Project Ducati: Letting go, and Maintaining Balance

 Saturday morning, I woke up early to get out some tools a coworker needed to borrow, as well as hand the Hurricane off to it's new owner.  Once that was complete, I planned on balancing the carbs and putting some miles on the Duc before I had to meet up with my kiddos.  

Adios Hurricane, you were a good bike and kept me sane during the pandemic. 

Coffee, breakfast, and wrenching. 

.

Nipple.

Be careful, there are 2 screws, one is the idle, the other is balancer.

Perfetto! Nice and balanced.

There was a small hiccup before I could balance the carbs.  I told R., the new Hurricane owner that he could ride the Duc.  But when I hit the start switch, I got nothing.  Not a whine, buzz, whimper, or crank.  Well, shit.  Electrical gremlins again.  After he left, I grabbed my multimeter and tested the switch, all was well.  So, I grabbed an allen wrench, uncovered the starer selonoid connections and ZAP she fired up!  One more part to replace.  But after some internet sleuthing, this appears to be rather common on the 900SS and M900, mainly due to the connector coming loose.  It happened again later in the day, and I wiggled the connector, it started.  One zip tie later, it's "fixed".  

I rode to the gas station, filled her up with petrol and took a quick ride.  Man, I love the feel of this engine.  It reminds me of riding vintage twin cylinder bikes with my friends back when I first got into riding.  Bikes like this have character, a soul if you will, which is something I find lacking on new bikes. They're just to clean and smooth, I like the visceral nature of this bike and engine.  You never feel the bike disappear beneath you, it's always there reminding you. 

I replaced the crank turning tool access cover with an oring I ordered off of Amazon, 10 pack for less than the prices of the Duc oring including shipping.  We'll see if this holds up to the heat.  

Stay safe out there. 

Project Ducati: Wire it Up and Fire it Up!

 My connector kit arrived and I made quick work of the foul repairs for my fuel pump, but also noticed another questionable wrap of electrical tape.  Hmm...we'll deal with that later. 

Much better!

I also decided to print a clutch gasket out of TPU instead of using the washers to space out the closed cover.  To be honest, I'm not a huge fan of the dry clutch rattle.  I think it takes away from the lovely L Twin sound. 

We'll see if it holds up to engine temps. 

So, with the wiring fixed, the last hurdle was those damn float valve seats.  With no more work to be done on the Duc, I started pulling all the remaining "stuff" off of the Hurricane.  I decided I would rather take less dough, and sell it to someone who wants to bring it back to it's full 80's plastic glory; instead of selling it to some rando on FB who'll put it in a ditch (or worse).  Stripping down the Honda was pretty easy, now I essentially have a street fighter kit in a box. 

I got a USPS notice about an inbound packing with a funky tracking number.  Could it actually be my parts, all the way from the Netherlands?!  It was indeed my friends! 

That night, I got the carbs assembled, and then installed them over lunch today.  With my kiddos gone for the evening, all resources were redirected to the garage.  I had one goal, and one goal only.  Ride the Duc, even if it was around my street.  All the remaining reassembly went rather easy (hmmm...maybe too easy).  I dropped in the new fat battery, put some fuel in the tank and turned the key.  The gentle whine of the fuel pump filled my ears.  So, I hit the go button!  It turned over a few times, and then back fired like a 5.56 rifle round going off.  Hmmm...too easy indeed.  Perhaps I swapped the plug wires.  About 1 minute later, I was hitting the go switch again.  One revolution, then.... nothing.  No lights, no starter, no fuel pump.  Just a buzz from behind the instrument cluster.  Is this it?  Am I getting the Ducati electrical curse right off the bat?  

I found the buzzing relay, luckily I had a replacement (never throw anything away). With the new relay installed, I turned the key.  LIGHTS! Glorious lights and the fuel pump singing like a choir of angels, then BUZZZZZZZ.  SON OF A B!TCH.  2 relays?  Wait a minute, this has to be something else.  Immediately, my mind went to a guy on YouTube that I've been following as he works on his 900ss.  He chased all kinds of issues and went way down the rabbit hole, only to have it end up being a bad ground.  So, I pulled the airbox (man this bike is easy to work on), cleaned up the ground cables and frame mounts.  

The moment of truth.... 

I threw on my helmet and gloves, and rolled out into the street.  I put about 3 miles on ripping, I mean, riding as a sane person.  Once the clock hit 10pm, I figured my neighbors probably didn't enjoy the fine music of my Italian motorbike, so I rolled into the garage.  The idle was still high, so I referenced the good book  and found the idle screw.  I dropped the idle, it sounded better, then I noticed the damn "enrichment circuit" (it's not a choke, according to Ducati), was still about half on.   It's reversed from my Honda and has a pretty far throw so I goofed on it.   With the circuit closed (open?), I reset the idle and it seemed happy.  Tomorrow I'll sync the carbs, and pass the Hurricane on to it's new owner.  

Stay safe out there. 

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. 

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 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. 

Project CBR600F: A little bit here, a little bit there.

 I'm slowly getting the CBR back to being road worthy.  The clutch cover has been patched, the oil leak on the pulse generator cover has been fixed (I think), the valve cover gasket and the radiator (and thermostatic switch) have been replaced.  I need a replacement coolant hose (between the water pump and the cylnders), then I can put some fluids back in and see what leaks out.  

Once the leaks are confirmed fixed, it's on to uh... well, firing it up!  Been wrenching on my wagon too, this time nothing as complex as the timing belt and HPFP.  Replaced the RCV and alternator pulley. Nice to finally have cold AC, and no more squealing at start up.  

There some changes coming to what lives in my garage....stay tuned and stay safe out there. 

