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Repairing my crash damaged 916

Discussion in 'Builds & Projects' started by Jefr0, Oct 16, 2013.

  1. Ministry, my Dad say's it was just a bit of ally that he bent in a vice. If I work on the Duc anytime soon I'll take a good picture of it.

    I finally been paid out for the bike! Although not the rest of the claim but it means I can start buying more bits!

    I recently bought the below, standard air tubes and rear sets with the linkage, mint condition.

    Only need the LHS rear set but it all came as a set, I'll probably sell the rest, including the heal plates.

    Duc rear sets and tubes.jpg

    I also just won a mirror bracket from the headlight bucket in mint condition also.

    The main two bits I need apart from the rest is a tank and a headlight, so if anyone is selling :wink:

    I've been hunting everywhere for a set of carbon tank sliders but can't find any otherwise that'll be perfect as the tank isn't punctured. There is a set on eBay but they are a yellow carbon :frown: - anyone know if they were or still are for sale anywhere?

    That's all for now, maybe at the weekend I'll get fixing the new bits on.

    Cheers

    Jeff

    Duc rear sets and tubes.jpg
     
  2. When it's ready, be sure to come to the DOC GB 'Kent' meet and show it off!
     
    • Like Like x 1
  3. It's been a while since I updated and I've been busy collecting parts and slowly rebuilding!

    Since the last update I have managed to buy these parts:

    Tank
    Tank pad
    New fuel filter and O ring
    New LH indicator
    Another nose fairing (better condition than the one previously bought with a bit missing)
    Mirror support
    Brand new clutch reservoir with new lever, bottle etc from Ducati
    Bar ends (74p each!!)
    Front paddock stand
    Headlight
    OEM mirror bolts (purposely snap)

    To do list:

    Buy switchgear
    Buy or repair passenger hanger
    Buy 3 more screen/fairing bolts
    Fit screen to nose fairing and fit to bike
    Fit mirrors with new bolts
    Fit tank pad
    Fit new clutch reservoir and lever
    Take wheels off to put new rubber on
    Fit air boxes
    Tidy headlight bucket

    Done: (removed from to do list)

    Fit bar ends
    Fit rear sets
    Fit mirror bracket
    Fit headlight
    Fit seat panel
    Fit tank
    Fit new side upper fairing to lower side fairing

    As you can see, there has been a lot to do and I've managed to get a few bits done. I'll be trying to get more done this weekend also.

    Here are some pictures:

    IMG_3619.jpg

    Front paddock stand, LH indicator, bar ends, mirror bolts

    IMG_3620.jpg

    New bar ends fitted

    IMG_3621.jpg

    New mirror post, comparison with old one

    IMG_3622.jpg

    Before and after with rear sets (will be selling carbon heal plates)

    IMG_3624.jpg


    IMG_3627.jpg

    As it stood when I worked on it a little while ago, pair of scrubs to go on.

    IMG_3628.jpg

    My shed was turning into a parts shop!

    IMG_3692.jpg

    IMG_3691.jpg

    New tank fitted, although will be coming off again to check alignment and to fit air tubes (quicker than unscrewing 18 bolts from the air boxes!)

    IMG_3699.jpg

    IMG_3700.jpg

    New tank pad (to match old one), new clutch reservoir with lever, bottle etc)

    IMG_3778.jpg

    Got to removing the screen bolts from the old panel, 8 out of 9 from the accident isn't bad considering how expensive they are!

    IMG_3779.jpg

    Fitting new bolts to the side panels which proved a little awkward getting the first couple in.


    IMG_3780.jpg

    IMG_3781.jpg

    Old headlight vs new (might clean it up a little bit - was a hard part to get hold of)

    IMG_3783.jpg

    End of today fitting the various parts and getting ready for tomorrow to do some more.

    Cheers

    Jeff

    IMG_3619.jpg

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    IMG_3783.jpg
     
    • Like Like x 4
  4. Keep going, you're doing a fine job! Hope you're looking after your girlfriend as well as the bike :wink:
     
    • Like Like x 1
  5. If you are interested I have a CF swing-arm protector for sale.
     
