Most of the 1098 series gears come like that already. The shop told me that since those were hardened gears, it probably wasn't a great idea. Plus it didn't save much weight really, compared to the pounds I got off the flywheel. Title: Re: 999 Rebuild (warning, many pictures) Post by: muskrat on May 04, 2009, 09:03:18 PM I really like the tail on that bike. the cover looks very nice over the exhaust.
Title: Re: 999 Rebuild (warning, many pictures) Post by: Slag on May 05, 2009, 04:50:47 AM I really like the tail on that bike. the cover looks very nice over the exhaust. Negative. That tail needs to be circumcised... Title: Re: 999 Rebuild (warning, many pictures) Post by: muskrat on May 05, 2009, 05:40:43 AM what can I say, I like a fat ass.
Title: Re: 999 Rebuild (warning, many pictures) Post by: bryant8 on May 05, 2009, 01:06:59 PM Good work Ron!
Title: Re: 999 Rebuild (warning, many pictures) Post by: James.M on May 08, 2009, 12:20:15 PM Wow Ron, your new race bike is coming along quite well... Just in time for me to come by and pick her back up and put her back in my garage! haha
Oh btw, I looked for those white things, I didn't see them laying around... I know you probably looked several times, but were there none in that bag of bolts and what not? Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on May 08, 2009, 07:51:18 PM Wow Ron, your new race bike is coming along quite well... Just in time for me to come by and pick her back up and put her back in my garage! haha Oh btw, I looked for those white things, I didn't see them laying around... I know you probably looked several times, but were there none in that bag of bolts and what not? Sharkskinz website shows a white cupshaped washer under the fastener head (I found 1) and a split ring that keeps the fastener from falling out of the body work when the parts are detached (found none of those). I did find a little baggie of clear washers that looks like the 1098 washers. I'll try using those in place of the white cups for now. Haven't had a chance to mess with it yet. Title: Re: 999 Rebuild (warning, many pictures) Post by: jbuilds on November 20, 2014, 12:54:50 PM Bump for a nice build, Ronr.
This build is being featured in the BikeBuilds.net We’re currently displaying only a reduced-size photo (similar to what you’d find in Google Images). We'd like to ask for your permission to publish the original full-size image with your build listing. If anyone would like to have a build of their own listed, just send me a message with a link to the build thread and we’ll take care of the rest. Cristian Title: Re: 999 Rebuild (warning, many pictures) Post by: Ronr on November 24, 2014, 06:17:58 PM Bump for a nice build, Ronr. This build is being featured in the BikeBuilds.net We’re currently displaying only a reduced-size photo (similar to what you’d find in Google Images). We'd like to ask for your permission to publish the original full-size image with your build listing. If anyone would like to have a build of their own listed, just send me a message with a link to the build thread and we’ll take care of the rest. Cristian I originally posted that thread for users on this Ducati board. The fee for a license agreement for one of my photos is $500. Let me know if interested. |