I need help - 2003 1000ds engine - belt drive pulley clearance issue

[mitt]

I posted this issue 3 years ago on TOB, but never got a good answer.  It is time again to change my belts.  I have a problem, I think is unique to very early 1000ds engines, and might have been a design oops.  

To remove existing belts, I have to take the drive pulley off, because there is not enough clearance between the pulley lip and the engine case:


Can anyone with a later 1000ds engine tell me how Ducati fixed this problem?  A picture would be helpful.  Did they remove the lip on the pulley?  Did they add clearance to the engine case?  

mitt

[ducpainter]

I'm told it can be done with great difficulty.

[mitt]

I swear on the good book that I can't force it out with my bike.  

Last time, I machined a castle nut socket, a pulley holder, etc etc.  It worked, but there must be another way?


mitt

[ducpainter]

I swear on the good book that I can't force it out with my bike. 

Last time, I machined a castle nut socket, a pulley holder, etc etc.  It worked, but there must be another way?





mitt

I can't argue...

because I have no FHE.

It's funny...

if you do stuff every day it becomes easy.

When we mortals play with our bikes it is a brand new experience every time, whereas when the pros do it...

it's...

easy.

[ducpainter]

I swear on the good book that I can't force it out with my bike. 

Last time, I machined a castle nut socket, a pulley holder, etc etc.  It worked, but there must be another way?





mitt

...or I could say it's the engineer in you making it difficult.

[mitt]

Another reason I think Ducati "fixed" it, is because the part number changes from a 255.1.023.1A to a 255.1.023.2A for the pulley somewhere around 2005.  I have always wondered if they shortened up the lip by 1mm just so the belt can be forced through.

Paging Speeddog - he has probably done a dozen of these things.

mitt

[mitt]

can you see any of the pictures I posted?  I could see them at home, but not now at work 


mitt

[Duck-Stew]

I've never measured the OD of he two pulleys, but that makes sense Mitt...  I've done belts on a 03&04 M1000 and you're right...  It's a pregnant dog.

Ducati also machined the cases differently on the later 1000 motors so that there's more clearance between the pulley & case.

I have some '07 1000 pulleys at the shop I could measure in the next couple days if no one pipes up that they've got some more readily available...

[mitt]

I've never measured the OD of he two pulleys, but that makes sense Mitt...  I've done belts on a 03&04 M1000 and you're right...  It's a pregnant dog.

Ducati also machined the cases differently on the later 1000 motors so that there's more clearance between the pulley & case.

I have some '07 1000 pulleys at the shop I could measure in the next couple days if no one pipes up that they've got some more readily available...

A - on the 03/04's - did you have to remove the pulley, or is it humanly possible without?

B - do you have a picture of the machined case?  Probably not feasible for me to do but interesting none the less.

C - that would be great if you could take some lip diameter measurements, and I will too and we can compare.

mitt

[He Man]

mitt is possible to remove the belt. let me post a pic. I have an 06S2R1k so i mnot sure how hte motor is. but yes its a PITA.

You just have to shuffle it from side to side. you have to have them offset*** so the cam gear and the teeth on the belt is a bit compressed. so it comes out easier. u jsut have to pull one side out then the othe side and shuffle it in and out.

[Christian]

B - do you have a picture of the machined case?  Probably not feasible for me to do but interesting none the less.

Is it possible that the stator cover is a little bit machined? You might be able to swap yours out for an '05+ and get the clearance. If that's the case.

[mitt]

mitt is possible to remove the belt. let me post a pic. I have an 06S2R1k so i mnot sure how hte motor is. but yes its a PITA.

The trick is to have the teeth line up with the grooves and then you kind of shuffle it side to side. if the teeth are offset on the cam gear then it will just get stuck.

here is a pic of mine for reference



mitt

[Speeddog]

I've always taken the drive pulleys off on the DS motors.

Taking the old belts off, I really don't care how they come out.
Putting new belts in, I'm not going to force them past a flange, as I have no desire to rebuild an engine for free.

I've got a late model DS in the shop now, I can measure the flange diameter and take a pic.

[Spidey]

Mitt, it's humanly possible to do it without removing the pulleys ('03).  It just sucks.  I think the last time I may have used a pick to help get them off (because I didn't care about the belts).  

Install I've always done by hand, but it's a pregnant dog.

[mitt]

I've always taken the drive pulleys off on the DS motors.


I've got a late model DS in the shop now, I can measure the flange diameter and take a pic.

A - Do you reuse the castle nut or use a new one?

B - That would be great.  I will measure my 2003 and we can compare with Stew.

mitt