Project S4 base gasket/lean issue repair progress

[Speeddog]

With the cam drive pulley at 7 O'Clock ....it's mark should line up with the hashmark on the
This will put the marks on the horizontal cam pulleys at 12 O'Clock for the intake and 6 O'Clock for the exhaust.
Verticals will be at nearly 12 O'Clock.

With the crank in that position, the horizontal cylinder is at TDC fire.

That's the position that you should remove and install the belts.

After removing the belts, ensure that all cams rotate freely a bit, rotating forward and back.
When you take the vertical belt off, the intake cam *may* rotate rather strongly on it's own, due to the closer springs.
Don't let it pinch you when the belt comes off.

If you rotate the engine so that the cam drive pulley is at 9 O'Clock, the vertical cylinder is at TDC overlap.

With the belts off, always confirm that all valves are closed before turning the crank.

[fouramdesigns]

With the cam drive pulley at 7 O'Clock ....it's mark should line up with the hashmark on the ......?

Do I turn the crank with the special tool (haven't bought yet), or can I just rotate the rear wheel while my bikes on the rear stand? I ordered the Desmo Times manual from Ca Cycleworks, hopefully that will be in by the time I hit the valve job.

[gage]

Do I turn the crank with the special tool (haven't bought yet), or can I just rotate the rear wheel while my bikes on the rear stand? I ordered the Desmo Times manual from Ca Cycleworks, hopefully that will be in by the time I hit the valve job.

Put the bike in sixth gear and rotate the wheel

[fouramdesigns]

B) You can use this opportunity to install some fuel line quick-disconnects, Motion-Pro sells 'em, get two of the 5/16" size.
    Assuming you've still got the OEM fuel lines that drop down past the belt cover...
    Pick a spot on the lines where the disconnects will be accessible, but not in the way, like near the vertical frame tube.
   Clamp one hose closed back towards the rear of the tank, then cut the fuel line, have a shoprag under it to catch the bit of fuel that will come out.
   Install the 'female' QD in the end of the hose that connects to the tank.
   Snip a length of hose about equal to the length of the QD from the line that goes to the throttle body, then install the 'male' QD in the end of that hose.
   Do the same for the other fuel line.

How many feet of hose should I order from Motion Pro?

[64duc]

After looking at the service manual, and determining what I'm looking at, this is on the same side as the breather. My hose looks pretty dry rotted coming out of the unit. I guess all I can do is ride, and keep a watch, and if it happens, clean, then try the foot powder to find the source. I'm going to buy a tool set today. I'm dead set to tackle this myself, and learn about this bike. When I have the mechanics in order, I'm starting this project full force. Powder coated frame/tank/wheels. I love this damn bike, and will not give up on him yet. I almost convinced myself to spend $13K for an 08' KTM Super Duke. Why? When I can have my own, custom creation, that I know has been done correctly. Now where's a good place to purchase the Ducati special tools, or is there an alternative?

  You won't need any "special" tools. Sears sells everything you will need. A good piston ring compressor that comes apart makes life much easier. This is what I have.  http://www.mytoolstore.com/kd/kdengi08.html

[Speeddog]

How many feet of hose should I order from Motion Pro?

You can use the hose that's there, you only need to snip out the length of hose that the QD takes, about 1 1/2".

Regarding tools, you will *definitely* need a piston ring compressor.
The oil rings are cast iron, and are very fragile. DAMHIK.

Also, you will need a special wrench to torque down the head nuts.

[fouramdesigns]

You can use the hose that's there, you only need to snip out the length of hose that the QD takes, about 1 1/2".

Regarding tools, you will *definitely* need a piston ring compressor.
The oil rings are cast iron, and are very fragile. DAMHIK.

Also, you will need a special wrench to torque down the head nuts.

Yeah I saw the torque wrench at Sears, I assume the torque specs will be in the Desmo Times manual? Thanks guys for all the help. Just sucks I have another issue that I'm not so sure of once I get this all back together, but first things first.

[Speeddog]

Special wrench like this:



Garden variety combination wrench with a socket welded on.
A bit of grinding on the box end was necessary to get it to fit in.

[fouramdesigns]

Special wrench like this:



Garden variety combination wrench with a socket welded on.
A bit of grinding on the box end was necessary to get it to fit in.

What do I use that for? I thought I torque wrench was needed to torque the heads? Where does this come in? I don't have access to a welder at the moment, so where would I get this on the net?

[Speeddog]

You need it for torquing the head nuts.

Ca-Cycleworks may have 'em.

[jerryz]

I have done this job on 2 S4s and a M1000 but found I did not need to remove piston. Time taken 6 hours in total.

[gage]

I have done this job on 2 S4s and a M1000 but found I did not need to remove piston. Time taken 6 hours in total.

Likewise, but only on one S4, I do believe that the OP was going to install Hi Compression pistons while he was in there though. Took me closer to 8 hours and I had to borrow the tool mentioned above.

[fouramdesigns]

Likewise, but only on one S4, I do believe that the OP was going to install Hi Compression pistons while he was in there though. Took me closer to 8 hours and I had to borrow the tool mentioned above.

I decided not to. Just the basic base gasket fix, valve adjustment.

[fouramdesigns]

Got Desmo Times manual in yesterday. LT is freakin' hilarious. So I guess I begin this project this weekend. Just a little nervouse about TDC and the belts. I suppose I will fix the gasket leak first, then hit the valve adjustment.

[Porsche Monkey]

If your taking the heads off then do the valve adjust on the table. Much easier IMO.