Project CBR600F: Still in Storage

 The Hurricane is still in it's winter cocoon of garage junk.  I could have sworn I ordered the clutch cover gasket but I can't find it, so the replacement should be here end of the month.  I still need to replace the radiator switch, and hoses.  

So, what did I get done over the winter... NUTHIN.  I spent the first chunk of warmish days wrenching on my TDI wagon (timing belt, DPF/EGR work, CP3 HPFP swap, ECU Tune, etc).  I'm enjoying my sporty wagon, and look forward to upping the tune to stage 2 (maybe 3 with a turbo swap in the future).  

Riding has kind of taken a back seat, it's just hard to find/make the time for it.  Plus, the roads aren't getting any safer out there.  

One way or another, I gotta get off my butt and get the CBR back on the road.  

Project CBR600F: Hints from the Moto Gods

 Well, I found the source of my oil leak, in addition to the split timing plug. 

Pulling the clutch cover involves draining the oil, and since it appears the thermostatic switch (radiator temp sensor) is also bad, I need to drain the coolant.  I replaced the fan as mentioned previously, and got the temp up to >210 degrees, no fan.  But when I ground the wire from the thermostatic switch to the radiator, the fan runs, so bad switch. 

I get it, I get it, all signs point to pulling the engine.

To Do List: 

1. Degrease

2. Replace Valve Cover Gasket

3. Check Valve Clearance

4. Replace old coolant hoses and clamps

5. Replace Thermostat (just because)

6. Check Countershaft Seal

7. And so on... 

I did trim down the handguards, took all of 10 minutes. 

So, the 2023 riding season is officially over for me.  I think I logged maybe 100 miles. Better than none I guess. 

Stay safe out there. 

Project CBR600F: Blowin' in the Wind

 After trying a couple of different fans from Amazon (I didn't want to buy a used fan from eBay), I finally found one that fit perfectly, but did require a little bracket to mount.  

Ready to reassemble the rest of the bike, and hook up the test tank to, uh, well, test once the bike gets up to temp. 

Stay safe out there.  

Project CBR600F: Fallin' like the Berlin Wall *UPDATES*

 Some days, the universe gives you little hints that your day won't go as planned.  Others, it smacks you in the face and says in a stern voice, "NOT TODAY.".   Well, Wednesday was the latter of the two. 

Gravity tested, working as designed.

Behold my feat of strength! 

Free shorty lever!

$20 later, good as new.

With the new lever on, I realized my handguard was too bent.  To be honest, these dual mount guards have been a pain since day one. The angles are all wrong with my big switch sets, and long levers.  So, instead of dropping $100 on a single sided mount style, I gonna make my own. 

Surgeon, cut here.

When I get some garage time again, and it's not 150 degrees outside with 200% humidity, I'm gonna cut 'em down to size and mount them back.  

Stay safe, and hydrated out there. 

**UPDATE**

Took the bike out on a quick errand today, once it was up to temp, it ran great.  Picked up my groceries, and decided to take the fun way home.  I noticed my foot was slipping off my brake lever a few times but figured it was bad body position due to barely riding this year, or something on my boot.  

Pulled into the garage, to let the bike run the carbs dry since I don't know when I'll be riding again.  When I shut the bike down, there was a clunk and lots of gurgling.  I looked at the temp gauge, it was at 255 degrees! Then looked at my boot, it was coated in oil.  

So, I have two problems. 

1. My cooling fan isn't running. 

    a. The wiring got pulled/damaged when I was working on my headlight. 

            Check all wiring and connections.

                    Wiring was fine, but I did find some leftover wired bits from the switched circuit the

                    previous owner made.  Repaired the harness.

    b. The temp sensor got damaged (not sure how, it's on the left side).

            Test sensor.

                    Sensor is fine.

    c. The fan assembly itself is damaged.

            Test fan with power for functionality.

                Fan ran once with direct power, then never again.  Looking for more universal replacement.

2. Revenge of the oil leak, this time with spray action!

    a. Crack in the right crankcase cover.

            Close! The timing inspection plug was cracked.  It has been replaced.

    b. Damaged or loosened timing cover bolts.

    c. Bent side cover, and/or damaged gasket. 

            Speaking of damaged gaskets and leaks, I think it's finally time to just pull the engine, degrease,             and replace all the gaskets and seals, as well as the hoses.  No more leaky bikes.

The fun never stops! 

            Neither does the learning! 

Project CBR600F: Neon Nights

 Back in the early days of this build, a guy on the F@cebook Hurricane Group posted a vintage 80s Lockhart windscreen for sale, it was neon pink and I had to have it.  The price was a bit salty but man, it was like concentrated 80s.  I tried to come up with ways to mount it but eventually gave up and just decided to stash it for later.  

Well, today is later.  I printed up some TPU (flexible filament) spacers, ordered longer bolts and decided to just freaking do it already.  I was worried about getting the mounting holes lined up so, so I pulled the black fly screen, centered it as best I could, and clamped the two together.  I should have taken pictures, but I get excited and want to finish the work.  

I used a hot pick and made pilot holes, even starting with a small drill bit, I had some chipping on the screen.  Thankfully most of it is covered by the bolt caps, hopefully the cracks don't get worse. 

Behold the cherry on top of my Cyberpunk style Hurricane: 

I'm currently printing some taller spacers to test, with a higher infill so the don't crumple.  Probably need to get some shorter bolts too.  We'll see. 

The pictures make it look more orange, but I promise you, it is very very pink. Now, I need to get back to the idea of making a new warning light cluster, using an LCD panel and Arduino with some cool animations, but that's going to take a lot of time. 

Stay safe out there. 

**UPDATE**

I printed a different sized spacers, taller on top works better.