Project Ducati: What's your clearance Clarence?

 With a second set of hands, we were able to check the closing valve clearance.  Thankfully, all valve clearances (closers and openers) were within Ducati specifications.  No tinkering with shims for me, at least not yet.  I've heard from multiple sources that once Ducs hit this type of mileage, the clearances are pretty stable.  Sorry for the lack of pictures, would have needed another set of hands.  Although, I have been thinking about using a remote camera and starting to do video of work in the shop; but video editing is not something I'm familiar with.  

Initially, I thought the valve covers had been installed with gasket material and gaskets, but I think it is just residue from the factory gaskets. Either way, it's been a mess to clean up without damaging the engine cases.  I've been using a little 3d printed piece from a previous project and it's working great! See, that's why you save useful stuff!  With the valves covered up, it was time for new plugs. 

Hmm...going to need to address this as well.

I ran out of new-old hardware, time to buy another bag.

The big delay is going to be those damn carb parts.  That's what I get for being a ham-fisted moron at times.  Slow down, especially when working with old plastic parts.  With the carbs complete, it will be time to sync them with my fancy electric sync tool.  I think I'll gladly trade more frequent service intervals for doing half the work, and that work being easier to access.  

I got the clutch basket cleaned up, and everything installed.  I had printed a clutch holder tool out of PETG.  When I first tried to fit it, I thought it didn't align correctly, however it did fit the basket and hub.  What did not align were the bolt holes, but it worked.

2 outta 3 ain't bad, but it's not ideal.

I was worried about this bolt bending, but it worked.

Single use tool, but it got the job done up to the required 136ftlbs!

Once everything was bolted down, it was time to put in the plates and pressure plate. Under the spring caps, I found 2 small washers, which I don't see on the parts diagram. I don't really see the purpose of them, as you do not crank the springs all the way down, otherwise the clutch would not function.  I need to get a torque wrench that goes down to 5ft-lbs to check the spring bolts. 

Starting to look like a motorcycle again. Who knows, maybe it will be running this week.  Still need to put on the new front tire, and flip the rear.  

Stay safe out there. 

**UPDATE**

Right after I hit publish, I remembered I DO have torque wrench that goes down that low, but in inch-pounds.  And I realized why those washers were there.  So, with each spring assembly removed, washers added, I was able to set the proper torque value. 

One of the many cool vintage tools that have been passed down from my Grandfather.

 

Project Ducati: Clutching my Rusty Plates

 When we picked up the Duc, I knew the clutch was going to be a trouble spot. Open clutch, steel plates, being sedentary, and East Coast air were not kind.  I managed to pull some of the plates but the rest were fused together.  

I know a certain motorcycle that is getting a closed clutch cover for it's birthday!

Back of the pressure plate.  This could be cleaned up, but the recesses for the springs have some bad wear, so it's time to replace.

The rod is stuck in the bearing.  Shouldn't pull it out from the right side.

Crunchy

Reminds me of the brake drums I pulled off my Jeep Commanche.

Going to hit this with a wire wheel and high temp paint.

Time for clutch pack, springs, and a new pressure plate. 

It's easy for me to say, screw it, I'm buying all new parts, but my budget does not line up with that. So, I'm replacing what needs to be and what doesn't can stay until the future.  

My float seat assemblies have shipped from the Netherlands, who knows when they'll arrive but at least they're in transit.  Once those are in place (assuming I have the valves checked and serviced if required) all that will be left is the clutch, and general reassembly.  Then we can test start for real! Oh wait, I need to repair the fuel pump wiring too.  THEN we can test.  If it's operational, then I'll get the tires swapped, (and if budget allows) replace the chain and sprockets.  

The Hurricane is road ready.  The thermostatic switch is still giving me fits, so I wired in a bypass switch to activate it manually.  Good thing I mounted a spare switch on the cluster back when it was assembled!  I've pulled the side cases and the Lockhart neon windscreen, so it's down to it's fighting weight. 

Now, it's ready to sell. But I'm dreading putting it on FB market place due to all the crap. 

Update: 

The steel plates, pressure plate, and the damper spring and plate have all been cleaned up.  Now, I just need to tackle the basket.  The plates are stacked up and ready to go.  

Stay safe out there. 

Project Ducati: Keeping Time

 With the Honda being stuck in limbo until I get my new rad cap on Friday, it was time to finally do the belts and valve service.  

A friend graciously passed his 2v Ducati tools along to me a few weeks ago.  After a quick run to pick up a bolt for the engine turning tool and a length of all-thread to use in addition to my ceiling straps to secure the bike, it was time to get working.  

