DS1000SS Nekkid Roadster Build

[Nekkid Tim]

After looking at the airbox, I got thinkin'.

Have that cut rear battery ignition section and get another airbox sans battery section and bolt or Dzu fasten them together.

Then you remove the airbox baffle panels, put a K&N filter on top of the lid, gut the stock filter and use the filter seal between the lid and airbox. I cut out the filter supports and expoxied them up under the new filter location. Some filters are rigid enough depending on which one you choose. The lid becomes the filter for cleaning. This will maximise the airbox cavity volume by putting the filter as far away from the stacks as possible and make all the airbox volume available to each cylinder on each intake stroke. I got 5 more hp doing this on the too small/shallow carbed airbox. I think the ie airbox is a better starting point. I had a thread on this somewhere..

I have been looking at K&N filters just a little smaller than stock to go on top of the lid, so you have an open airbox lid at the very top. Still plenty big enough. I have used the stock size K&N filter but it's a squeeze. Silicone sealant and the Dremel are your friend.

By having it two piece, you can reroute the harness to a more sane location and have easy servicing access while still having a good airbox. Next would be incorporating the billet stacks into your open, extended airbox. The best of both worlds.

Hi; looked at your thread; great work there!   Really detailed dyno tuning to quantify the results - I like that!

In my case, I won't have room for any airbox at all as I am going to relocate the oem coils that were originally mounted on the outer left side of the frame (previously hidden by the oem fairing) under the fuel tank, as I did on my track bike:



I'm hosting the 13-year-old son of a late motorcycling buddy of mine this coming Saturday (and possibly my nephew, again) and we'll fabricate a duplicate of that aluminum bracket, and relocate the coils.  If we have time, we'll also install the spare TPO "Beast" velocity stacks that I have left over from the track bike project.

[Nekkid Tim]

A little more progress to report;

Completed the prep of the S4Rs for sale and listed it here and on eBay.

.............

Fabricated and installed the bracket that holds the back of the fuel tank and the front of the tail unit.
Bought and installed a set of BST carbon fiber wheels
Installed a titanium rear axle that came with my black anodized swingarm (not installed yet; will be used in the final build)
Bought and installed a bunch of titanium fasteners from TPO. (Just to keep the juices flowing)
Mounted the Napolean Baren bar end mirrors
Drilled and clamped the throttle assembly
Replaced the oem handlebar grips with latemodel stock 848 Superbike grips (with "Ducati" logos)
Finished the wiring extension for the Euro  headlight/starter/kill switch assembly, drilled the bars and mounted the switch
Drilled the bars and mounted the turn signal switch
Bought a used Sargent monoposto saddle, installed it in the carbon fiber tail unit, wired, and mounted the tail (the carbon tail is HUGELY lighter than the oem ABS plastic Ducati 916 monoposto tail.)
Found a source for a carbon fiber rear hugger, bought it, and mounted it.
Ordered a Shorai Li Ion battery; it's on its way.

Oh, and I removed the heavy steel license plate bracket off the carbon fiber rear fender; I'm going to find a clean, oem-looking way to attach the Virginia license plate directly to the rear fender without an intervening steel plate!

DS1000SS Roadster Project continued by s4rsrider, on Flickr

DS1000SS Roadster Project continued by s4rsrider, on Flickr

DS1000SS Roadster Project continued by s4rsrider, on Flickr

DS1000SS Roadster Project continued by s4rsrider, on Flickr

DS1000SS Roadster Project continued by s4rsrider, on Flickr

DS1000SS Roadster Project continued by s4rsrider, on Flickr

DS1000SS Roadster Project continued by s4rsrider, on Flickr

DS1000SS Roadster Project continued by s4rsrider, on Flickr


Left to do for the "dry build" :

Install the velocity stacks
Connect the front wiring sub-harness and all connectors and secure them
Install the battery
Install a fuel pump in the  fuel tank
Fill and bleed the front brakes
Temporarily re-install the stock 1000SS instrument gauges (until I can get the Euro GT1000 gauges mapped to the oem SS1000 ECU)
Install the Power Commander III
Oil & filter change
Gas
Test start
Take it to my local race shop for dyno tuning and Power Commander set up.
Take it to my local Ducati dealer for mapping the Euro GT1000 gauges to the oem SS1000 ECU.  Anyone know what this entails?
Ride it.

[Nekkid Tim]

I love Ti; but the Shorai battery at 1.88 pounds will save more weight over the stock battery (at 7.6 pounds) than all the Ti weight savings.

