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Author Topic: 999 Rebuild (warning, many pictures)  (Read 17873 times)
Ronr
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« 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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« 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
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« 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
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« 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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« 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
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« 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 » Logged
El Matador
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« 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 » Logged

rob lay
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« 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.  chug
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Ronr
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« Reply #8 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.  chug


Thanks man, she just moved up on the list   waytogo
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Ronr
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« Reply #9 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]
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Duc L'Smart
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« Reply #10 on: May 02, 2009, 06:41:21 PM »

Just AWESOME, RonR waytogo

Can't wait to see you at the track... Grin

How's the shoulder?!?
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« 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  chug

Nice step-by-step pics  waytogo
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Ronr
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« Reply #12 on: May 02, 2009, 06:59:35 PM »

Just AWESOME, RonR waytogo

Can't wait to see you at the track... Grin

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.
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dallas2r
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« 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.  waytogo
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A motorcycle will get you through times of no money better than money will get you through times of no motorcycle. -Unknown
fastwin
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« 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. waytogo Hope you are up and riding again sooner than later. applause
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