The belt change was really easy.  Once I had the engine set for horizontal TDC, I refreshed the marks, added a second to each cam gear and loosened the tensioners.  The vertical belt was a bit of a struggle since there was tension on the cam gear, but using the belt and sheer determination, I got it set back in alignment and the belt slipped on.  The horizontal was no issue. 

This makes life much easier, but my stuck clutch plates don't.

This is the last belt these tensioners will see.

New belts with proper tension.

Another thing I purchased from eBay was a bag of hardware from a torn down 900SS, it was a great deal for $25.  I replaced any mangled or rusted allen bolt I could from my hardware grab bag.  One day a full set of stainless bolts will be obtained, maybe when the engine is nice and pretty after powder coating.

I finally managed to track down the float valve seat assemblies to replace the two I broke, after emailing multiple eBay vendors, carb shops, and our local Ducati dealership.  However, two problems....  1. I accidentally ordered 2 sets from two different vendors.  2. One vendor is in the Netherlands and the other Australia.  I guess we'll see which one gets here first, and it won't hurt to have a spare set.  Although, I am STRONGLY considering a set of FCR39 flat slides, instead of the DSG and Stage 2 tune for the TDI wagon.  But we'll see. I think I'd like to just ride the 900SS stock for a while, but man do those carbs and open air box sound good. As my friend that gave me the Duc tools said "They sound like how Cate Blancette looks in Thor: Ragnarok".  

In the meantime, I needed someplace safe to store  my nice, clean carbs.

I moved on to the valve check but it was late and my brain was struggling at this point. My horizontal openers are within spec, but I was struggling with depressing the closer and checking the clearance.  I'll need to try again, or, ideally, have a second set of hands. 

This project needs a catchy name until it's road worthy, like how the Hurricane was Project LOL (lots of leaks) for awhile.  I kinda like Project: Secondhand Duc, but I'm open to suggestions (not like anyone else is reading this).  

Stay safe out there. 

Dueling Projects: Fighting two fronts at once.

 Tonight, I had dedicated shop time, as much as I want.  I had big plans, swap the thermostat on the Hurricane, take it for a test ride.  Enjoy the heat blowing off the new fan, go get some dinner. Then come back, and start on the 900ss.  Well, the thermostat got replaced and off riding I went.  At first, it seemed like all was well, but soon the temps started climbing.  Fine, back home in defeat I went.   

Time to work on the Duc.  Immediately, my eye was drawn to a questionable wad of oddly crunchy electrical tape near the connector for the fuel pump.  I've never found good things under wads of electrical tape, regardless of their texture. This time was no different. As a matter of fact, it was worse. 

Well, that doesn't look good.

Dear gods! What in the hell is that doing under my gas tank!

I noticed that run of wire from the main harness was rather stiff. The harness on this bike is very simple, I could definitely repair that section but I hate mixing colors of wires. So, off to eBay I went to look at replacement harnesses.  They're out there, and not too spendy. Time to add that to the list.

I started breaking down the carbs, and unfortunately ended up breaking the float seat assembly on both carbs.  These are made of the finest unobtainium and apparently only available from the Netherlands.  Immediately, my brain says, "Screw these CV carbs.  You need flat slide FCRs and K&N pod filters!". Now is not the time to amplify the Song of the Sausage Creature, that comes later. The bike must run first, then let the insanity blossom.

Crusty bowls. I think someone tried to use sealant instead of new gaskets.

Dammit. This is what happens when you work too fast.

Using my Dremel, flexible extension, and a nylon wheel, I cleaned up the mating edges as best as I could and blasted and sprayed, and sprayed and blasted.  Finally, they were all assembled, even new diaphragms. Now I just have to track down the parts I broke. 

So, to recap on the Hurricane, that's a new fan, new radiator, fresh coolant, and now a new thermostat.  I can feel (and see) coolant moving, so to the best of my knowledge the pump is functional.  But that fan just doesn't turn on. I tried burping the system but ended up just making a damn mess. Next is replacing the radiator cap and testing again.  

Having two project bikes is no fun, unless you have plenty of spare time and funds.  Gotta get the Hurricane operational and sold to fund the Duc. 

Stay safe out there. 

Project Ducati: Starting the strip down

 I've started pulling the carbs for a rebuild, as well as getting to more gunk that needs to be removed.  While the carbs are out, I'll be doing the cam belts and valve clearance check.  According to my secret sources, since my bike is just past 14k miles, I may not need to play the shim shuffle; as they tend to bed in and be pretty stable. Should be quite the adventure!  Cam belts and gaskets should be here any time. 

