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Ducati Monster 900 restoration

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buzzer1955
Borekit Bruiser



Joined: 12 Jan 2019
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PostPosted: 09:53 - 12 Nov 2020    Post subject: Ducati Monster 900 restoration Reply with quote

Thought I would start a new thread... It's been a very strange year... I normally build something over winter, but this year I have been busy on my last build all spring and summer, and that is finished and at the back of the garage ready for spring.

So I have started a rebuild on a 1998 Monster 900, a bike I have always wanted to own. I like the looks, and simplicity of them, and they handle great! this will be a straight restoration and I will be keeping it looking the same save for it being red and probably gold frame and wheels. I started the stripdown yeasterday...

https://jtccc.files.wordpress.com/2020/09/ducati-monster-900-restoration-1.jpg
https://jtccc.files.wordpress.com/2020/11/nov-12-1-copy.jpg
https://jtccc.files.wordpress.com/2020/11/nov-12-2-copy.jpg
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arry
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Joined: 03 Jan 2009
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PostPosted: 10:44 - 12 Nov 2020    Post subject: Reply with quote

Cool Thumbs Up

Look forward to progress with interest.
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Keithy
Renault 5 Driver



Joined: 22 Sep 2020
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PostPosted: 11:20 - 14 Nov 2020    Post subject: Reply with quote

Love that garage.
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buzzer1955
Borekit Bruiser



Joined: 12 Jan 2019
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PostPosted: 12:53 - 14 Nov 2020    Post subject: Reply with quote

The stripdown continues… so far just one slight hitch… a broken bolt in the swinging arm… soon drilled and tapped out though... I bought a set of cobalt drills last year, they are brilliant for this sort of thing. wish I had bought them years ago!

https://jtccc.files.wordpress.com/2020/11/strip-down-copy.jpg

https://jtccc.files.wordpress.com/2020/11/tap-in-swinging-arm-copy.jpg
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Paddy.
Red Rocket



Joined: 14 Feb 2008
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PostPosted: 21:07 - 14 Nov 2020    Post subject: Reply with quote

Another one! Laughing Love these builds.
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buzzer1955
Borekit Bruiser



Joined: 12 Jan 2019
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PostPosted: 16:15 - 15 Nov 2020    Post subject: Reply with quote

Tried to remove the cush rubbers today as I am going to have the wheels powder coated... the rubbers were good, so I didn't want to destroy them. You can't knock them out as the drift just bounces off the rubber, and there is no way to get to the outer sleeve... So I made this puller, that has a split threaded cotter. its a bit fiddly, but they came out a treat, and I can re use them now


https://jtccc.files.wordpress.com/2020/11/cush-drive.jpg
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buzzer1955
Borekit Bruiser



Joined: 12 Jan 2019
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PostPosted: 10:10 - 16 Nov 2020    Post subject: Reply with quote

Just preparing the frame and parts to take to the powder coaters... On the grab handle there were two small dents that I just know that if I left them they would bug me forever, so I TIG brazed them up and filed them down. there is something really satisfying about TIG brazing!

https://jtccc.files.wordpress.com/2020/11/dent-in-frame.jpg
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arry
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PostPosted: 10:30 - 16 Nov 2020    Post subject: Reply with quote

Top work Cool Sounds like you're going to town Thumbs Up
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buzzer1955
Borekit Bruiser



Joined: 12 Jan 2019
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PostPosted: 13:30 - 16 Nov 2020    Post subject: Reply with quote

arry wrote:
Top work Cool Sounds like you're going to town Thumbs Up


thanks! I always enjoy a bike build... I want this to be a good one and its a bike I always wanted...

Looks like the engine has never been worked on, apart from someone has removed the alternator cover and put it back on with what could best be described as glue! normally they come off with a tap, but in this case I had to resort to a puller…


https://jtccc.files.wordpress.com/2020/11/alternator-cover-puller.jpg
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buzzer1955
Borekit Bruiser



Joined: 12 Jan 2019
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PostPosted: 16:35 - 18 Nov 2020    Post subject: Reply with quote

the engine is all apart, and I am pleased with its condition... no bore wear, and everything look good. the main reason to take it apart is to bead blast the cases... which of course means a complete strip. I am glad I did it anyway as people have pointed out the crank plugs come loose which damages the cases. While this one was not loose, it was not tight either can came out with a gentle twist of the screw driver... disaster waiting to happen! its locktited in place now...

https://jtccc.files.wordpress.com/2020/11/crank-plug-copy.jpg


[img]I hate bashing bearings out,and where possible try to make a puller of some sort… in the case of the swinging arm bearings it’s easy, just a stepped bush (it does destroy the inner seal..) and out they come. the step needs to clear the circlip though… some of the engine bearings are more difficult as you can’t get to the back… for this I made an expandable stepped puller, that expands into the bearing as a bolt rides up an internal taper. with this they come out easy…[/img]

https://jtccc.files.wordpress.com/2020/11/bwaring-removal-3-copy.jpg

https://jtccc.files.wordpress.com/2020/11/bearing-removal-2-copy.jpg

To get the bearings out I also heat the cases… I would like to use the oven as its a more even heat… but I can’t for two reasons.. the first is the cases are too big… and secondly she gets upset, particularly as its a new oven! So over the halogen heater it is… keeping an eye on the temperature… I also like to mark EVERYTHING, so it can go back where it came from, and in the same position. I am not keen on centre pops, instead I use a little diamond burr in the dremel… this will even mark bearings and means you can number stuff as well, and it does not cause stress raisers…

https://jtccc.files.wordpress.com/2020/11/bearing-removal-1-copy.jpg

Of course parting the cases means the primary gear has to come off… and they are VERY tight… you can forget anything but a really robust puller. here is one I mad a few years ago. with this it came off easily.

https://jtccc.files.wordpress.com/2018/01/puller-11.jpg

The frame and wheels have gone to the powder coaters...
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Fisty
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Joined: 11 Apr 2007
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PostPosted: 17:33 - 18 Nov 2020    Post subject: Reply with quote

I like this thread and like your style.
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buzzer1955
Borekit Bruiser



Joined: 12 Jan 2019
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PostPosted: 18:33 - 21 Nov 2020    Post subject: Reply with quote

here are the carbs, they are in remarkably good condition! I had some genuine new floats and needles so I used those in the build. I did bead blast the outsides, taking care to use silicone bungs in all the holes… they came out a treat!

https://jtccc.files.wordpress.com/2020/11/carbs-1-copy.jpg
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