During the 1st day of tear down, I decided to prioritize what I discovered on my first walk around. The first item on the agenda for me was stopping the oil leaking out of the engine.
For one, I didn't want the shop manager getting mad at me for the oil dripping on the concrete. I'd temporarily solved this with some cardboard under the bike but I wanted a permanent solution.
I narrowed down the leak to the alternator cover so decided to start there.
I have the Ducati recommended alternator puller tool as it is the same used on my 996. I got down to business and removed all the stuff that would end up in the way. Side stand, oil lines, regulator/rectifier wires, shift lever and counter shaft cover....pretty sure that was all.
This is what greeted me when I removed the counter shaft cover. The chain lube and debris is about a half to 5/8 of an inch thick.
I removed the timing plug and all the bolts on the alternator cover. Once done, I installed the puller and pulled the cover off. What a mess!
It was immediately obvious that someone with either no knowledge of Ducatis or just simply didn't give a sh!t about what he or she was doing had been inside this cover. I soon found out exactly why someone needed to be in there.
This is the cover side. You can see the distortion from the chain derailment on the edge of the cover. Also one the of the cracks. The discoloration of the metal is distortion of the sealing surface. The gray areas were not actually in contact with the mating half of the crankcase. As moisture worked its way in, the aluminum began to oxidize. At least until it got coated in oil.
There was gray silicone all over the place. More of it inside the cover than out. There were pry marks all around the cover, but worse still, there were indentations in the crankcase half.
Looked very much like a #2 common screwdriver had been pounded in with a hammer to remove the cover.
I was prepared to find damage, but this was a bit more than I prepared for. Anyway, how to fix this mess. From the looks of things, the chain had derailed at some point. No telling when. The impact to the crankcase and cover had distorted the metal as well as cracked both.
Crankcase half. Here you can see both the crack and the distortion quite clearly. Again, the distortion is evident due to the graying of the aluminum. You can also see from the build up of grime how easily this kind of damage is hidden.
The crack in the crankcase half didn't look too bad. It was small, less than a 1/4" in length and didn't look like it went all the way through. The cracks in the cover on the other hand were worse.
Here it is all sealed up and cleaned up. I spent a while with a can of mineral spirits and toothbrushes to clean it all up to what you see here:
Not a lot worse but definitely worse. Two cracks one less than 1/4" the other more like 3/8" and it definitely went all the way through. Nothing I could do about cracks. That's either a weld it up or replace the part.
The cover is not a big deal. One can be had on eBay for not a great deal of money. The crankcase half on the other hand is a huge deal. Either repair or replacement means the engine has to be separated from the frame.
Replacement is not the desired fix as California tracks the engine in the bike on the title. Guess where the engine vin is? Yep. On this particular crankcase half.
More after my next session at the shop....sean