Two questions for the brains trust: Am I missing any parts here? Things look very chaotic (ignoring the water pump cover) and the wiring looks very disorganized. Second question, is there supposed to be a bolt or screw in this hole? I couldn't find this exact drawing in the parts cattle dog:
This was easier than I thought. Nosecone off, remove the headlight assembly, remove the horn, undo the speedo cable, then three small (hidden) nuts to remove the clock assembly. Then just yank the bulb right out of the temperature gauge. Some bad news though, the headlight assembly is cracked quite badly. I'll keep an eye out on eBay but they tend to be quite expensive now. I guess I could epoxy it? It's cracked (more or less) down the middle, between the two glass lenses. If you look at the picture above, is the blank paint around the "edges" of the headlights normal?
The matt black paint around the lights tend to wear off with time. It’s an easy fix, though, if you like careful jobs, like on models. Plus undoing the entire headlight assembly will allow you to clean the lenses, which go white inside due to some sort of weird build chemical reaction, giving your bike the stare of a dead fish… This was on my 916 Biposto, at 45.000 km.
Thanks Guillaume. I have bad news to report.. when re-installing the monoposto tail last night, I had to move the petrol tank to the side in order to find a washer I had dropped. When I started the bike this morning, it is absolutely pissing fuel out from the bottom of the tank. I'm not sure if it's the inlet or the outlet port, but it is very clearly pressurized fuel leaving the tank at a high rate of speed. Can anyone spot anything wrong with this setup? I did add regular (not Oetiker) hose clamps to both the inlet and outlet hoses after taking this picture, but besides that it is 100% how I received the bike. Note that one of the hoses from the "Y" fitting has come loose, and that the small metal port on the base of the tank (breather valve?) has nothing connected to it. I'll look in the service manual now.
You really need to loose the plastic fittings, they do not age well at all… Go for the stainless ones and never look back. And don’t forget the « rings » that keep the hoses tightly connected to the fittings. There’s some pressure in there.
You were right of course, the plastic had was quite brittle and one of them snapped off when I was trying to gently remove it. I will go with this kit for stainless replacements, but I'm confused about one thing. How do I get the old fittings off? When I try and pull them out, it's almost as if there's another hose within the existing hose. It's hard to take a picture of, but this is what I mean: You can't really tell from the photo but I'm pushing quite hard in order to move the "outer" hose down off the fitting, and yet I can still see another hose inside.
I emailed the guys at Gotham Cycles to ask about the fittings and this is what they said: Because my plastic disconnects had metal tangs and an engraved CPC logo, I assumed they were aftermarket. I guess I was wrong! I'll order new fuel lines, new metal disconnects, and be done.
I am sorry, but I have to disagree with what Gotham told you. You definitely do not need to change the entire fuel lines. I have done it on my 998 Matrix without any issues. Yes, the 998 fuels lines are reinforced which makes the job a little harder. They have a kind of white hard plastic tube inside. But you can still work your way around this. On my 998, I cut the hoses right at the end of the fitting tube, in order to minimize the fuel hose loss of length. You’ll find out there’s more than enough left to not have to replace the entire hose. Then, the tricky part is to push the new couplings in those hardened fuel hoses. For this, you need to order the right size. Check this website and carefully read what he says about hose inside diameter vs hose barb diameter. Choosing the right diameter is paramount… https://www.benzinkupplung.de/A-DU-set3.html Finally, to remove the old female couplings and screw the new ones in the fuel pump assembly plate, you will need to undo the tabs to be able to use a socket (17mm if I remember correctly). Then, read the mounting instructions carefully as you will need to use a proper fuel resistant sealant on the threads (benzine Kupplungs provide their « formula 8 » sealant in their kits). Female stainless couplings have a conical thread and will not screw all the way in. Do not go too hard on them or they will snap!
Pas de souci* - I'm actually ok with changing all the lines. It's a 20yo bike and, as we say in Australia, it has been ridden hard and put away wet. It has probably had Ethanol (and god knows what else) in the lines as well during its time. So when I try and pull the fittings out, I'm seeing the inner hardened fuel hoses? That makes sense, now that I think about it. I do have some Oetiker-style clamps lying around as well. The Gotham kit for the quick disconnects includes Viton o-rings and fuel-resistant sealant as well. * Apparently French people don't like saying this any more? I saw some news headline about it..
Yes, by « rings » I meant the Oetiker-style clamps. I couldn’t remember that name when I wrote yesterday. Why wouldn’t we say « pas de souci » anymore? It’s a very common thing to say.
This is the article I was thinking of: https://theconversation.com/pas-de-souci-the-french-war-on-saying-no-worries-168878 When I lived in Mali we'd say "pas de probleme" or, in the local language, "probleme tala" I should have figured that out for myself. Thank you!
Some journalists really need to get a day job… That and the Immortals need to wake up and dust their splendid uniforms off.
I ordered the new fittings but they haven't arrived yet. What am I supposed to do with the single fitting (both hoses flow into it) listed on the left-hand side of part #25 - can that be replaced or not? I emailed the vendor to ask if they included one in their kit but they didn't reply.
Kit showed up and that fitting isn't included. I get the male and female ports for the bottom of the fuel pump assembly itself, as well as new rubber hose and hose clamps, but not that union fitting. I guess I try and salvage the old one?
I've been down this route fairly recently myself, those plastic fittings don't like being disturbed in their old age. I bought new dry break fittings off ebay and steel braided injection hose from Demon Tweeks. I re-used the brass fitting where the fuel hoses meet and the 3rd pipe shoots off up into the airbox. I initially tried reusing the original hose but there was no way I could get the inner hard line soft enough to go over the new fittings and the Ducati part comes as a full assembly at silly money.