Still; the Ti fasteners (already in hand; most but not all installed - some are awaiting the final, cosmetic reassembly) look nice and do save some weight; the bag of steel parts that have been replaced is pretty darn heavy to heft:

all disk rotor bolts
front fork and triple tree pinch bolts
front axle nut
all brake caliper mounting bolts and caliper half clamp bolts
rear shock upper and lower bolts
handlebar clamp bolts
brake and clutch master cylinder perch clamp bolts
rear brake linkage (plunger rod)
rear brake pivot bolt
gearshift pivot bolt
rear sprocket nuts
exhaust hangar bracket bolts and nuts
headlamp bucket mounting bolts
headlight support bracket mounting bolts
countershaft sprocket nut
rear axle and nut
engine mount through bolts and nuts
footpeg hangar bolts
rear subframe mounting bolts


I have removed and measured (and temporarily replaced) the following fasteners that will soon be ordered in Ti:

All engine side cover bolts
cam cover bolts
coil mounting nuts and bolts
coil mounting bracket nuts and bolts
horn mounting bolt
footpeg heel plate mounting bolts
rear brake master cylinder mounting bolts
rear brake master cylinder remote reservoir mounting bolt
rear brake hose routing bracket mounting bolt
underseat taillight and rear seat latch mounting bolts
seat/fuel tank mounting bracket bolts
shift linkage nuts and bolts
sidestand mounting bracket bolts
front fender mount bolts
frame rail fuel tank mounting rubber mounting bolts (I had a couple of Ti bolts that fit the threads, but are WAYYYY too long)
oil cooler mount bolts
rocker cover bolts

...a few more.

Should save a few more ounces!

[Nekkid Tim]

Perusing the factory parts fiches; it appears that I am missing a spacer that goes behind the sprocket on the countershaft (P/N 713.1.201.1A).  It's on its way along with a couple of other minor parts I need.

Got the spacer, removed the chain, removed the front sprocket....   the spacer is already there.   So, I think maybe the countershaft is just LONGER on this bike.  Sighted, lined up, rotated the chain/sprockets with both the oem rear wheel and now with the new BST rear wheel, and there's no mis-alignment and no visible wear or interference, no strange sounds, no excessive drag.

[Speeddog]

Hmmm, perhaps there's different shafts. Odd. Brad Black mentioned something related a while ago, can't remember now.

That OEM speedo trigger on the rear caliper bracket cannot see those Ti rotor bolts.

[koko64]

More fine work and attention to detail. The vicarious pleasure was worth waiting for.
Gotta love a maniacal committment to light weight.

[Nekkid Tim]

More fine work and attention to detail. The vicarious pleasure was worth waiting for.
Gotta love a maniacal committment to light weight.

Thanks!

So, another part of this process seems to have come to closure; sold my Monster S4Rs last night, new owner to pick it up on Saturday.

Got the front brakes filled and bled.
The Monster intake boots I ordered off of eBay did NOT arrive, seller refunded and said that the auction was posted in error.   Bought another pair that are now marked as "in transit" to arrive next week sometime.
Received the Shorai Lithium Ion battery (actually got two; one for the track bike).  it's amazing how light 1.88 pounds is compared to 7.6 pounds!

Placed the following (final?) order with my Ti dealer:

---------------------------------------------------------------------------------------------------------

Description   Quantity   My Usage (OEM = OEM Ducati DS1000SS unless otherwise noted)
      
M8 x 25mm (any thread pitch) bolt   2   Custom muffler bracket to rear subframe
M8 nut (Matching above thread pitch)   2   Custom muffler bracket to rear subframe
      
M6 x 10mm 1.0 thread pitch bolt   4   Secure heel guards to footpeg hangars (OEM)
      
M6 x 15mm 1.0 thread pitch bolt   2   Rear brake master cylinder mounting to alloy carrier  (OEM)
      
M6 x 17.5mm (3mm shoulder) 1.0 thread pitch   16   Rocker cover to cylinder head mounting (OEM)
      
M8 x 60mm (30mm shoulder) (any thread pitch) bolt   2   Bar end mirror retention  (aftermarket)
M8 nut  (Matching above thread pitch)   2   Bar end mirror retention  (aftermarket)
      
M6 x 10mm 1.0 thread pitch bolt   2   Oil cooler mount (OEM)
      
M6 x 20mm 1.0 thread pitch bolt   3   heim joint shift linkage (2), shift linkage to shift shaft(1)   (OEM)
M6  1.0 thread pitch nut   2   heim joint shift linkage  (OEM)
      
M6 x 20mm (5mm shoulder) 1.0 thread pitch bolt   4   front fender mounts  (OEM)
      
