ducts 916 rebuild

Watson84

Watson84

New member
So finally got the bike out of the shed at the weekend to try and drop out the engine which was a real pain in the ass couldn't get the swing arm engine pivotal out end up giving up :mad:will give it another go tomorrow will post some picks of progress when i get my computer back misseshas just now hopefully once i the engine out i can make some progress jobs too
strip engine down
small weld on frame (anyone around my way who can do this i don't have a welder )
find bolt for rear of fuel tank
indicators to get
new tyres
respray all of bike got some ideas in mind something different custom paint job if i can afford it
so here's hoping it done before all the nice weather disappears:cool:
 
They can be a @@@@@@@ to get out those swingarm pivots, good chance you will have to distroy it.
 
Right haven't posted progress on my bike for what seems like a decade. so have started a parts list seems to be longer than when I started. been slowly picking bits up off the bay of doom! dose any one have a yellow relay kicking about ? Any will pull my shed apart this week go through parts I have and maybe get the engine out of the frame or it could be more of this :banghead: against the wall will post pics of the bike and the parts I have will post my parts list maybe some one has spares or doubles of something I need need to get bike back on road so I can get out and about ,go to some ride outs and meets :flash:
 
Get an SDS drill with a reciprocating function, get a tool to get a good purchase on the end of the engine/frame bolt and hammer it out......I've heard it generally works.....and plenty of lube....
 
Watson84 said:
So finally got the bike out of the shed at the weekend to try and drop out the engine which was a real pain in the ass couldn't get the swing arm engine pivotal out end up giving up :mad:will give it another go tomorrow will post some picks of progress when i get my computer back misseshas just now hopefully once i the engine out i can make some progress jobs too
strip engine down
small weld on frame (anyone around my way who can do this i don't have a welder )
find bolt for rear of fuel tank
indicators to get
new tyres
respray all of bike got some ideas in mind something different custom paint job if i can afford it
so here's hoping it done before all the nice weather disappears:cool:
Click to expand...

Try removing the pinch bolts fully first before taking out the swing arm pin, could weld your frame but maybe a wee bit out of the way for you.
 
Not been on here for over a year and the bike still no further forward after moving of jobs and other family commitments.i did manage to get the cover off her still looks great, even if she is still in bits.I was hoping some one might want to help me out or point me int the right direction of a Mechanic who would be willing to rebuild my engine. I was going to do this myself but not sure it the best idea for my first venture into an engine should I fix the one I have or replace not sure what damage was done to the insides of the engine crank cases ad cracked well when say cracked there is a huge hole in the bottom. But I did get some crank cases when I bought the bike or should I look out for a complete engine and just keep the other for parts if any of it is useable. Anyway need to have it ready for next June when I get married hoping to be able to ride it to the big day stay in at Andrews so if any one know of some one who could help or garage that would take the engine repair on . Thanks if I get it on the road will defo be more active with the club ride outs and events can't wait even a track night would be great :D
 
any body got any idea for getting the swing arm bolt out out wd40 has work a weebit but it has decided to get stuck half way through the engine casings this is holding me up so i can have frame repaired and possible thinking of sending engine away to be rebuilt any ideas on the colour i should do the frame original gold or red maybe even black:dunno: any one no a good painter for the painting and somewhere to get it sandblasted/stripped cheers
 
You could have a word with Abernethy Motorcycles, not far from you, they aren't Ducati specialists but handle all makes of modern and classic bikes, they do blasting and polishing too. As for paint you could try G's custom paints in Blairgowrie, Gavin did an excellent paint job for me on my Buell. Best of luck with everything and keep us posted with your progress.
 
The factory tool is just a big aluminium drift. So, just get yourself an aluminium drift and keep on hitting it. You will likely need to dress both ends before the job is done as you really need to get medeival on it and the aluminium will mushroom.
 
Had a similar problem on my wee BMW a few years back. The swingarm pivot seized solid. Took two evenings with a steel drift, a lump hammer, an angle-grinder to cut the ends of the drift square, and a surprisingly varied selection of swearwords to get it shifted.
 
