Duke 916 strip down and re-build...

No posts of the stripping all of it down as i just hammered out as much i could today...

Stripped out all of the front and back looms, radiator,chain,subframe,front end etc...

Drained the oil and water....

Noticed a few bits of metal shavings on the sump plug, so thats another thing to have a look at....

Most of the wiring has rubbed like fuck on the frame causing a bit of rusting

Heres a pic of todays efforts... (i will be taking a lot more pictures now, esp of the rebuild and engine out.... and belt changes)

Coolant out...


urgh..


Going to have to heat these up to try and get them off... if not they will be left and polished on the engine


rusty...


Mate said this looks very good for a 48k duke....




New seals needed...

Bit of spit and polish needed lol !


This was a new (second hand) shock on there to replace a busted one back last year.... needs a bit of referb !


The Engine is held in place with three bolts, one being through the swingarm.So if you ever want to remove the swing arm, the engine has to come out or be swung forward....
This is the pita bolt in question which is stuck..




Nice bit of crap build up




So..New bits and bobs needed to wack the feck out of the swingarm bolt needed.....

Nice job on taking the bike apart. I've done that to mine two years in a row. I destroyed the threads on my first swing arm bolt upon removing it... now I use it as a pusher between the hammer and the new bolt...

BTW, removing the engine is the best way to clean it, this is how I do mine:



Good luck with it! By the time you're done, you'll be so much happier with the bike and it'll never be neglected again. One more thing, you'll find yourself replacing more than what you thought. It's all apart so why not right? :think:

Looking good there...well relatively speaking lol. Getting it torn down is the easy bit. I did this to my 748 the day I picked it up (1500k but ridden hard and put away wet at the track). Just be patience and take you're time. I would suggest powder coating the frame, much more durable than paint and won't rub through.

Just as an example, here's mine thus far after about 6 months of work (and too much money lol). I had my frame powder coated as well as the triples.




Make sure you label EVERYTHING! Especially all the electrical connectors. I'm not running into some trouble remembering what goes where as there are several item that use the same style connector on the bike. I'll prob have to steal my buddies 748 for reference lol. Good luck with the project!