M6 x 10mm 1.0 thread pitch bolt   2   license plate mounting  (custom)
      
M5 x 15 0.8 thread pitch bolt   1   rear brake line securing bracket (to swaged-in swingarm brass insert)  (OEM)
      
M5 x 15 0.8 thread pitch bolt   1   secure air temp sensor to bracket behind headlamp  (custom)
M5 0.8 thread pitch nut   1   secure air temp sensor to bracket behind headlamp  (custom)
      
M6 x 10mm 1,.0 thread pitch bolt   1   rear brake m/c fluid reservoir mount to frame (utilizes weld nut)    (OEM)
      
M6 x 15mm 1.0 thread pitch bolt   1   Speedometer sensor mount to rear brake carrier  (OEM)
      
M8 x 15mm 1.25 thread pitch bolt   1   Mounting horn to frame (OEM)
      
M8 x 30mm (any thread pitch) bolt   2   Mounting custom coil bracket to frame
M8 nut (matching above thread pitch)   2   Mounting custom coil bracket to frame
      
M6 x 25mm (7mm shoulder) (any thread pitch) bolt   4   Mounting coils to custom coil bracket
M6 (Matching above thread pitch)   4   Mounting coils to custom coil bracket
      
M6 x 10mm 1.0 thread pitch bolt   2   Mounting rubber fuel tank pads to frame (OEM)
      
M6 x 20mm 1.0 thread pitch bolt   2   throttle assembly housing pinch bolts (OEM)
      
M6 x 20mm 1.0 thread pitch bolt   2   custom seat/tank mounting bracket to frame
      
M6 x 10mm 1.0 thread pitch bolt   2   tail light to monoposto seat unit (OEM Ducati 748/916/996/998 monoposto)
      
M6 x 25mm 1.0 thread pitch bolt   2   monoposto seat unit latch bracket(OEM Ducati 748/916/996/998 monoposto)
      
M5 x 6mm 0.8 thread pitch bolt   2   intake manifold vacuum bung fillers (OEM)
      
FOLLOWING ARE ALL M6 ENGINE COVER BOLTS:      (ALL OEM)
      
M6 x 65mm (40mm shoulder)   1   Clutch cover
      
M6 x 70mm (45mm shoulder)   1   Clutch cover
      
M6 x 30mm   2   cam belt covers
      
M6 x 15mm    5   cam belt covers
      
M6 x 25mm   5   clutch side engine cover
      
M6 x 35mm (10mm shoulder)   1   clutch side engine cover
      
M6 x 30mm   1   starter motor on clutch side of engine
      
M6 x 15mm   2   countershaft sprocket cover
      
M6 x 15mm   3   clutch slave cylinder
      
M6 x 25mm   8   engine cover proper (drive side)
      
M6 x 30mm   3   engine cover proper (drive side)

---------------------------------------------------------------------

No more excuses, now.  The S4Rs is out of the way, the garage is complete and the workshop set-up, and (assuming the sale goes smoothly on Saturday)  I will have the cash from the sale of the S4Rs on hand to pay for the initial work to get the project running!

[Nekkid Tim]

Hmmm, perhaps there's different shafts. Odd. Brad Black mentioned something related a while ago, can't remember now.

That OEM speedo trigger on the rear caliper bracket cannot see those Ti rotor bolts.

Grrrr.   Street bike.  Need the speedo.   But also need the Ti rotor bolts.   Thinking about solutions now.  Any ideas?

[koko64]

GPS driven speedo?

[Duck-Stew]

Grrrr.   Street bike.  Need the speedo.   But also need the Ti rotor bolts.   Thinking about solutions now.  Any ideas?

Nothing comes to mind that would weigh less than using 6x steel bolts.

[kopfjäger]

Grrrr.   Street bike.  Need the speedo.   But also need the Ti rotor bolts.   Thinking about solutions now.  Any ideas?

Magnet fitted into top of Ti bolt.

[Nekkid Tim]

Magnet fitted into top of Ti bolt.

 

Now *THIS* I like!!!!

Thank you!!!!!!

[Speeddog]

That's cool, but the sensor is looking for ferrous material.

You could do the same with steel though.

[Nekkid Tim]

That's cool, but the sensor is looking for ferrous material.

You could do the same with steel though.

Tiny little Torx-shaped steel inserts for the Ti bolts.........  I'll machine some of those up tonight!     

[kopfjäger]

That's cool, but the sensor is looking for ferrous material.

You could do the same with steel though.

I'm running an M-unit sensor.