  6. Cheers snips. Yes she's being very well looked after, so is the girlfriend :biggrin:

    Lucazade, thanks but no thanks, trying to keep it stock.

    Another update soon.
     
  7. Today I managed to get a couple of bits done, here is the amended to do list:

    To do list:

    Buy switchgear
    Buy or repair passenger hanger
    Buy 3 more screen/fairing bolts
    Fit screen to nose fairing and fit to bike
    Fit mirrors with new bolts
    Fit tank pad
    Take wheels off to put new rubber on

    Done: (removed from to do list)

    Fit bar ends
    Fit rear sets
    Fit mirror bracket
    Fit headlight
    Fit seat panel
    Fit tank
    Fit new side upper fairing to lower side fairing
    Fit new clutch reservoir and lever
    Fit air boxes
    Tidy headlight bucket

    I realised that before I could do a few things the main bit to do was the new clutch reservoir change over.

    I set up rags around the area just in case of spillage. First loosened the banjo bolt whilst it was on the handlebar then did it up finger tight. I had to loosen the bolts holding the clip on on so it could slightly twist so I could get access to the screws holding on the clutch reservoir. Once the reservoir was off the clip on I undid the banjo bolt and put it in a container.

    IMG_3786.jpg

    Then I put the old one in a container to contain any fluid.

    IMG_3787.jpg

    The new reservoir came in parts and I had to attach the bracket and the hose which was about 5 times the length it needed to be. So cut the tubing down and added the clips.

    IMG_3788.jpg

    Once that was done, here is the old vs the new:

    IMG_3789.jpg

    Then was fitting it back to the bike. It first involved loosing attaching the banjo bolt. Then the bracket was loosely put on to get it all in position. (There is a locating lug on the clip on which makes it perfect fit)

    IMG_3791.jpg

    IMG_3792.jpg

    Was all well and good getting to that stage but then it came to bleeding the clutch as it had air in the system from the changeover. It involved a tube in a jar for the excess fluid to come out from the clutch. At the reservoir end the cap was loosely on. It involved a quarter turn on the nut at the clutch end then pulling in the lever. Tighten the nut quarter turn and slowly release the lever. Kept repeating till there was no visible air bubbles going up the tube.

    IMG_3794.jpg

    Was glad it all went smoothly. Next job was to get the air tubes on, easiest way (as I had already done up the screws - 18 of them) was to remove the tank, just 2 quick release fuel pipes, electronics and a breather. I wanted to re align the tank anyway as I don't think it sat perfectly. Rear seat unit was also removed as it was a 30 second job. Air tubes went on and clipped inside from the airbox.

    IMG_3795.jpg

    Then the tank went back on and the seat unit. Then I added the mirror support and fed through the wires of the indicators.

    IMG_3796.jpg

    This was how it was left for today as the next job was to fit the front and side panels, mirrors, indicators etc. But what was stopping me was the nose panel's little vents on the new panel I got. One was very loose and came off with my hands just seeing the fit. So I've used some glue and they will set othernight. Then I can get the other bits done.

    Whilst I was doing the vents, I attached the screen although I'm 3 bolts short!! - If anyone has any spare :upyeah:

    Also need to know how to fit the tank pad, it's come with a couple of two sided tape strips but not sure if I need anything else? I can't imagine it being very secure with just the two?

    I'll be able to do some more tomorrow!

    Cheers

    Jeff

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    • Like Like x 1
  8. Jeff, I got new OE screen bolts from Moto Rapido about £5 each I think.
     
    • Like Like x 1
  9. Doing a great job there Ted:upyeah:
     
    • Like Like x 1
  10. Mine only came with two pads as well, quick trip to B&Q and a roll of double sided tape bought, fitted around edge of tank guard with two extra strips top to bottom, I used the same tape to refix the nose and seat unit vents.

    this stuff
    image.jpg

    image.jpg
     
    #30 Mykie916, Jan 4, 2014
    Last edited: Jan 4, 2014
    • Like Like x 1
  11. Cheers for the recommendation Mykie, popped out and got it today!

