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post #1 of 322 (permalink) Old Oct 25th, 2011, 3:02 pm Thread Starter
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Project 1989 900SS Performance Rebuild

With TAftonomos doing his refresh, I'm inspired to share my own comprehensive performance rebuild, which I've just started.

To re-cap, my bike was once upon a time a mild mannered 1989 900SS. For those of you who live where this bike wasn't sold (USA?) I've attched before and after pics. The '89-90 was a very different bike to the 1991-on 900SS and had as much in common with the 900 Paso as the later bikes incl: slab sided shark mouth fairing, right way up forks, Weber double downdraft carb, RHS clutch with thrust bearing in-cover, Magneti Marelli ignition, different frame, etc. In its' original form it was, in short, a pig.

Anyway, after my bike fell over in 2nd of the big Earthquakes in Feb, (with only minor fairing damage thankfully) I thought I'd go all out and make it into the bike I always wanted.

To recap, here's the list of previous modifications:
* Kawasaki ZXR front wheel and USD forks (Racetech valved)
* Full floating Disks
* Ducati 888 Front mudguard (Carbon)
* Braided brake lines
* GSXR750 Master Cylinder
* Dual projector beam headlights (off-set Le Mans style) with carbon fibre internal mounts
* Custom front sub-frame
* Carbon Fibre Instrument Cover
* Kawasaki speedo
* Custom Ducati tacho face
* Custom wiring loom incl uprated alternator
* Kawasaki Regulator/Rectifier
* Custom top triple clamp (Ignition barrel now sits between V)
* Custom CNC headstock nut made by Rob Selby (ex Britten)
* Later model Ducati switchblocks
* Frame braced and modified to fit later shock. All footpeg hangers removed from frame, new brackets added.
* Ohlins rear shock
* '95 900SS footpeg hangers
* Upside down gear linkage
* Billet alloy footpeg adjuster made by Rob Selby
* Gear lever & foot brake milled
* Ducati Supermono replica fairing (carbon fibre) Mould taken off a Supermono but changed & widened.
* Ducati 916 mirrors
* 95 Ducati 900SS tank
* Ducati Paso (aircraft style) tank filler
* Ducati 955 Corsa tail section - QB Carbon
* Custom Seat
* Vee Two Australia 944cc big-bore high compression pistons. Motor balanced
* Carbon fibre belt covers
* KTM Sprag Clutch
* Keihin 39mm FCR Flat-slide carbs (racked)
* Chris Beaumont (V8 Supercar) fabricated spaghetti exhaust pipes.
* Nuts for lambda sensor probes.
* Carbon mufflers
* Aftermarket indicators
* Custom Numberplate bracket (Carbon Fibre)
* Personalised number plate ‘DCATI’
* Custom paint job
* 1000DS Swingarm with underslung brake caliper and Marchesini 5 spoke rear wheel.

And here's what I'm in the middle of...
• Keihin 41mm FCR flat-slide carbs (split) with Malossi short manifolds and K&N Pod Filters
• New crank cases with close ratio gearbox (change to master & slave cylinder set-up) (original balanced crankshaft, alternator and cover retained.)
• New brake master cylinder
• Cut outs in clutch case
• Barnett aluminium clutch basket
• Motorize (Germany) aluminium clutch plates
• Rizoma billet clutch pressure plate
• Mad Duc clutch cover
• Heavily lightened machined 400SS flywheel
• Stainless steel engine bolts
• Ignitech adjustable ignition
• New oil cooler with braided lines
• Ported and polished heads
• New Ducati Performance cams
• 900SSie adjustable pulleys
• MBP valve collets
• 45mm high rise spaghetti exhaust with carbon (Akrapovic I think) mufflers.
• Polishing: manifolds, exhausts
• Walnut blasted motor (to be repainted. Cases in Charcoal, covers in Magnesium Gold)
• ’02 lower triple clamps with ‘95 top in brushed stainless finish.
• ’95 Supersport forks with Race Tech valves
• Ducati Speedo (modified speedo drive)
• Brembo Gold calipers with new braided lines
• Late model Brembo 916SPS (same as Superlight) rotors with cast iron discs
• Marchesini 5 Spoke front wheel.
• CNC milled rearsets
• Shorai Lightweight Battery
• LED Indicators
• Re-covered (Alcantara) seat.
• Ilmberger (Germany) Carbon 1000DS Hugger
• Ilmberger (Germany) Carbon 888SP2 front mudguard
• Carbonworld (Germany) Vented Sprocket Cover
• Billet bar ends

