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Long time lurker but my first post on the forum so go easy on me! I've been looking for a project to keep me busy during the colder months up north, I finally stumbled upon this 1996 900SS CR a couple weekends ago. Loaded up the truck the next day and drove to Idaho to pick it up for $2k! To my surprise, the bike was actually in really nice shape all things considered. The bike is mainly stock with the exception of some Ferracci slip-ons and the wider rear wheel which should make for a great starting point for this build.

I am college student studying engineering and have access to some CNC's and thought this would be a fun way to continue learning about machining. Currently plan on swapping the front end off of a 1098 onto the bike. Not exactly sure what the plan is for wheels yet, but I know that I will be needing a new set of clamps to make this happen so those are on the to-do list. Planning on making some rear sets to get rid of the rather ugly stock pieces and will also be making some axle adjuster plates to tide me over until I swap the swingarm for an aluminum unit down the road. I will post up some unfinished CAD renderings of the one off pieces I will be making.

As far as other upgrades go, I am hoping to find a SL tail/ seat as well as some high pipes as I prefer that look. Any leads there would be much appreciated. Engine will remain mostly stock for the time being as the long term plan is to swap the engine with 1000DS/1100DS down the road when I can source an appropriate donor bike.

This will be an ongoing build but hoping to have it rideable by spring time and looking forward to putting some miles on it! I will keep this thread updated as I go but that is all for now. Also, I appreciate all help that I can get as I imagine I will have plenty of questions as I progress!
 

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Welcome to the forum, the bike looks in great shape. Do the diligence on the matters you will find mentioned here that these old girls need before spring before going mad with the 3D printer and you will be enjoying a classic. In particular, I would like to see what you develop on the chain tensioning setup, but the front end business has been sorted in better ways far more cheaply.
Even with good boots I still like the OEM rubber style rear sets, the bike vibrates a lot as all Vtwins do but I have swapped mine out with solid ones for the 20 minute sessions on track day. (Point of fact: the exhaust grinds before the stock pegs)
And if the CNC madness overtakes you, design a brilliant Escort radar detector mount,... real world problems require real world solutions.
 

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And don't forget, your front wheel and brake package will not fit the 1098 forks without some serious machining work. Most people would just use a newer wheel and caliper set on it.

Also, be aware that alot of the 1000/1100DS engines are a little narrower at the swingarm pivot pin area, and have a bushing in there instead of needle bearings.

Read, search, study and read some more on here... ;)
 

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Discussion Starter #4
The weather over the past couple weeks has been pretty incredible for late February/ early March! I've put a few hundred miles on the bike and really been enjoying it. That said, the bike needed a bit more work than I had originally thought.

The first issue that I encountered was the front fairing stay had been broken and needed some love. Thankfully a local fabricator was able to get it welded up and back in working order. The next problem I encountered was a blown voltage regulator while out riding. Checked the stator and everything checked out, replaced the regulator and everything seems to be working again.

As far as maintenance goes, tires have been replaced with Michelin Pilot Power 2CT's. New Renthal sprockets in 15/40 to give the bike a bit more pull off the bottom which will be paired to a DID ERV3 chain.

I've been making slow progress on some of the pieces that I am making for the bike. Finished up the axle adjuster plates and think they turned out pretty nice. Next on the list was replacing the stock fender with a laser cut piece that will be bent to final shape made out of 3/32" aluminum. I did this as I thought the stock piece was fairly bulky and also cracked. The new one will allow the use for some smaller turn signals and just look a bit cleaner. Finished up the fixture plate to make the clamps, hopefully knock them out this week. Still trying to track down a set of M4/M50 calipers for a decent deal to mate to the 1098 forks.

Overall, things are coming along nicely and very happy with the bike even in its current, fairly stock form. Very fun bike!
 

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Discussion Starter #5
Had a little bit of time to get some things finished up over the past couple weeks! Finished machining the triple clamps and pressed in the 900SS stem so that I could mount the 1098 forks up and sas also able to track down some Brembo M4 calipers. I still need a few parts to finish the front end including a wheel, brake rotors, and brake lines. Unfortunately, I do not have 1098 in front of me to look at so I have started to wonder what the best route to take with brake lines is.

Most of the front end is coming from a 1098 which leads me to think that 1098 brake lines should work; however, I'm wondering if I may need some custom lines. If someone could point me in the right direction, that would great!

Anyway here are a few pictures of the front end set up as things sit today!