It's absolutely amazing to me how easy it is to access everything on this bike, and how simple it is, compared to the Hurricane.  

New petcock installed, and the gas tank has a kick stand!

New Brake pedal, in a faster color.

Damn right!

I must consult the three oracles.

What in the fettuccini is this doing on my fine Italian motorbike?

Pulled the crankcase evap canisters to help make room. Not sure if they'll get put back.

Look at all that room!

Engine just hanging out in the breeze.

Big battery sipping the juice.  No wonder the little Hurricane battery was struggling! 

Hopefully I'll get the carbs rebuilt tonight and the bike prepped for the rest of the service.  Once that's done, I need to install the new front tire and give it a once over.  Then it's time for the BMV! 

I'm still eyeing powder coating guns with the idea of picking up a cheap used stove and coating the smaller bits (engine covers etc) in house. It's kinda crazy how easy it looks compared to painting.  

Project CBR600F: Soup is good for you!

 The Hurricane had some plugged pilot jets that were driving me nuts, as well as a loose plug wire at the coil.  Finally, it's starting like it used to but still overheating.  I replaced the radiator recently, due to boogered up threads on the one that came on the bike.  The fan was not coming on (again), so here I am, thinking maybe it's the thermostatic switch again and trying to find the correct one.

I took the bike out over lunch, put some fresh fuel in the tank, and on the way, my temp gauge hit 235+.  I coasted into the gas station, fueled up, and let the bike cool off.  About a mile from my place, the temp was spiking again.  Fan still off.  

Well, time for soup.  

This was pretty fun. I had never tested a thermostat before.

According to my factory manual, it should open at temps over 176 degrees, after a few minutes.  Well, it started to...but not really.  This is all it opened when we were pushing 200 degrees for almost 10 minutes. 

Not even close to the stated 8mm opening.

So, off to Partzilla I went.  The replacement should be here next week, and that SHOULD be the last issue on the Hurricane.  I gave my coworker, what I believe to be, a very good price.  But, funds are tight all around, so we'll see.  If that doesn't work out, I'll be advertising it to the local Mad Max Run hooligans and see what it turns up. I'm gonna miss the Hurricane, but if I keep it, it will just sit (plus, I need the funds for the Duc).  At some point I want to keep a spare bike for visiting friends, but that's not now. 

From the pasta side of the shop, I fired up the Duc last night, using the Honda's battery and some starting fluid. Man, she sounds good!  That poor little battery was struggling!  Lots of Duc stuff is on order.  Going to get it on the road, enjoy riding season, and do the big tear down this autumn. So, it will be belts, valve service, oil change, air filter, plugs, and full systems check. According to the folks at Ducati.ms, my bike doesn't have the failure prone engine studs, so we'll just replace the nuts and address any leaks that come up. 

Still plan on pulling the engine, soda blasting it, breaking it down to replace gaskets, and address the galley plug.  There are talks of powder coating the engine, frame, and wheels.  We can do everything but the frame on our own, that's too big.  This is not a restoration, but rather, a resurrection.  It won't be perfect but it will be functional and mildly aesthetically pleasing.  

I have a modified (you know I can't leave anything alone) front fairing idea, well two of them.  One no fairing with a fixed cluster and neon pink windscreen, and a replacement front cowling (the middle piece) with a cutout for a set of Buell XB headlights. Maybe some thoughts about how to mount my yellow Pelican cases too.  Running and reliable takes precedent over mods. 

Stay safe out there. 

Operation Duc Hunt: Baby's first bath.

This post is going to be mostly pictures, as my brain is mush from driving to Maryland and back, plus being out in the heat all day spraying, washing, and a good once over.  Plus working on the Hurricane.

How she looked after being exhumed from her tomb, loaded in the van and taken back home. 

Some shots of the rust and crust. 

Baby needs a bath. 

This is one of my favorite features.

Always cool finding personal touches like this. 

Results of a battery spill, I'm guessing.

Something always breaks. 

Looks fast, sitting still.

Not too bad....

Well, shit.

The cylinder studs will most likely need to be replaced, they're very  rusty and a common weak point.  If we're going down that route (and we should), we might as well take a peek at the crank shaft oil galley plug.  That little silver sliver may be from it backing out and grinding away. 

Gotta do belts, and valve service, so I'm probably just going to pull the engine and do it on the bench. 

It's very surreal to have this motorcycle, yet it feels like, in some ways, it was always mine. Like I was just waiting for it to fall into place. 

Stay safe out there.  

Oh yeah, the Hurricane is running better. Not calling it fixed yet.