The objective is to make the bike 'mint'! And go as good as it looks. It had 82rwhp before so 95+ should be achievable. Most of the stuff I've bought new and its winging its' way to NZ from the 4 corners of the globe. I'll go "OMG What have I done???" when I get my credit card bill!

The only thing I havent got sorted is the oil cooler. I'm thinking Monster S4RS but not sure about it compromising rear head cooling.... anyone got some cool (exuse the pun) and not horrifically expensive oil cooler ideas?

Last few pics are my old spaghetti system (have a new big-bore now), some pics of the repairs I discovered to my cases when I pulled the motor out, (Eeeek!) some gear faces were also rooted, and pics of the motor and heads as they went to the media blaster.
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Hamish, ex Britten Motorcycle Company

'89 900SS now Superdue: '95 cases, close ratio box, XX9R Ohlins R&T front end, Monoblocs, Speedymoto Upper Triple, Apex Clip-ons, 5 spoke Marchesinis, Bespoke discs, Hel Lines, Carbon/Composite tank with c/f filler, carbon Supermono fairing, dual projector beam headlights, billet rearsets, carbon 955 Corsa tail, 944cc, Lightweight flywheel/Barnett clutch, Aluminium Plates, DP Cams, ported heads, 41mm split FCRs with 90mm CNC velocity stacks, 45mm Spaghetti pipes with carbon cans, Ignitech, Dyna Coils, Magnecor wires, Ohlins shock, 1000DS swingarm. Lots of Carbon and Titanium. EVERYTHING else is custom. Just about finished...


Plus
'95 900SS/SP: Bought May '11.
07 Aprilia Tuono: Sold. '06 GSX-R1000: Full Ohlins: Sold. (written off same day by MadMartin!) '03 Monster 620ie: Sold. '00 Aprilia Mille R: Sold. (Gone but not forgotten) Several 750 Pasos, ZZR-1100, VFR750 and other small Hondas etc

Last edited by Kiwihame; Oct 25th, 2011 at 3:10 pm.
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post #2 of 322 (permalink) Old Oct 25th, 2011, 10:55 pm
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that cooler i have on mine hamish works wonders and wasn't overly expensive for the whole setup.

what are you doing with your old spaghetti system?

todd.

1995 900ss, 2002 injected 900ss turbo, triumph 675 front fairing off a race bike modded for street, 916 rear tail section and a few other mods.
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post #3 of 322 (permalink) Old Oct 26th, 2011, 2:06 pm Thread Starter
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Originally Posted by catilover View Post
that cooler i have on mine hamish works wonders and wasn't overly expensive for the whole setup.

what are you doing with your old spaghetti system?

todd.
Yes, I hear the i.e. Oil Coolers are much more efficient. Dont quite know what I'm doing with it yet, will compare ground clearance and rear wheel power on the dyno and decide then. Damn thing cost me $1K just to revise it for DS Swing arm, add lambda nuts and polish it up.

Hamish, ex Britten Motorcycle Company

'89 900SS now Superdue: '95 cases, close ratio box, XX9R Ohlins R&T front end, Monoblocs, Speedymoto Upper Triple, Apex Clip-ons, 5 spoke Marchesinis, Bespoke discs, Hel Lines, Carbon/Composite tank with c/f filler, carbon Supermono fairing, dual projector beam headlights, billet rearsets, carbon 955 Corsa tail, 944cc, Lightweight flywheel/Barnett clutch, Aluminium Plates, DP Cams, ported heads, 41mm split FCRs with 90mm CNC velocity stacks, 45mm Spaghetti pipes with carbon cans, Ignitech, Dyna Coils, Magnecor wires, Ohlins shock, 1000DS swingarm. Lots of Carbon and Titanium. EVERYTHING else is custom. Just about finished...


