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Discussion Starter #21
I'm ditching the Kawasaki ZXR front end the bike came with when I bought it. It had bearing shells as spacers taking up the height difference between the Kawa head axle and Ducati stem. Frightening! :eek:

In anticipation I bought some 5 spoke Marchesinis which I decided to paint satin black. Which took me 1/2 a bloody day to sand and mask up. Pic is after sanding.

Muzza had decided he was going to put a Superbike front end in his 900SS so I bought his forks, triple trees and brakes. The forks have Gold Valves inside and have been reanodised Ohlins gold. Nice.

Going back to Ducati needs I need to replace my Kawasaki speedo (pictured) with a Ducati one. Because I'm using the later Marchesini wheel I need a later (ie Supersport) speedo. Anyone have one of these per chance? Heaps of mph ones on eBay for about US$100, no km/h ones. :( Muzza was very proud of the job he did sorting out the speedo gearing so the older forks with the new wheel will work with the speedo. (I made the carbon cover and my own tacho face a few years back.)

We also managed to find a set of genuine barely worn Brembo Cast Iron Rotors, (see pic) though had I just waited I could have bought these of my mate Liam from Fast Bike Gear. Ducati Brembo replica full floating cast iron discs [Rep-Brembo-49240081A] - NZ $599.00 : Fast Bike Gear
 

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I'm ditching the Kawasaki ZXR front end the bike came with when I bought it. It had bearing shells as spacers taking up the height difference between the Kawa head axle and Ducati stem. Frightening! :eek:

In anticipation I bought some 5 spoke Marchesinis which I decided to paint satin black. Which took me 1/2 a bloody day to sand and mask up. Pic is after sanding.

Muzza had decided he was going to put a Superbike front end in his 900SS so I bought his forks, triple trees and brakes. The forks have Gold Valves inside and have been reanodised Ohlins gold. Nice.

Going back to Ducati needs I need to replace my Kawasaki speedo (pictured) with a Ducati one. Because I'm using the later Marchesini wheel I need a later (ie Supersport) speedo. Anyone have one of these per chance? Heaps of mph ones on eBay for about US$100, no km/h ones. :( Muzza was very proud of the job he did sorting out the speedo gearing so the older forks with the new wheel will work with the speedo. (I made the carbon cover and my own tacho face a few years back.)

We also managed to find a set of genuine barely worn Brembo Cast Iron Rotors, (see pic) though had I just waited I could have bought these of my mate Liam from Fast Bike Gear. Ducati Brembo replica full floating cast iron discs [Rep-Brembo-49240081A] - NZ $599.00 : Fast Bike Gear
I am loving this thread, and it is inspiring me as well ! Now looking for my project bike to park next to my project car wonder which will be finished first.....
Keep the info and pics coming.
Thanks,
Darryl
 

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Discussion Starter #23
I am loving this thread, and it is inspiring me as well!
Keep the info and pics coming.
Thanks,
Darryl
Thanks Darryl. Great to hear you're inspired. It's a lot of fun.

Attached, a pic of the more golder anodised forks I previously mentioned. And the machined 600SS flywheel. It's a road bike so I don't want it to be totally lacking in low down low oomph! Just need to bolt on the (Kokusan now) ignition pick-ups and button it up. Then it can go on the frame.
 

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Discussion Starter #24
Frame...

Ahhh the frame. Two weekends ago I did a bit of um 'prep' before thinking about sanding and painting.

I've bought a Shorai Battery from Motowheels and some K&N Pod Filters for my 41mm Split FCRs from Ca-Cycleworks. The filters are HUGE so, for both reasons, the steel battery box had to go...

Pic 1: Frame prepped for surgery. You can see my offset Le mans style headlights.
Pic 2: The horn is also somewhat oversized! Would like to swap that for a Nautilus, but that would fup the whole lightness ethos. The light grey things are the coils (being swapped out for some Dyna-minis.)
Pic 3: The offending battery box. Note where someone has previously welded some stainless steel brackets onto the frame for the oil cooler. On this model SS the cooler originally sat under the headlight. Also note the 'gusset' patches over the frame rails, to stop the Kawa forks dinging in the frame.
Pic 4 and 5: Too late now!
Pic 6: After. The cross shaped aluminium bracket is for a Kawasaki Regulator/Rectifier. (Come on, you gotta let me have just one Kawa part on it!) Note, needle roller bearings already, but they need replacing.
Pic 7: After a bit of help from the power-file, all smooth. You'd never know a battery box was there.

Question now was to paint the frame black again, or maybe red???
 

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Discussion Starter #25 (Edited)
So with the motor and now everything else having been taken apart, the bike has now been down to its component pieces, which (for me at least) is an achievement, albeit unintended!

