Project S4 base gasket/lean issue repair progress

fouramdesigns · May 21, 2009, 03:48:20 PM

Apparently someone has had this fixed by Ducati out of warranty in the past. Wonder if there's a chance to still have this done?
http://www.ducatimonster.org/forums/tech/112980-base-gasket-leaking.html

Speeddog · May 21, 2009, 04:36:27 PM

Quote from: fouramdesigns on May 21, 2009, 03:48:20 PM
Apparently someone has had this fixed by Ducati out of warranty in the past. Wonder if there's a chance to still have this done?
http://www.ducatimonster.org/forums/tech/112980-base-gasket-leaking.html

Well, you could give it a shot, worst they can do is say no.

More info on the how-to soon.

Speeddog · May 23, 2009, 08:30:40 AM

'Tutorial' post updated...

Edit
---------------
Link to my previous post:
http://ducatimonsterforum.org/index.php?topic=23736.msg419236#msg419236

fouramdesigns · May 27, 2009, 05:42:43 AM

Quote from: Speeddog on May 23, 2009, 08:30:40 AM
'Tutorial' post updated...

Thanks man, I really appreciate you taking the time.

fouramdesigns · May 31, 2009, 04:55:09 PM

I'm going to keep within this post as not to have multiple post. I've documented my progress thus far with pictures.

I've pulled the tank, radiator, plugs, disconnected related hoses, and disassembled the air box. This is what I've found so far:

The air box seemed to have a little oily residue in the lower portion of it. Had no visible color, I'm thinking it may be the oil from the charging kit for the BMC filter.

As I got the intake stacks off, I noticed oil around the intake ring, now I'm getting worried. Also the lower vent hose on the air box has a little oily reside, I'm assuming coming from the small accumulation in the air box compartment.

This is my DP ECU that came with the Termi cans. Thought an identification of what the bike has as far as fuel/exhaust etc may help.

I get the plugs pulled, the ones I just installed 4 weeks ago, The top plug's has a lot of soot accumulation, and smells of gas. The lower (2nd) is rusty, was some moisture on the plug boot, I assume from being lower to the road, and driving in the rain a few times?

And the lower exhaust gasket, seemed to have a little oily residue on the gasket itself, as well has the manifold.

And last for now, this is my right Termi can that was damaged when my bike fell over on me while trying to unload it on a single ramp. Wonder if there's an exhaust leak?

So it appears I may have several issues with the S4. This is my only means of transportation at the moment, so I need to find the issue/issues, and get this bike back on the road. Any help is greatly appreciated.

Spencer

Howie · May 31, 2009, 08:30:44 PM

A little high temperature sealant and a rivet should fix that can up just fine.

Some oil film in the intake tract is normal.

The plugs? How was the bike running before? If, other than the base gasket leak, the bike ran fine and was just started and not warmed up the plug may not have cleaned itself off yet.

fouramdesigns · May 31, 2009, 08:34:24 PM

Thanks for the reply. The bike has been running terrible, started last week. I ran out of gas, so while I have the tank off, I'm replacing the filter, just can't figure out how to get inside the tank. I took off the cap, and the 8 or 10 small allen screws around the rim, but it won't lift out, not sure if I'm doing that right. But by the looks of the plugs, they look pretty fouled up. When I flog the throttle, the bike barely accelerates, so I've got multiple issues here.

Howie · May 31, 2009, 09:21:18 PM

Oh well. At this point I think you are on the best track since you can't do much without the bike running. Dump the old gas, replace the filter and pray to the motorcycle gods. If the bike still runs like crap when you put it back together post again. The cap will need a little persuasion to come out, a little nudge with a hammer handle should do it. Do be careful though, you don't want to damage the tank. Putting it back is fun too! Grease on the O ring and firm pressure are needed.

ducpainter · June 01, 2009, 05:33:03 AM

Quote from: fouramdesigns on May 31, 2009, 08:34:24 PM
Thanks for the reply. The bike has been running terrible, started last week. I ran out of gas, so while I have the tank off, I'm replacing the filter, just can't figure out how to get inside the tank. I took off the cap, and the 8 or 10 small allen screws around the rim, but it won't lift out, not sure if I'm doing that right. But by the looks of the plugs, they look pretty fouled up. When I flog the throttle, the bike barely accelerates, so I've got multiple issues here.

Stick a hammer handle in the opening at an angle and give it a rap with your hand. To replace grease the flange and the o-ring and push or tap in.

pigmy · June 01, 2009, 06:31:37 AM

speeddog ...you are the man

fouramdesigns · June 01, 2009, 07:59:56 AM

I'm stopped, or should I say stuck on the belt removal. I've yet to figure out how to align TDC etc. I looked briefly as I finished up for the day, and did not see any marking to align hash marks. I'm also going to hit the valves while I'm this far in. What special tools are required for the job? I read the Ca-Cycleworks has a video tutorial available.

gage · June 01, 2009, 12:03:02 PM

What kind of mechanical experience do you have?

I'm thinking this is a large best left to someone with experience or alternative means of transportation.

Definately should buy a couple of manuals...

However, if you are committed, There is a dot on the pulley which aligns with a dash on the case- It is at abut 7 oclock This will give you TDC (can't remember if on H or V cyclinder) stick a long screwdriver in the spark plug hole and watch as you rotate the motor. TDC of the compression stroke for the opposite cylinder is 270 degrees from that point...

Good Luck

fouramdesigns · June 01, 2009, 01:15:49 PM

Quote from: gage on June 01, 2009, 12:03:02 PM
What kind of mechanical experience do you have?

Good Luck

Well I've worked on my Honda's, Mercedes, on an oil platform running a hydraulic workover rig. Pretty good with instructions, just need them at this point, I can follow along, and am pretty technically inclined. I guess I will pick up the Desmo Times manual from Ca Cycleworks. Speeddog has been a big help and getting me in the right direction. Also, what's the screwdriver in the cylinder accomplish, does it indicate when TDC has been reached by stopping?

gage · June 01, 2009, 01:37:05 PM

Quote from: fouramdesigns on June 01, 2009, 01:15:49 PM
Also, what's the screwdriver in the cylinder accomplish, does it indicate when TDC has been reached by stopping?

Yes, TDC is achieved when the screwdriver is at max height.

corndog67 · June 01, 2009, 09:20:06 PM

It's good to see some one go for it. The only way to learn how to do it.

News:

Project S4 base gasket/lean issue repair progress

pigmy

corndog67