Plus
'95 900SS/SP: Bought May '11.
07 Aprilia Tuono: Sold. '06 GSX-R1000: Full Ohlins: Sold. (written off same day by MadMartin!) '03 Monster 620ie: Sold. '00 Aprilia Mille R: Sold. (Gone but not forgotten) Several 750 Pasos, ZZR-1100, VFR750 and other small Hondas etc
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post #4 of 322 (permalink) Old Oct 27th, 2011, 3:15 am
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remember mines the MOCAL oil cooler twice the size of the stock cooler.

1995 900ss, 2002 injected 900ss turbo, triumph 675 front fairing off a race bike modded for street, 916 rear tail section and a few other mods.
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post #5 of 322 (permalink) Old Nov 1st, 2011, 7:19 pm Thread Starter
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Bits coming back...

Heads and cases back from the media blaster today...

Now I just need to think about what colour to paint the motor. Open to suggestions so feel free to weigh in.
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Last edited by Kiwihame; Nov 1st, 2011 at 7:24 pm.
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post #6 of 322 (permalink) Old Nov 1st, 2011, 7:28 pm
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Quote:
Originally Posted by Kiwihame View Post
Heads and cases back from the media blaster today...

Now I just need to think about what colour to paint the motor. Open to suggestions so feel free to weigh in.
Damn! what did they blast that with? a shotgun?

Vintagedesmo.com

Link to all of my bikes and builds: *Click!*
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post #7 of 322 (permalink) Old Nov 1st, 2011, 7:47 pm Thread Starter
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Damn! what did they blast that with? a shotgun?
Walnut. I was dubious about soda, prefering something which is inert. It's a weird very dull sortof finish I know. Not like glass beads, which leave a patina, but not like soda either, which is shinier.
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post #8 of 322 (permalink) Old Nov 22nd, 2011, 4:38 pm Thread Starter
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A roomful of aftermarket goodness.

Machining of flywheel and clutch cover completed

Heads away for porting

New parts starting to come together; just waiting for a new more bits.
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post #9 of 322 (permalink) Old Jan 6th, 2012, 12:49 pm
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subscribed! loving this, I just started a conversion on the same bike, less radical and more old school....

DUCATI CAFE RACER PROJECT | Flickr - Photo Sharing!
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post #10 of 322 (permalink) Old Jan 7th, 2012, 1:02 am Thread Starter
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Thanks for the note, I'm just waiting in my ST4 oil cooler and then we can touch up the frame and start reassembling the bike! Nice work on your CR!

Hamish, ex Britten Motorcycle Company

'89 900SS now Superdue: '95 cases, close ratio box, XX9R Ohlins R&T front end, Monoblocs, Speedymoto Upper Triple, Apex Clip-ons, 5 spoke Marchesinis, Bespoke discs, Hel Lines, Carbon/Composite tank with c/f filler, carbon Supermono fairing, dual projector beam headlights, billet rearsets, carbon 955 Corsa tail, 944cc, Lightweight flywheel/Barnett clutch, Aluminium Plates, DP Cams, ported heads, 41mm split FCRs with 90mm CNC velocity stacks, 45mm Spaghetti pipes with carbon cans, Ignitech, Dyna Coils, Magnecor wires, Ohlins shock, 1000DS swingarm. Lots of Carbon and Titanium. EVERYTHING else is custom. Just about finished...


Plus
'95 900SS/SP: Bought May '11.
07 Aprilia Tuono: Sold. '06 GSX-R1000: Full Ohlins: Sold. (written off same day by MadMartin!) '03 Monster 620ie: Sold. '00 Aprilia Mille R: Sold. (Gone but not forgotten) Several 750 Pasos, ZZR-1100, VFR750 and other small Hondas etc
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