    IMG_3798.jpg

    The vents set overnight so I got round to fitting the front fairing. This is how it started (luckily didn't rain today)

    IMG_3800.jpg

    The nose cone went on ok, just had to adjust the mirror posts slightly for the best fit. Also put on the mirrors with the new bolts. Also thread through the indicator wires (new LH indicator also) and fit the indicators:

    IMG_3801.jpg

    Starting to look like a bike again! Next job was to get the fasteners attached to the nose fairing and connect the side panels:

    IMG_3802.jpg

    IMG_3803.jpg

    It's been so long since it has been together! Was very happy how it came out with the new parts.

    IMG_3805.jpg

    The passenger bracket and peg were damaged in the accident so thought about bending the bracket back as it had bent. Well it took quite a few attempts to get it perfect and straight again but it got there in the end. For now the peg has been made to look nicer until I get a new one.

    I didn't get round to fitting the tank pad even though I had bought the tape! I may be able to visit a Ducati dealer next Saturday to get the new tyres on and get the 3 remaining screen bolts. Bike is now rideable, started up fine! Just needs a good run, I'll be doing a oil and filter change soon too.

    Updated list as of today (I've only seen the switchgear for sale once, so if anyone has one for sale? I have a vgc other type switchgear if anyone is interested also)

    To do list:

    Buy switchgear
    Buy 3 more screen/fairing bolts
    Fit tank pad
    Take wheels off to put new rubber on
    Clean and polish!

    Done: (removed from to do list)

    Fit bar ends
    Fit rear sets
    Fit mirror bracket
    Fit headlight
    Fit seat panel
    Fit tank
    Fit new side upper fairing to lower side fairing
    Fit new clutch reservoir and lever
    Fit air boxes
    Tidy headlight bucket
    Buy or repair passenger hanger
    Fit screen to nose fairing and fit to bike
    Fit mirrors with new bolts

    Cheers

    Jeff

    IMG_3798.jpg

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    IMG_3802.jpg

    IMG_3803.jpg

    IMG_3805.jpg
     
    #31 Jefr0, Jan 5, 2014
    Last edited: Jan 5, 2014
    • Like Like x 3
  12. She looks cracking Jeff, job well done
     
    • Like Like x 1
  13. So today I took a trip to my local Ducati dealers to get the tyres changed over and to have a general look around and see if they have any bits I need.

    Well I got the tyres changed over and whilst that was being done I was having a look at the bikes there. Noticed the standard fasteners on a few of the bikes there and took a liking so bought myself a brand new set :biggrin:

    Also got the 3 screen/fairing bolts needed and cleaned and polished the bike last weekend.

    On leaving the dealer, the rear mudguard was rubbing on the wheel as it was a higher profile tyre. They did a fix for me to get me home but my Dad will be making me a bracket to raise the mudguard slightly.

    Also going to be on the hunt now for a Strada seat unit I think :cool:

    The tank pad didn't seem to sit right when I came to doing it just resting against the tank. Seems to take a lot of pressure to keep it pressed to the tank so I'm going to leave it off for now.

    The switchgear, still can't get hold of one, can't find them anywhere!

    Here's the pics of the fasteners and a before and after of them fitted. I much prefer them and don't know why it's taken me so long to change them!

    IMG_3824.jpg

    IMG_3823.jpg

    IMG_3830.jpg

    IMG_3832.jpg


    New tyres on, much better :upyeah:

    IMG_3825.jpg

    IMG_3826.jpg


    Here is my updated list:


    To do list:

    Buy switchgear
    Fit tank pad
    Check if handlebar is bent
    Fit screen/fairings screws

    Done: (removed from to do list)

    Fit bar ends
    Fit rear sets
    Fit mirror bracket
    Fit headlight
    Fit seat panel
    Fit tank
    Fit new side upper fairing to lower side fairing
    Fit new clutch reservoir and lever
    Fit air boxes
    Tidy headlight bucket
    Buy or repair passenger hanger
    Fit screen to nose fairing and fit to bike
    Fit mirrors with new bolts
    Buy 3 more screen/fairing bolts
    Take wheels off to put new rubber on
    Clean and polish!