Had another go at the swing arm it moved a wee bit not much then I got side tracked on ebay and bought a carbon rear hugger and some t shirts from the club shop and found a ohlins shock that looks interesting tempting any one have thoughts on these how much better are theses if at all the the Showa one looking forward to getting the engine out cos a soon as it out the frame can go away to be welded by a kind gent from on here be not to far from where mum stays so wee trip to see her drop of the frame once that is done will strip the engine down happy days so some more swearing and hitting that swing arm till it falls out hope fully not too long
 
So not updated this in a while so finally got the engine out almost went through 10 hack saw blades cutting it out but done now. so next thing to do is clean the engine and take the heads off then take the cases apart and see what damage has been done. also need to go through my boxes of bits as I have doubles of bits and bobs to raise some more cash to spend on other bits needed. hopefully get some of that done this week and get the front forks off too get them ready to be referbed or should I do this myself? Also then I can get the frame welded and the journey to get it back on the road will be a bit closer but at the rate it is going at will be another two years before its finished fingers crossed
 
this project went from having what looked like an almost complete bike to finding out that alot of parts were no good and had to replace alot of parts.
piece i have aquired so far
complete 916 engine
frame
wiring loom by tech guru Derek
lots of bolts
fairing kit from pro bolt
mono seat pad
not sure they are termingoni carbon fiber exhausts
handle bar clip ons
fairing set
steering dampener
front discs
rear disc
carbon fiber rear hugger
new battery
swing arm bolt
so all in all it has cost me way more than buying a bike outright but think half the fun has been looking for bits and looking for bargains couple of parts i am still looking for are an ohlins rear shock seen one on ebay but with xmas round the corner think i might have to wait for this also the mid link pipe which i had asked about.thereis one on ebay is not cheap but will keep my eyes out for one next year have standard ones to fit any way so will post some pics of the bike at weekend once parts arrive and i have engine running going to get it running then strip back again double check everything and put back together ready for the road
 
so parts arrived to day and i have missed the seal/shim for the neutral switch also the oil pressure switch seal so will need to pick them up :comp2: while i am talking about them whats the best socket to use on them to archive the correct torque level on these what should i use a crowfoot ? advice please no pics cos not had any thing to do on it yet here's a pic i took a wee while ago this was a cheapish set of fairing i got but have some originals that i want to get sprayed red or maybe yellow are maybe something differentView attachment 10802
 
These are both pretty low torque fittings. I can't remember the values off the top of my head but have never used a torque wrench on them myself, just nipped them up hand tight amd a little bit more.
 
So got everything together routed the loom and fitted the battery and put oil, coolant bought petrol was excited to start the bike for the first time when the to turn on and nothing no lights not even a beep out if the horn checked connections seem to be ok so tomorrow will be fun stripping down and starting again :confused::hissy:
 
I'm disappointed to hear that Jamie as I'm pretty sure the loom is ok. There are a few simple checks you can do before pulling things to bits.
When you connect the battery, Fuse 1, the one to the front of the bike, should be live even with the ignition off. Check that there is 12V at both sides of the fuse with a meter or preferably a test lamp. If that's ok go to the main relay down beside the battery. The white wire comes from Fuse 1 and also should have 12V on it, as should the white wire to the ignition switch. When the switch is turned to ON the yellow/black wire from it should get 12V which goes to pin 86 of the main relay, turning the relay and hence the rest of the bike ON. If it gets 12V to the yellow/black wire and isn't switching make sure that the relay pin 85 (black wire) is connected to earth.
It's my guess that the relay is either faulty or not being switched.
If you get stuck give me a shout and I'll come over.
 
Ycheers for the advice I am also sure the loom is ok as I did have it mocked up and lights and everything else seemed to be working I was thinking that it was a relay that has gone check the fuses and all look good didn't get time to look at it today so hoping get some time on it during the week after work hopefully once have had time to check in more detail it will become obvious to what went wrong thanks again for giving us a few places to look at first before I take the loom off the bike I know it was all working before I rerouted it a round the engine and frame thanks for offering to come have a look Derek might have to hold you to that if all else fails
 
How are your earths? On a new painted bike they might be covered in paint. Also have you got the earth strap to the engine from the battery in place.
 
