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999 Rebuild (warning, many pictures)
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Topic: 999 Rebuild (warning, many pictures) (Read 20513 times)
Ronr
Hero Member
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Posts: 1776
999 Rebuild (warning, many pictures)
«
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....)
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Ronr
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Posts: 1776
Re: 999 Rebuild (warning, many pictures)
«
Reply #1 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.
Left cover off
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.
End of crankshaft
Flywheel and Alternator Rotor, outboard side
Flywheel/Rotor, inboard side
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.
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.
Machined flywheel and rotor reinstalled
Cover reinstalled with water pump cover rewelded and repainted by RichD
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Ronr
Hero Member
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Posts: 1776
Re: 999 Rebuild (warning, many pictures)
«
Reply #2 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
Removed clutch hub nut. Impact wrench.
Removed clutch hub. Oil leaking into clutch via clutch basket bolts.
Clutch hardware removed
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.
Clutch gear removed. That's the oil pump down on the right.
Clutch gear. That big seal is getting replaced.
Clutch cover and big seal. That's a fun seal to replace.
Pulled clutch hub apart due to some damage. Replaced one or two of the rubber bumpers.
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.
Cover with new seal installed
Cover back on
Torquing down clutch hub nut with tool provided by RichD (many thanks!!)
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)
New open clutch cover
Also removed and cleaned the oil screen. Found a few aluminum particles in it.
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Ronr
Hero Member
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Posts: 1776
Re: 999 Rebuild (warning, many pictures)
«
Reply #3 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.
Old suspension parts that were replaced by kit parts
Replaced clip ons and grips. Left side had been damaged. Replaced stock throttle with a Yamaha R1 quarter turn throttle tube.
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.
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Ronr
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Posts: 1776
Re: 999 Rebuild (warning, many pictures)
«
Reply #4 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.
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Ronr
Hero Member
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Posts: 1776
Re: 999 Rebuild (warning, many pictures)
«
Reply #5 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.
«
Last Edit: May 02, 2009, 05:09:31 PM by Ronr
»
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El Matador
Do I need knee pucks for my
Hero Member
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Posts: 3708
'06 S2R1K, '07 695 - Sold, '99 996 - Sold, '04 Hurricane Project
Re: 999 Rebuild (warning, many pictures)
«
Reply #6 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
«
Last Edit: May 02, 2009, 05:54:57 PM by El Matador
»
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rob lay
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Posts: 2
Re: 999 Rebuild (warning, many pictures)
«
Reply #7 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.
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Ronr
Hero Member
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Posts: 1776
Re: 999 Rebuild (warning, many pictures)
«
Reply #8 on:
May 02, 2009, 06:20:53 PM »
Quote from: 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.
Thanks man, she just moved up on the list
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Ronr
Hero Member
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Posts: 1776
Re: 999 Rebuild (warning, many pictures)
«
Reply #9 on:
May 02, 2009, 06:26:14 PM »
Quote from: 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
Nothing wrong with that. Nothing makes me happier than bolting on a new goody to the bike [moto]
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Duc L'Smart
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Posts: 6315
Re: 999 Rebuild (warning, many pictures)
«
Reply #10 on:
May 02, 2009, 06:41:21 PM »
Just AWESOME, RonR
Can't wait to see you at the track...
How's the shoulder?!?
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'07 1098s, '06 Paul Smart LE, '99 BMW K1200RS,
'73 BMW R75/5
,
'67 Ducati Monza 250 Bevel Drive
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'63 Vespa GS 160
caffeinejunkee
Hero Member
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Posts: 2657
'07 M695--sold; red '96 900SS CR; '04 Busa--sold
Re: 999 Rebuild (warning, many pictures)
«
Reply #11 on:
May 02, 2009, 06:51:27 PM »
Too cool, man--congrats on the re-build and thnx for letting us see 'er nekid
Nice step-by-step pics
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Ronr
Hero Member
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Posts: 1776
Re: 999 Rebuild (warning, many pictures)
«
Reply #12 on:
May 02, 2009, 06:59:35 PM »
Quote from: Duc L'Smart on May 02, 2009, 06:41:21 PM
Just AWESOME, RonR
Can't wait to see you at the track...
How's the shoulder?!?
Can't wait to take it to the track.
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.
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dallas2r
Hero Member
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Posts: 1751
Re: 999 Rebuild (warning, many pictures)
«
Reply #13 on:
May 02, 2009, 07:52:04 PM »
Badass.
The synchronous healing of one 999 and one shoulder. Cool stuff.
Thanks for the pics.
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2007 Monster S2R1000
2016 Multistrada 1200S Touring/Urban
A motorcycle will get you through times of no money better than money will get you through times of no motorcycle. -Unknown
fastwin
Guest
Re: 999 Rebuild (warning, many pictures)
«
Reply #14 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.
Hope you are up and riding again sooner than later.
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