Pic 1: The wiring loom (obviously). What struck me is how many wires I will no longer be using or which will, in this upgraded itineration of the bike, be going to different places. No more Magnetti Marelli Digiplex Ignition for a start. (figured if this was rare, it might be worth putting on eBay)
Magneti Marelli digiplex 2S MED442A Electronic Ignition Ducati 900SS / Paso | eBay

Pic 2: I was thinking about replacing the plastic box and the alloy plate that the electrics sit on with another in better cond, (though realised there will be no need for it by the time I'm done). But when I saw a pic of a standard 1990 900SS (Pic 2), everything was in a different place!

The plastic box in mine is different. The alloy 'plate' with all the electric components: Digiplex ignition, fuses, starter solenoid, etc sits in the very back. My frame is waaaay different. Now I knew one of the previous owners had modified the frame. But to the extent that all the wiring would have had to have been extended so the electrics are at the back? WTF??

Really I can't imagine anyone going to that much trouble but given the changes made to the frame, may-be? Then again, maybe Ducati moved the electrics gradually forward, until with the '91-on bikes (what most of you have) when they went: "Eh Mario, shouldnt we have all the electrica closa together??" Doh!

Pic 3: Compare the standard frame (red) to mine, which I've started sanding down. Different eh? Odd.

Pic 4: Just talking about those long wires... this 'sportsfans' is the starter solenoid wiring. :eek: "It was HOW long?" And I wonder why the damn bike is forever blowing starter solenoids. My mates have all got sick of me and my ever present tool kit, doing roadside fixes, but my biggest bugbear by far has been electrics.

Last time I went out on this bike (with my best mate who is a Triumph 675 Daytona riding lawyer with no mechanical aptitude) of course, at the first gas station we came to, the starter solenoid went pop. He was very unamused; another ride ruined by my unreliable Ducati. "Dont worry, I said, I can fix this" and started walking the bike away. "Where are you going?" I pulled out my screwdriver, whipped the tail off, pulled out my wallet, stuck the screwdriver in it and held it across the solenoid terminals until the bike started. Was almost worth it for the look on his face as the sparks flew and, for all intents and purposes, I electrocuted myself. :abduct:
Answer: A safe distance from the pumps.

Anyway, enough is enough. Have also bought a Motolectric wire kit, so (fingers crossed) all issues should be solved and electrics 'sweet-as'.
 

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Discussion Starter #26
First, sorry for taking so long to get back to this. Lots of other stuff going on. e.g.

I was super keen to get the bike finished to take it to the New Zealand National Ducati Rally (Pic 1) (hoping I might win a trophy for Best Modified?) but it soon became pretty evident that getting it finished wasn’t going to happen, so I took my very tidy but relatively standard 15,000km 1994 900SS. And won the trophy for best Supersport! Go figure!! :D (Pic 3 is me getting said trophy from Ducati guru and Author Ian Falloon, having a laugh cos 1) I dont I know my own numberplate ("Does anyone own this bike?" :eek:) or 2) I couldnt believe I'd actually won something for it.

Also on show was a nice Supersport engined 999 (Pic 4), which is the next Ducati 'Special' I’m planning. They didn't have a trophy for Best Modified. :p

Riding the standard Supersport highlights the difference between this and the modifed bike, even in its old, (pre this rebuild) form. The standard bike is like a soft pudding to ride, comfy and sweet; a really great all rounder. Also interesting how it lacks turn in with the too high a profile front tyre.
 

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Discussion Starter #27
Back to the thread...

Okay, so with everything stripped of the frame, I could get a good look at it.

The '89-90 frame from the "Nuova 900ss" is very different to the that on the 91-98 bikes that most of you own. It (and the swingarm) was made by Verlicchi, has a different steering head angle, the cross tubes on the trellis frame are quite different. That's definitely a reason for keeping it.

Mine has also been 'modified'. In New Zealand this is now a big 'no no' but it’s got a VIN plate so let’s stick with that. Pic 3 FYI is an original '90 frame, with a MHR frame, for scale. :eek:

Firstly, I note my frame has steel patches welded to the front tubes on either side of the steering head. (Pic 4) More likely to prevent the Kawasaki ZXR USD forks that it came with from denting the frame, rather than bracing for crack protection.

Given the ZXR forks, I suspect this bike may have started life as a race-bike. These early Supersports had RWU forks and I’m told it wasn’t uncommon for racers to swap them for Kawa ZXR400 ones.

The rest of the frame is a bit more of a mystery.
- The middle has been cut and shut.
- The tank mount has been modified.
- The frame mount seems like it’s been fabricated.
- There's a weird sticky up seat mount thing, which the carbon fibre covered foam seat base attaches to.
- The footpeg hangers on this model were steel loops, now gone.
- The curved bits at the rear (Pic 5) seem a very strange and expensive solution to spacing muffler hangers when alloy ones would have been far easier to make.