So figured out what went wrong with the loom think earth cable was not right sorted and one off the relays was not clicked in right too so sorted that and get a bit excited and thought this could be it plugged everything got the key crossed my fingers and turned it on and lights, indicators work,horn neutral light came on and the petrol light and final the oil light needs topped up so did that then went to get the petrol can felt like Christmas Day finally get to turn the old girl over hear the sweet roar of the engine so poured some petrol in the tank light went out happy days I thought went to get the two boys out of the house to do the big turn on but before the I turned the key back on and get ready to hit the old girl over I smell fuel so turn it off and have a look better to be safe than sorry take the tank off and sure enough a leak gutted so took the pump out. Thought maybe I nicked the o'ring when I fitted it but no it looks fine so cleaned it and refitted the pump tightened up the bolts checked it again same still leaking so any way anyone know someone who has the know how to fix this on closer inspection I think the bottom of the tank is been dented slightly as the edge of the pump rim doesn't sit flush all the way round on the tank it dose look like the previous owner of the tank may have used some kind of sticky rubbery gasket kind of sealant would rather have it fixed properly was going to post pic but doing this on phone and can't seem to get it to work.[/ATTACH]
 
Last edited:
Check how you have the 'o'ring positioned on the pump base. Going from memory it sits on a small edge half way down the rim from the flange and not right in the corner of the flange. Once you pull it to bits you should get what I mean!
 
It looks like the flange isn't fully home to me. Its very easy to get it wrong and nip the O-ring. As SB says it sits on a lip and not that bottom of the spigot.

This one is from an ST but the fitting is the same. Note where the green O-ring sits.
-WFE0OegKXmZhnBODmvPD1w8V3JB7djE_btVPh0TtdxN9ybADRrZHp037cvlyD_hsO0u7y5L7Gi0jKGR6azTZ-ZmqIzS4lNbPYmqQm-sxvmK3v4ducURnVK8AgFU9Z0Y1vXFS-wO0sAD9KpYXqobv5PwJ9VUwwOcP85Xg5IS2WJaXci_ZbGBQ5z4WrjXBO0-qxwAHcCVphx9ideN6QVUHMxvGs4uQEZRuLysXl8PPAQfdoV1PNUbo8gyc4dB52ltA04tlEhy5sovi0X4AM73B7LRLDClVoPh6LMvAbcro19s8P1-EmJPnW3Qmo5bsZGkDQAwOqOiOrsNJoQL5r6XHJSAamJfHxMSGL_IpEM8Qx6TU3a6WNXegvRqlCd0Qlt8r9CSVgI5GBuUYC1R5EbqlodSKq7ToMLjUmdlM6Jmd3Od0qekuV--VZNFyFZwoXKKEgjggjRG1nBU4ncSEjc3BHhOtrUtCtSR4ZJXPzETGHdI1SL6ipNbHez7r197blKO3mzTSis9dZrQR7vF0zavJb_za8IIqSlVCg1hvkZv2tswYEe4UoH2yIX3FQ9_GyQAOnFA5A=w497-h388-no
 
Thanks for the advice I have had it off and made sure it was sitting correctly looks just like the one in Derek's pic maybe it is movin when I am pushing the pump back in to the fuel tank but on taking it back out it it still sitting in the right place on the pump not had time to look at it again yet will hopefully get Time tomorrow take some pics with the pump out of the tank as I think the pump is not sitting flush and that's why it's not sealing properly might have to buy another o ring but their are no nicks in it and it was new when i fitted it will post some pics of the tank hopefully it is some thing simple
 
So this thread had somewhat died it’s been 4 years since I touched the bike. I have been watching some restoration videos and got some inspiration to get back to it, had a lot on with work over the past few years but last night ordered some things I needed and with some spare time during the day, my work has changed the shift patterns so working late at night now. Need to sort out garage a bit and get back out there sorting the bike out. Think I was a bit put off with the fuel pump issues watched a video on YouTube about the same problem so have some optimism about getting it done now. also I have a question there is light rust inside The tank what’s the best solution for this and if using a cleaner what would people recommend for doing this would like to sort this out so I can at least turn the bike over then probably need to go over bike again from the start change oil, air filter fork oil and seals change brake pads and fluids also any suggestions for where to get the fairing and tank painted thanks for the helps in advance
 
Thanks Derek for the pm was wondering if anyone knows the best place to buy parts from during the lockdown how’s sending out pet quickly these days thanks
 
You must log in or register to reply here.
Back
Top Bottom