    Cheers

    Jeff

    IMG_3824.jpg

    IMG_3823.jpg

    IMG_3830.jpg

    IMG_3832.jpg

    IMG_3825.jpg

    IMG_3826.jpg
     
    • Like Like x 2
  14. Jeff, I sat my carbon tank pad in front a fan heater for 10 minutes before I fitted it, softened it enough to mould better to shape of tank,Myk
     
    • Like Like x 1
  15. A few bits came through this week which I've been after, managed to get them for bargain prices also.

    Finally found a switchgear! It was listed under a cagiva so I need to check that the plug in will work or I'll have to get modifying the wires.

    The bar appeared bent and was confirmed by a dealer so I went hunting on eBay and found a bar with the one bolt clip (rather than the two bolt which I didn't want) and got it for a good price.

    I also came across some touch up paint and lacquer which I also got for cheap, the lacquer is un used and the red only 3ml has been used. I don't actually think I need it but I've always got it now.

    Clip on - paint - switch.jpg

    So I'll need to fit these bits soon. Couple hours ago I managed to bag myself a set of R&Gs too, I like eBay! I plan to get a set of track fairings, 2nd hand or new. If I hear of any good 2nd hand fairings I'll get them.


    Here is my updated list:


    To do list:

    Fit tank pad
    Fit screen/fairings screws
    Fit switchgear
    Fit new bar and clip
    Buy a top yoke
    Find a original monoposto seat unit (so I can switch between)


    Done: (removed from to do list)

    Fit bar ends
    Fit rear sets
    Fit mirror bracket
    Fit headlight
    Fit seat panel
    Fit tank
    Fit new side upper fairing to lower side fairing
    Fit new clutch reservoir and lever
    Fit air boxes
    Tidy headlight bucket
    Buy or repair passenger hanger
    Fit screen to nose fairing and fit to bike
    Fit mirrors with new bolts
    Buy 3 more screen/fairing bolts
    Take wheels off to put new rubber on
    Clean and polish!
    Buy switchgear
    Check if handlebar is bent

    Cheers

    Jeff

    Clip on - paint - switch.jpg
     
  16. Hi all

    Been a little while since update. I was on the hunt for a monoposto seat unit for some time. Well, I ended up buying two :biggrin: Both OEM and original paint. I prefer the plain red strada unit so I'm selling the red/white on eBay currently :upyeah:

    1.jpg

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    4.jpg

    3.jpg

    I also got round to taking the clip on off and checking if it's bent. Well....

    5.jpg

    Also, this is the clip that I'm replacing, it's immaculate and with the pin unlike mine that got broken off!


    6.jpg

    I also had got hold of a cagiva switch to have a play with. Looks exactly the same except the wiring block was different and would involve stripping both callipers which I didn't fancy doing so it's back on eBay. So still after one.

    7.jpg

    I'm still after a top yoke. I fit the new screen/fairing screws also so no holes now!


    Here is my updated list:

    To do list:

    Fit tank pad
    Buy a switchgear
    Buy a top yoke
    Buy track fairings
    Test fit R&G's with track fairings
    Repair old tank
    Try my hand at carbon fibre and make tank sliders


    Done: (removed from to do list)

    Fit bar ends
    Fit rear sets
    Fit mirror bracket
    Fit headlight
    Fit seat panel
    Fit tank
    Fit new side upper fairing to lower side fairing
    Fit new clutch reservoir and lever
    Fit air boxes
    Tidy headlight bucket
    Buy or repair passenger hanger
    Fit screen to nose fairing and fit to bike
    Fit mirrors with new bolts
    Buy 3 more screen/fairing bolts
    Take wheels off to put new rubber on
    Clean and polish!
    Buy switchgear
    Check if handlebar is bent
    Find a original monoposto seat unit (so I can switch between)
    Fit new bar and clip
    Fit screen/fairings screws

    I've got no pictures of before and after the handlebar but there wasn't really pictures to take except I now have a straight bar!

    4.jpg

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