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748 Engine Refresh Thread
I figured I should put some of this stuff into one thread instead of posting a bunch of different ones.
Flying Bulldog helped me wrestle the bike off the engine and then lift the engine onto the jack.
No big surprises taking parts off the bike. A couple of dumb mistakes, including spilling an awful lot of coolant, but no major stumbling blocks.
Next up:
1. Remove the heads and replace the head gaskets
2. Remove the cylinders and replace the base gaskets
3. Replace the belts
4. Remove the stickers (Flying Bulldog insisted)
5. Reassemble.
ape
Flying Bulldog helped me wrestle the bike off the engine and then lift the engine onto the jack.
No big surprises taking parts off the bike. A couple of dumb mistakes, including spilling an awful lot of coolant, but no major stumbling blocks.
Next up:
1. Remove the heads and replace the head gaskets
2. Remove the cylinders and replace the base gaskets
3. Replace the belts
4. Remove the stickers (Flying Bulldog insisted)
5. Reassemble.
ape
Attachments
21 - 40 of 61 Posts
Removed Pulleys - Waiting for Tool to Remove Head Bolts
I'm still not certain that I needed the pulley locking tools since I had aligned the crank and pulleys according to the Haynes manual's instructions, but I decided to play it safe.
They arrived, I installed them, and then I removed the tensioner pulley, belt, idle pulley, tensioner pullley bolt, and the backing plate for each cylinder.
When I tried to remove the head bolts with the special tool I bought for that purpose, it turned out that I had the 14mm version instead of the 15mm version.
I tried using a 15mm spanner, but it didn't work too well. You can get it on there, but after you turn it, it gets stuck.
So I decided to order the CORRECT wrench this time. I'll hold on to the 14mm wrench in case I buy an 848 some day. Sheesh.
I ordered the correct wrench from: MotoReva - Ducati Tools and Supplies
I found them via this post: http://www.ducati.ms/forums/56-superbikes/64542-tools-remove-heads-749-a.html
Pics below.
ape
I'm still not certain that I needed the pulley locking tools since I had aligned the crank and pulleys according to the Haynes manual's instructions, but I decided to play it safe.
They arrived, I installed them, and then I removed the tensioner pulley, belt, idle pulley, tensioner pullley bolt, and the backing plate for each cylinder.
When I tried to remove the head bolts with the special tool I bought for that purpose, it turned out that I had the 14mm version instead of the 15mm version.
I tried using a 15mm spanner, but it didn't work too well. You can get it on there, but after you turn it, it gets stuck.
So I decided to order the CORRECT wrench this time. I'll hold on to the 14mm wrench in case I buy an 848 some day. Sheesh.
I ordered the correct wrench from: MotoReva - Ducati Tools and Supplies
I found them via this post: http://www.ducati.ms/forums/56-superbikes/64542-tools-remove-heads-749-a.html
Pics below.
ape
Attachments
I was browsing through Sears the other day when an idea hit me. I just happen to be in the wrenches aisle and the idea popped into my head to use a 15mm boxed end wrench as my head bolt removal/installer tool. There's a twist to this though. You know what the special Ducati tool looks like right? Well how can one imitate this? Easy! Use a torch to bend the ends of the 15mm boxed end wrench 90 degrees. You could either weld a socket onto one end so you can use a 1/2" drive or simply place an allen head socket into it so you still have a 1/2" drive. Simple! Funny how things pop into your head like this
Not a bad idea. So you're saying you'd wind up with a 15 mm wrench that's shaped like a Z? That would address part of the problem, but you'd still have the problem of fitting the end around the bolt. There's very little room between the edge of the bolt and the head casing. :-/I was browsing through Sears the other day when an idea hit me. I just happen to be in the wrenches aisle and the idea popped into my head to use a 15mm boxed end wrench as my head bolt removal/installer tool. There's a twist to this though. You know what the special Ducati tool looks like right? Well how can one imitate this? Easy! Use a torch to bend the ends of the 15mm boxed end wrench 90 degrees. You could either weld a socket onto one end so you can use a 1/2" drive or simply place an allen head socket into it so you still have a 1/2" drive. Simple! Funny how things pop into your head like this
ape
No it would end up looking like a C, just like the Ducati special tool looks like. The problem of fitting the end around the bolt is a simple matter of a dremel and a grinding wheel to grind down some of the material on the end so the wrench will fit. I'm currently having to do this on the wrench I bought
You want the two ends to be directly inline. Thus the total arm is 0. If they are out of line then there will be an arm component and you'll have to adjust the torque
Thanks, Ron, for the service manual. I also bought one to accompany my Haynes manual. It helps to have both.