Someone has clearly gone to a lot of trouble. Hmmmmm:think:.

Anyway, all sanded back now and ready for paint.(?)
 

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Discussion Starter #28
Next we wanted to have a quick look at everything, just from a packaging perspective. i.e.:

- How do the carbs and filters fit? (and are all the screws within reach when I tighten it all up)
- Where will the battery go?
- What are we going to do re mounting the oil cooler? The silver thing holding it in the mounts is the old gear linkage rod. (Not only are us Kiwis famous for our #8 wire mentality we're also into our recycling.)
- Where are we going to put the Ignitech and coils?

Wow! It actually looks like a motorbike, sort of...
 

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Discussion Starter #29 (Edited)
The bottleneck!

Because I’m now using a Shorai Battery, we need to find somewhere to put it! Prior packaging would suggest (the battery on the '89 sat directly behind the steering head remember) that there should still be enough room, even with the (once upon a time installed) airbox, or the (now installed) monstrous K&N filters. And there is! Choice! :)

With the intention of making a battery box out of aluminium I made a cardboard template. (Pics 1 and 2) Well pleased with myself, I remarked to Murray, Look Muzza, a battery box! What do you think?" In his typically laconic style he replies "It'll be alright... until it rains...."

The other thing we need is somewhere to put the Ignitek programmable ignition module and the coils. Re the coils, I was lucky enough to purchase some near new Dyna Minis. The most logical location for the coils is away from the Ignitek and in the airstream, not least because 3Ohm Coils run quite hot. There is a bracket on the front lower frame rail from which a crude stay used to secure the fairing. Add another and it’d be a perfect. (Another welding job for Muzza.)
I notice this is where Bimota mount the coils on their latest bikes.

As for the Ignitek, cue another cardboard template. (Pic 3) =) This will be made into a plate which will sit between and above the cylinder heads. On one there will be a tab to which the starter solenoid will mount, on the other side the ignition barrel.
 

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Discussion Starter #30
Nek Minute

Like i said, other stuff gets in the way...

It's been 20 years since I was involved in racing (for Britten) and then I never raced 'the' bike, but Muzza, bless him, is on the BEARS committee and so, the next day, I had the opportunity to rent and race his BEARS Bike. (Pic 1, - I said these were my training wheels on Facebook - (and many a true word said in jest!)

I’m sure you all know that BEARS stands for (B)ritish (E)uropean (A)merican (R)acing (S)eries). Muzza has a couple of bikes for those who think they might want to go racing. So I grabbed one. A bloody good day all round, I didn't entirely disgrace myself, and yes, I’ve been bitten by the bug. It’s nice to be able to ride flat out without fear of falling foul of the law or our earthquake ravaged roads. (Pics 3 and 4 are my good self.)

In the meantime... the courier has been dropping more parts at my door. This is as close as I get to Christmas (I know I sound like a sad old prick, but I mean that in a good way!
 

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looking really good hamish!!! coming a long nicely :)

just a question, that plate in pic 3, are the coil's etc going on top or underneath it?? isn't that the area where the base of the gas tank sits with the fuel lines etc coming out before going up?? your still running the mid 90's tank yeah??

i am looking at moving my battery down on the side like how the 916/748 etc have them, most likely the right side to balance out the weight with the turbo.

we are moving house and once here i am stripping mine down to the frame and doing a full rewire and fuel line set up :)
 

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Discussion Starter #32 (Edited)
Nek Minute

Like i said, other stuff gets in the way...

It's been 20 years since I was involved in racing (for Britten) and then I never raced 'the' bike, but Muzza, bless him, is on the BEARS committee and so, the next day, I had the opportunity to rent and race his BEARS Bike. (Pic 1, - I said these were my training wheels on Facebook - (and many a true word said in jest!)

I’m sure you all know that BEARS stands for (B)ritish (E)uropean (A)merican (R)acing (S)eries). Muzza has a couple of bikes for those who think they might want to go racing. So I grabbed one. A bloody good day all round, I didn't entirely disgrace myself, and yes, I’ve been bitten by the bug. It’s nice to be able to ride flat out without fear of falling foul of the law or our earthquake ravaged roads. (Pics 3 and 4 are my good self.)

In the meantime... the courier has been dropping more parts at my door. This is as close as I get to Christmas (I know I sound like a sad old prick, but I mean that in a good way!
 

