[SBK Project: 2v Motor - 748/996 era Frame]

Started by junior varsity, April 06, 2010, 04:13:06 PM

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junior varsity

Well, I seem to have acquired a 2002 900IE motor. I'm part way into tearing it apart - cam pulleys look ok, belt rollers look a bit rusty, clutch is completely rusty, exterior is fairly dirty but no visible damage.

Glaring problems so far (without taking heads off and peering inside, or pulling alternator case cover off or clutch case cover off) is that somehow I bent an exhaust manifold stud on the horizontal cylinder. Looks like I may be able to hammer it back, but I am not sure this is a good idea - it likely got bent in my clumsy attempt at setting the motor down. Its bent at somewhere near a 30deg angle halfway up the stud.

It looks like I need to remove the stud and replace.

a) How?

b) Where to get a replacement?


More updates on this motor after I open it up, and see what other "goodies" await.

DarkStaR

Should be threaded on both ends.  My shop manual ('05) shows it as removable and with a part number, so if anything, you could get one at the dealer.

Also, there are various tools to install and remove studs.  

Vise grips to remove to save $$$.

Google it!   [thumbsup]


junior varsity

Yep, looks like I need to grab a 77150788B - M6x65 'screw' - only about $1.78.

Not sure if I can do a simple double-nut method to remove it since its bent. i'll give it a look tonight.

ducpainter

Quote from: a m on April 06, 2010, 04:32:52 PM
Yep, looks like I need to grab a 77150788B - M6x65 'screw' - only about $1.78.

Not sure if I can do a simple double-nut method to remove it since its bent. i'll give it a look tonight.
Exhaust studs are 8X 1.25...don't know the length.
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    is even more amazing than yours."
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junior varsity


ducpainter

"Once you accept that a child on the autistic spectrum experiences the world in
 a completely different way than you, you will be open to understand how that
 perspective
    is even more amazing than yours."
    To realize the value of nine  months:
    Ask a mother who gave birth to a stillborn.
"Don't piss off old people The older we get, the less 'Life in Prison' is a deterrent."



Speeddog

Yes, 8mm diameter.
Parts catalogue says it's a part# 037092050.
Ducati Omaha says they're $0.99 each.

Don't bother with a double-nut routine if it's bent.
As Darkstar said, vice grips, you're not going to re-use it.
- - - - - Valley Desmo Service - - - - -
Reseda, CA

(951) 640-8908


~~~ "We've rearranged the deck chairs, refilled the champagne glasses, and the band sounds great. This is fine." - Alberto Puig ~~~

junior varsity

For some reason when I did the online parts finder through Commonwealth, the part number's associated name was that M6x65. Dunno why.


Ok, so I was able to do the double nut method with one more good whack towards center with a hammer - and by god, it was far easier than I thought it would be. Ha, I can't get the nuts off now, but I don't care. Time for a new stud!

hcomp

While you're at it, you might as well replace all 4 of them. Exhaust studs see a ton of thermal cycling and tend to weaken over time.  I would replace them all if you are replacing one.  Less headache in the future.
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Turf

i've removed one before

threaded on both ends

can get it at your dealer for cheap

it's a pita to remove but heat the alum outside with a torch, double nut it and a breaker bar it comes out without too much trouble.
I may not have gone where I intended to go, but I think I have ended up where I needed to be.

2001cromo

#10
LISTEN HERE CAREFULLY

The older Monster motors were all 8's but the newer (that 2002 is the only 900 that uses the newer heads) and are actually the 6's so make sure you get the 6's (like the newer motors have) as that' what will fit them. The old one's used a 13mm wrench and the one's you've got use a 10mm wrench.

Does the secondary oil filter plug have the electrical connector on the end cap? if yes, then it's a 2002 900 (or someone changed it).

You can use the double nut method to remove/replace

One of the bigger PITA's you will have with that motor is that it uses the newer exhaust, so any old 900 exhaust header will not fit that head as the head itself is slightly different. that's why it uses the newer 6mm studs instead of the older 8mm's.

It's too bad cause the 2002 M900 is a bit of a bastard child, it's got the new style frame, it's got the 5.9 ECU and the newer style heads/exhaust. But it's the only 900 that ever had these bits since Ducati started producing the 1000 in 2003.

You could likely take the 1000 or possibly the 800 exhaust header and make that work, but there may be some cutting/welding involved.

a little bit of penetrant and the studs should come out pretty easy.

Also replace the nuts while your at it.

What are you putting this motor into?


2001cromo

Just for clarity.

I shoved a 2002 M900 into my girlfriends 02 620 a few years ago. So I'm speaking from first hand experience with that motor.
I personally have a 2001 M900 and have compared the differences personally.

Duck-Stew

^^^ Really?!?  6mm exhaust studs?  I'll have to disagree on that fact.  ALL 2V engines 1990 - 2008 are 8mm.  I know.  I have the following here in my shop right now and they're all 8mm:

2006 M620
2004 SS1000DS engine (in a monster frame now)
1995 M900
1999 M750

The old-school nuts were 13mm to remove, but you can get the 10mm 'new style' nuts to go right on there.  I put the 10mm nuts on the 1999 M750 last week BTW.
Bike-less Portuguese immigrant enjoying life.

junior varsity

Fantastic stuff.

Yes, I have it side by side by 1999 M900 motor. This was a 2002 900SSie motor. Has the electrical connection on sump at oil screen.

I thought the studs looked a little different but hadn't grabbed calipers just yet.

For purtiness, any chance I can throw on either SS, brass, or Ti studs? And if so, where to get?

Lastly, I can't find a source for a M10x1.0 grub/set screw. I want to remove oil pressure sender there - this is to be a barebones track toy.

i'm currently looking at a few various frames. The F042 frame from Pierobon is nice, but to get up and running, it costs nearly 10k for frame, subframe, etc. Not sure you can save money by using a sbk tank either. My goal is to put a 2v motor in a sbk frame so I can have sbk geometry and a relatively familiar motor feel.

While its an IE motor now, I don't think it will stay that way since I don't have any ECU or other parts for it (just the injectors/throttle bodies themselves). pricewise, it seems like it might be pretty costly to get those remaining IE bits, and not that much difference in $$$ to throw some Keihins on it.

But I haven't yet sorted all that out. Need to figure out how hard it is to make these cases work with sbk frame and swingarm. and by how hard, i mean, how much $$$ to have a rolling chassis. And by rolling chassis, I'm not including wheels, let me articulate: How much money to attach motor to frame, motor to swingarm, shock to frame/swingarm and put over in the corner while i save up some more.  Once I'm to motor-in-frame-and-swingarm, everything else seems to be straightforward.

Speeddog

#14
I've never seen a 6mm exhaust stud on an air-cooled Duc.

Parts catalogues show the same exhaust stud for '00 -'02 900 heads.

There are 13mm hex nuts and 10mm hex nuts to go on those exhaust studs, yes.

- - - - - Valley Desmo Service - - - - -
Reseda, CA

(951) 640-8908


~~~ "We've rearranged the deck chairs, refilled the champagne glasses, and the band sounds great. This is fine." - Alberto Puig ~~~