So here's the latest...
1. Loosened the head bolts just fine with a 15mm spanner wrench. Just had to make sure my spanner was aligned, then hit it with a hammer a few times to work the nut loose.
2. After I removed the four nuts from the vertical head, I tried to lift the head off the cylinder, but instead the cylinder came off WITH the head. I took some pictures of the gasket and mating surfaces. The gasket had a kink in it, but it's hard to see in the pictures.
3. The correct head bolt tool finally arrived, the 15mm instead of the 14mm, so I tried it on the horizontal head, which didn't have a leak. When I removed the bolts, that head stayed in place, even though it had some force applied to it from leaning against a block of wood.
So I lubed the bolts, then torqued the nuts in a cross pattern first to 15 Nm, then to 30Nm, and finally to 48Nm. The little wrench worked great.
I have a new base gasket on order. The gasket sealant is already here. As soon as the gasket arrives, I'll begin reassembly. The Ducati service manual has a handy-dandy flowchart so I don't forget something.
I'll also pay close attention to the vertical exhaust valve cover, in case that was the problem. I suspect it was the base cylinder gasket, but I'll still check both.
Pics attached.
ape
So here's the latest...
1. Loosened the head bolts just fine with a 15mm spanner wrench. Just had to make sure my spanner was aligned, then hit it with a hammer a few times to work the nut loose.
2. After I removed the four nuts from the vertical head, I tried to lift the head off the cylinder, but instead the cylinder came off WITH the head. I took some pictures of the gasket and mating surfaces. The gasket had a kink in it, but it's hard to see in the pictures.
3. The correct head bolt tool finally arrived, the 15mm instead of the 14mm, so I tried it on the horizontal head, which didn't have a leak. When I removed the bolts, that head stayed in place, even though it had some force applied to it from leaning against a block of wood.
So I lubed the bolts, then torqued the nuts in a cross pattern first to 15 Nm, then to 30Nm, and finally to 48Nm. The little wrench worked great.
I have a new base gasket on order. The gasket sealant is already here. As soon as the gasket arrives, I'll begin reassembly. The Ducati service manual has a handy-dandy flowchart so I don't forget something.
I'll also pay close attention to the vertical exhaust valve cover, in case that was the problem. I suspect it was the base cylinder gasket, but I'll still check both.
Pics attached.
ape
Attachments
Where was I?
Near the end of last winter my progress on the engine refresh of my 01 748S stalled on account of I was seized by an episode of moto madness (see below).
Fall has arrived, I have taken the cover off the bike, and I have noticed two connectors that don't seem to connect to anything.
The first connector appears in the first three pics. The second connector is in the last two.
Can anyone offer a clue?
Thanks,
ape
Moto Madness, if you must know:
- Put Harley Softail Heritage up for sale
- Bought used R1200GS
- Sold used R1200GS
- Bought 04 Honda XR650L
- Bought 10 Kawasaki 250 dual terrain (for Missus)
- Bought K1600GT
- Bought 08 Harley Softail Custom
- Sold K1600GT
- Bought R1200RT
Near the end of last winter my progress on the engine refresh of my 01 748S stalled on account of I was seized by an episode of moto madness (see below).
Fall has arrived, I have taken the cover off the bike, and I have noticed two connectors that don't seem to connect to anything.
The first connector appears in the first three pics. The second connector is in the last two.
Can anyone offer a clue?
Thanks,
ape
Moto Madness, if you must know:
- Put Harley Softail Heritage up for sale
- Bought used R1200GS
- Sold used R1200GS
- Bought 04 Honda XR650L
- Bought 10 Kawasaki 250 dual terrain (for Missus)
- Bought K1600GT
- Bought 08 Harley Softail Custom
- Sold K1600GT
- Bought R1200RT
Attachments
21 - 40 of 61 Posts