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Because I’m now using a Shorai Battery, we need to find somewhere to put it! Prior packaging would suggest (the battery on the '89 sat directly behind the steering head remember) that there should still be enough room, even with the (once upon a time installed) airbox, or the (now installed) monstrous K&N filters. And there is! Choice! :)

With the intention of making a battery box out of aluminium I made a cardboard template. (Pics 1 and 2) Well pleased with myself, I remarked to Murray, Look Muzza, a battery box! What do you think?" In his typically laconic style he replies "It'll be alright... until it rains...."

The other thing we need is somewhere to put the Ignitek programmable ignition module and the coils. Re the coils, I was lucky enough to purchase some near new Dyna Minis. The most logical location for the coils is away from the Ignitek and in the airstream, not least because 3Ohm Coils run quite hot. There is a bracket on the front lower frame rail from which a crude stay used to secure the fairing. Add another and it’d be a perfect. (Another welding job for Muzza.)
I notice this is where Bimota mount the coils on their latest bikes.

As for the Ignitek, cue another cardboard template. (Pic 3) =) This will be made into a plate which will sit between and above the cylinder heads. On one there will be a tab to which the starter solenoid will mount, on the other side the ignition barrel.
If you wanted to commit to the much smaller A123 type of battery, you could save a lot of space.
 

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Discussion Starter #34 (Edited)
Just a question, that plate in pic 3, are the coil's etc going on top or underneath it?? isn't that the area where the base of the gas tank sits with the fuel lines etc coming out before going up?? your still running the mid 90's tank yeah??
The coils will hang off the front lower frame rail (there's a bracket there I can use) well away from the Ignitech and in the airstream. Yes I'm still using the mid 90s tank and yes, there's no room for the coils under there anyway, with the fuel lines and the Ignitech. The Ignitech doesnt take up much space.

If you wanted to commit to the much smaller A123 type of battery, you could save a lot of space.
I checked out the smaller A123 (Ballistic) 4 cell battery, but ended up going with the bigger of the 2 Shorai options, mainly on the basis of this bike always having been hard to start. It has a low voltage alternator and high comp pistons, so it was just for extra insurance.
 

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I think you'll like the Shorai . That's what I have and it cranks my 944 fine . My bike still has stock cams and the long manifolds so it has over 205 psi cranking compression . With the longer duration cams you have and the short manifolds it should crank easily with that battery . I see you listed DP cams . Are you using those or the V2's you got from me ?

Ron
 

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Discussion Starter #36
I see you listed DP cams . Are you using those or the V2's you got from me ?

Ron
Hi Ron

Thanks for the add(s) on FB.

Have just had the VeeTwo cams repaired, and the man who repaired them had repaired several sets, and wasn't overly complimentary as to Vee Two quality. So I though best not to risk them in my shiny new motor, seeing as I found some new DPs.

Am gonna buy/build a race bike so will use the Vee Two cams in that and check for wear often.

Hope all is well
H.
 

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Hi Hamish
looks like you got some of the fine winter weather for the BEARS day. I'm only a couple of blocks from Ruapuna so heard the racket!
Your build looks fantastic cant wait to see it running.
BTW where was the Ducati event promoted? i would have got the Ds out for a run up to Hanmer if i'd known about it!

Cheers

Rob
 

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Discussion Starter #38
Hi Hamish
looks like you got some of the fine winter weather for the BEARS day. I'm only a couple of blocks from Ruapuna so heard the racket!
Your build looks fantastic cant wait to see it running.
BTW where was the Ducati event promoted? i would have got the Ds out for a run up to Hanmer if i'd known about it!
Cheers
Rob
Hi Rob, I cant wait till its finished either! =) The DOCNZ was probably only promoted to members. =/ Casbolts (the local Ducati shop) don't seem to do database marketing (muppets) so it's little wonder no-one knows about it! Cheers, Hamish
 

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Discussion Starter #39 (Edited)
There's always minor stuff to do, like bolting on the carbon belt covers. These ones proudly proclaim "d'Italia disegno". I wonder if the guy who "designed" them even saw what they were meant to go on; the fit is that bad! (Let's get the file out!! "Limato di Nuova Zelanda!") But still, they look the part.

Nice view of my machined clutch cover. Pic 3, you can see the tab/lug where the coils will mount. Just need to weld on another.
 

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Discussion Starter #40
Somewhere down the track I decided that it would be a good idea to make the plate for the electrics, the battery box and various other parts out of carbon fibre, so down to the composite shop I went and picked up a metre of 2kTwill.

Carbon fibre is evil stuff! It pulls, bruises, catches and moves and is generally difficult to work with. Plus it gets in your skin!

I made a battery box mould and a electric plate mould out of plastic.

And also did some general tidying up e.g. nice heat shrunk wiring. Of course then the brass screw-in washer wouldn’t fit over the top. :mad:
 

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