Firstly my thanks and gratitude to the members on this forum. I'm in the middle of dismantling two 900ss engines with the aim of making one good engine. Today I finally managed to remove the nut which holds the clutch basket. No big deal in the end I had built up some fear about it for some reason. I then removed the clutch cover casing, starter motor, and whatever else I could in a logical manner. I'm now a bit stuck with how to tackle the main alternator nut which seems to have a washer bent over the nut. How do I tackle this? Also how do I lock the system so that I can undo the alternator nut?
The nut in the picture is not the alternator nut. it's the primary drive gear nut. I used an air gun and deep socket to undo mine. If you haven't got an air compressor, you will have to refit the clutch basket and lock the driven gear with a holding tool.
Or place a copper 2p piece in the gears to lock them. Just make sure it's an old copper one, test it with a magnet.
I believe you can use two of the four holes in the cog to hold it with a tool(looks like a grinder spaner) then with an impact gun undo the nut. You can make one with two nuts and bolts and two lengths of steel. I believe this is what is listed in the Haynes manual.
ck_uk Presume you are totally stripping engine. Thought I had seen somewhere if you removed cyl head / barrel / piston then reinstalled gudgeon pin and chocked with wood against casing this would hold the shaft. Please look into this, I would prefer if someone else could back this method up. Next problem is removing the primary gear - what you got in mind. Cheers Gaz
Yes, the official tool is something like that (looks like a big camshaft nut tool) and an impact driver is much easier/less likely to cause damage (to the bike and to yourself) but the biggest issue is likely to be pulling the gear off the crankshaft after you've loosened the nut as there's not much room to get a puller in there and it will be fookin' tight.
ck_uk Think removing oil pump gives better access. There seems to be some threads on "Ducati.ms" and I think a 10T hydraulic puller (£43 ebay) is the preferred tool if you don't have the Ducati or similar generic tool off ebay (£100 plus postage from USA or £145 UK). Also leaving the nut on again seems to be the go as gear apparently comes off with a bit of force. This is all theoretical on my part just research, apologies for not having done it yet. Cheers Gaz
Just found a primary gear holding tool on E bay. Search on E bay for "pt no 887130137". This guy does some really nice tools for Ducati.
Thanks for the replies, please forgive my faux pas in the first post - of course yes that pic shows the primary gear. I think I will need to get the correct tool for that job then. Anyway I spent quite a few hours today working on both engines, taking off the remaining parts that I was able to, and bagging up. I reinstalled the each engine in the frame and have managed to remove the alternator assembly on both engines. One small step for ck_uk, one giant leap etc. I'll continue one I've got the right tools. I'm doubting the suitability of my Laser tools 3-leg puller but hoping this will be up to the job when the time comes. Bedtime reading: Forum postings and Ducati Haynes manual..
You will struggle to fit any puller to it as there isn't the space to get the legs behind the gear, a 2-legged puller may just fit? but will be a struggle. I think I said this before but I see your profile says you're in Leicester? I'm not far from you and I've got the proper puller and holding tool if you want to borrow them - it's a piece of cake with the right kit plus the gear won't fly across the workshop when it lets go because the tool encloses it.
DD, At circa £150 a pop the puller is a bit expensive unless you're using it regularly, bit cheeky but any chance you could do a quick sketch with some dimensions? Have access to a lathe and mill and looks fairly straightforward job to make one Thanks Mike
Been a while since I've done any technical drawings and I don't have the time, patience, software or ability to do it on the computer but if you want, I can upload some pics from the required angles that you could make a drawing from and leave the necessary dimensions blank (X, Y etc.) and I'll send the dimensions to you?
See the pics here; https://onedrive.live.com/?cid=487d...pub=SDX.Photos&sff=1&authkey=!AJxjAuxEta2oAIs from 3 angles, if you can somehow mark or indicate what measurements you need. The actual 'circle' part that fits around the gear is 100mm od and 56mm id to give you some perspective and the extractor bolt is a 16mm x 80 ground/turned to a point. It is a snug fit on the gear though so probably quite important to not be oversized, I had to round one of the 'corners' slightly to get it to fit.
DD, That's great, did not twig it was in two parts, that simplifies the machining, I can work out the dimensions from the pics and measuring the primary gear. Thanks for taking the trouble. Mike
This is an aftermarket version, don't know if the original Ducati tool is in 2 parts or not? but, yes it greatly simplifies machining that way and it seems plenty strong enough as it is (weighs nearly 2kg). The best way to shift the gear seems to be to tighten it moderately and then give it a sharp tap on the top of the bolt to loosen the gear, I've only used it a couple of times but never needed more than a few 'applications' of the hammer...
DD, Looks a chunky beast, I've got a nice piece of billet to do it with so looking good. Pretty normal using a puller on a hub to give it a tap to free off so not unexpected, thanks again for the help. Mike
Progress report: I've now managed to split the casing on one of the engines (again my thanks to Dukedesmo). Some pics as follows. Beautiful to look at. Anyway, this was the engine I bought with a knackered 6th gear. There's some fragments of what looks like a large circlip (?) of some sort attached to the back of the sump drain plug. A couple of other pieces fell out when the casings came apart. Take a look below. What do you think's happened here? My guess is that it's a retaining ring of some sort on the gear assembly. Haven't got the manual to hand so I'm not sure. Here's the gearing, teeth knackered... and I'm guessing those cogs should be sitting firmly next to each other. The bit I'm stuck on now is how to get the final drive (?) out, there seems to be an acme-sized circlip/washer device held in place by two allen keys which seem impossible to get an allen key on without it being at an angle. Is this what's holding it in place?
