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Discussion Starter #1 (Edited)
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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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.
 

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Discussion Starter #3
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.
 

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remember mines the MOCAL oil cooler ;) twice the size of the stock cooler.
 

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Discussion Starter #5 (Edited)
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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Discussion Starter #7
Damn! what did they blast that with? a shotgun? :eek:
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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Discussion Starter #8
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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Discussion Starter #10
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!
 

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Discussion Starter #11
Here's some more pics. Motor prepped for paint.
 

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Discussion Starter #12
Primer black. Looks kinda cool eh?
 

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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.
Slightly off topic, but relevant.

I had some 1964 Lambretta parts vapour honed with amazing results. The cases look like new and no pitting at all.

Many terms are used for the process, such as vaqua blasting, vapour blasting. US friends use vapor when searching.

It uses beads, but blasted with water and possibly solvents depending on condition. The water also helps keep the part cool as blasting imparts heat.

In Sydney there are two blasters who do excellent work. Cambells Classic Motorcycles and Dave Mac. Apparently there is someone in Brisbane who also does excellent work. As a rough guide, I reckon a Duc V twin would cost about AUD$250 - 300

Richard

I suggest you check references first, as it is a specialised process.
 

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Discussion Starter #14
Good to know. FYI I WOULDN'T use walnut blasting again.

I was so careful to seal the heads and cases and yet it went *everywhere*. "Luckily" my bearings were all rooted, but had they not have been, I dont know how happy I would have been with them full of walnut. :(

Walnut IS pretty abrasive and Ducati aluminium is pretty porous so whoever did it would have to be super careful.

Your alternative sounds like it'd be worth investigating.

Cheers.
 

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looking more forward to this road trip now hamish and seeing this beasty of yours!!! lol
 

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Discussion Starter #16 (Edited)
Um, yes she used to be a smoker... rooted valve seal vs new.

And... HOLY CAMS! Heads ported, polished and painted, DP Cams installed, desmos done.

Other side... MBP valve collets for longer and more reliable valve adjustment.

Adjustable cam pulleys from a fuel-injected 900ss. (thank you Todd) Because my heads are old (they have an (19)88 stamped on them) and are actually a different casting to the later (91-98) heads, the pulleys weren't a straight bolt on fit! :confused:

The pulleys are deeper so I needed to um... modify the 'rubber' the pulley sits on, so it didnt rub. Every man should own a power sander. :p
 

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Discussion Starter #18
Okay, so after much deliberation on what colour to paint the motor I decided upon:
- Titanium Grey for the cases
- Magnesium Gold for the covers

The pics dont really do the colours justice. They are both lush and technical. I'm stoked.

Like everything the motor is an amalgam of several other bikes.
The heads and barrels are off the orginal bike, and as previously mentioned the heads have an 88 on them. The barrels came from Vee Two in Auzzie. The covers are off the original bike too, because we needed to retain the lightened and balanced crankshaft, rods and 944 pistons. Unfortunately that means I have to keep the alternator which Ducati upgraded several times from my model to the later ones. But my Ignitech Ignition, Motolectric wiring and other electrical upgrades will help offset that.

The clutch cover was machined by Rob Selby, my old mate from Britten Motor Cycle Co. He works for a company that restores exotic cars from all over the world, old Astons, Bugattis, Ferraris etc.

I wasn't fussed on keeping the original cases as they'd been poorly repaired at some stage in the past, (see earlier pics) and when we pulled the barrels off we noticed the gear faces were pretty worn. Bugger!

Muzza, my mechanic, painter, Ducati guru and all round good sort, whose workshop door I darken most Saturdays, whose tools I lose, and whose blingy Ducati parts I appropriate, reluctantly says to me...

"Well... I do have a motor in the corner over there, the heads are wrecked but its got a close ratio gearbox..."

"A CLOSE RATIO GEARBOX! WOW!!" Now, I have absolutely NO need for a close ratio gearbox, except nothing on this bike should be standard, so that fits the bill nicely. :D

As an aside I notice the new cases have 94 on one side and 95 on the other...

A mate of mine says: Your bike is like "The Borg" off Star Trek, it assimilates every other bike that comes near it. May-be.
 

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Discussion Starter #19
Howdo Hamish!

Top work! Keep those pictures coming...we likes shiney!

Cheers Pablo
Hi P.P. Nice to hear from you. Will do, another installment before I head off to work. Oil cooler solution coming soon! :)
 

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Okay, so after much deliberation on what colour to paint the motor I decided upon:
- Titanium Grey for the cases
- Magnesium Gold for the covers
Those colors look really good! I'm jealous. :D
 
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