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Depends on where you live--If your east of The Mississippi call
Spiegler
If your on the west side call Galfer---you can give them the length and the type of fittings you want and they make them a ship it
 

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Discussion Starter #7
Little bit of an update on where the project is at... the CR was sold a couple weeks ago as I was moving and figured I could find a bit nicer of a bike to start with later on. I figured it would take me awhile to find a bit before I found another 900SS; however, it did not take very long before I came across this SP. Took a drive this past weekend to check it out and shortly after it was loaded up and coming home with me.
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It's really in nice shape and has a lot of the parts on it that I had originally planned to do the original CR. It's got a 944 big bore, cams, FCR 41's, Nichol's flywheel, Staintune full spaghetti exhaust, 5 spoke Marchensini mag wheels, and a few other trick parts on it. Not totally sure what the plan is for this bike quite yet, but will be starting with giving it a good once over and some general maintenance like tires, chain and sprockets, etc. Forgot to take any good pictures of the bike before I started taking it apart but here are a few of the bike without the fairings, clutch and belt covers.
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The bike also came with a slew of other 900 spares as well including an alloy swingarm, engine parts, and some other pieces as well. Not sure on the history of these parts so any info such as brand or anything else would be much appreciated!
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That seems like a hell of a score of a sweet SS quaackattack, nicely done!
Other than perhaps a brake upgrade ( m/c and callipers) you could almost leave it alone for awhile and just enjoy it
 

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Discussion Starter #9
That seems like a hell of a score of a sweet SS quaackattack, nicely done!
Other than perhaps a brake upgrade ( m/c and callipers) you could almost leave it alone for awhile and just enjoy it
Was looking for a bit of a project but it really doesn't need anything! I have some Brembo RCS master cylinders on the shelf that I think will end up on this. After that, it will probably just be left alone and enjoyed! That said, at this point I've gathered quite a few parts that I should really start putting together another bike with... The wheels in my head are spinning again.
 

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Discussion Starter #10
Had the rear wheel off to throw a new sprocket on only to remember that Marchesini wheels don't use the stock sprockets... Anyway, got a new rear sprocket on the way. However, felt the wheel bearings and need to replace them. Does anyone know if the mag Marchesini wheels take stock sized bearings? Thanks in advance!
984595
 

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Discussion Starter #11 (Edited)
Quick update and could use a little bit of help as well... Got new Michelin 2CT's mounted up and put on the bike along with new chain and sprockets. Got everything else back together and went to take the bike for test ride to make sure everything was working properly. Unfortunately, did not even leave the driveway. Went to start the bike and the starter caught for a brief moment before it was just spinning freely and not engaging. It did not have any problems when I took it for a quick test ride when I picked the bike up, but I believe the starter sprag is in need of replacement. Does this seem correct?

From there I decided to investigate a bit, built a puller for the alternator cover and proceeded to take the flywheel assembly off and take a look at the sprag clutch. It doesn't appear to have much wear on it but also read that it doesn't take much wear before they start slipping. Anyway, any guidance is much appreciated!

Last thing, as I was pulling off the flywheel, I forgot to make note of the exact flywheel position relative to the crank... I assume the mark on the flywheel lines up directly with the key on the crank? If someone could point me in the correct direction that would be great. Thanks in advance!
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This is just something to throw out there, I have no idea about a Ducati But on BMW K models the older horizontal 3 & 4 cylinders They also use a sprag clutch. It is known with these bikes that after the break in period you ALWAYS run synthetic oil. The sprag in lubed by the engine oil --I have never seen one come apart that was running synth oil, but with Dyno oil I have seen them gum up where they no longer work & I have seen them come completely apart and break into alot of pieces--Now I understand that the Ducati is supposed to be running synthetic oil all the time--But I wonder if the same issue could be seen on the Ducati as the BMW if someone is running Dyno oil. I'm sure ducvet or Belter will have an answer to this question
 

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Discussion Starter #14
Haven’t changed the starter clutch but that is what my thought was and will be changing it while I’m in there. Hoping that will fix my issue. I’ve been reading some guys have used a KTM sprag as it is the same one as the Ducati unit? Only ask as it is less than half the cost of the Ducati part.
 

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I can’t speak for it working on a Ducati but for certain it works on an Aprilia. As the Ducati sprag is also supposed to work for the older V-twin Aprilias it would make sense for the KTM sprag to also work for a Ducati.

In the thread on the Aprilia Forum, there was some chatter that a BMW sprag also will work. I just don’t remember which model or what years.

I replaced my Aprilia sprag several years ago with the KTM sprag. Not so much because it was cheaper but because it was available.

By that I mean, I could walk into a KTM dealer and buy one at the parts counter then and there. It was a 2 week wait for the Aprilia part and similar from the local Ducati dealers.

After I replaced mine, the info about the BMW sprag appeared so again, I don’t know much more than that. Mine was done so I didn’t continue to keep up with the thread developments.
 

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Staintune header warning: the loop at the bottom is easy to crunch on speed humps. I have repaired mine twice, and last month crunched it again when I bottomed out on a causeway. It seems to be that once a year now I take it to the exhaust specialist to have it repaired and polished.
The loop hangs too low, lower than Sil Moto, etc. But they look great polished and undamaged.
 

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Discussion Starter #18
Staintune header warning: the loop at the bottom is easy to crunch on speed humps. I have repaired mine twice, and last month crunched it again when I bottomed out on a causeway. It seems to be that once a year now I take it to the exhaust specialist to have it repaired and polished.
The loop hangs too low, lower than Sil Moto, etc. But they look great polished and undamaged.
The loop hangs very low on Staintune's... This one has a bit of rash on the bottom side but is still in decent shape! Certainly a very nice exhaust and does not seem to be many of them around.
 
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