Project Super Sport comments thread - Page 3 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #51 of 56 (permalink) Old 4-1-2019, 7:17 PM Thread Starter
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Quoting myself here:

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Tomorrow I'll install the steering head bearings and triple trees...maybe the forks too if all goes well. In fact, if all goes well, I'll also install the swing arm so I can get the chassis up on stands.
Today most certainly did not go as planned. At least, not once I started on the PSS. After I went out for a pedal this morning, I got busy out in my garage. I figured I better get all the stuff together and into installation shape before I got too far into mounting the triple trees and forks.



To that end, I checked the new to me forks I bought to see if the axle I had on hand was going to fit. It did not, as the threads on the insert are smaller on the old leaky fork than on the insert in the new to me forks. So, I checked the diameter of the flange and it was the same on both. I thought okay, no big deal, just remove the insert from the old fork and install it on the new one.



I wish it were that simple. The old forks were in horrible shape, and I expected nothing less from the insert. Indeed, it was mostly seized in place. I loosened the pinch bolts and tried to move the insert...no dice. I did the same on the new fork and the insert simply popped out with a bit of pressure.



That began an hours long removal process. When I finally got the damned thing out it was readily apparent why it was so hard to remove. Some idiot decided to peen the end of the thing to prevent it from coming out. All that had to be done was to not loosen the pinch bolts and it would have never moved.



Instead, the insert was all kinds of misshaped and mushroomed on the end that had been peened. There were pipe wrench marks on the flange as well as the insert body itself. I wish I'd taken before pics of it but I was so irritated I just went straight at repairing the damage.




The one on the left is OEM and not at all modified or repaired in anyway. The one on the right is the one I removed from the old fork leg and then repaired. Seriously, you should have seen it before I fixed it. At least now it measures the same 0.98" instead of 0.995"








Keep in mind, this is AFTER being repaired. It now pops right into the left fork leg on my new to me forks just like the one that came out did. Along the way, I figured I'd repaint the fork bottoms bronze as all the bronze color has worn off or sun faded. Once I do that, I'll brush on some anti-seize to keep it corrosion free, now that all the cadmium finish is gone.



To top off the day, I finally got to where I got the forks ready to go in, and the triple trees cleaned up...I go to install the inner steering head bearings and no dice. Nope, they don't fit. About .5mm too small ID. Now I have to research new ones with a slightly bigger ID but the same OD. And I thought I was going to be all clever and pack them nice first, then set them on a hot plate until they were 250 degrees so they'd slide right on. NOPE. Denied.



There went my whole day. At least I made SOME progress if not actually accomplishing what I'd set out to do today. Oh well, one step forward = 2 steps back. .... sean


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My garage: 2000.5 Aprilia Mille R, 2000 Ducati 996, 1994 EX500 basket case, 1993 Ducati 900 SS, 2004 Suzuki GSXR600, 1992 GSXR750 oil boiler, 1983 Suzuki XN-85 Turbo

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post #52 of 56 (permalink) Old 4-6-2019, 8:38 PM Thread Starter
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Busy day...

Today was kind of busy with other things besides the PSS. As such, I did not get much accomplished on the PSS. I had to fix my little Nissan as the wiring to the fuel temp sensor broke off again. 3rd time fixing that in 5 years. Then I replaced the starter in my Honda. There went most of my day. After lunch and a break to watch SBK racing in Aragon I finally got a few minutes to work on the PSS.



I cleaned up the fork bottoms which after last weekend's faff with the threaded insert I could see needed some attention. I sprayed them with a fresh coat of bronze. Seemed to match the OEM color quite well. After the bronze dried I treated the paint with a matte clear coat that I used on the frame.



That stuff is wheel paint and meant to resist brake fluid and other such things a wheel ends up in contact with. Hence my choice of using it for fork and frame. Pics in the PSS later once I remove the masking paper and tape....sean


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post #53 of 56 (permalink) Old 4-14-2019, 12:31 AM Thread Starter
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Originally Posted by Apriliarider View Post

As for the clutch...something is amiss there. The installed clutch is a brand new HDESA unit. I am unfamiliar with the ins and outs of this particular brand.


The stack is the proper height but the spider spring retainer was rubbing on the cover (hence it's bare state right now) so I removed the cover. It was the stock metal one, complete with the elephant on the inside.


Puzzling as the stack height is correct. Also, some of the plates are not what I expected when I removed them for examination. The "coned" Belville spring plate is not a full sized plate in the HDESA stack. It's a smaller ring like plate with another larger diameter plate that it sits inside of. Odd.
Did a little poking about with the clutch parts today. Nothing big as I was getting ready to take the 996 out for a ride over to Sonoma to meet up with my oldest riding buddies. Not that they're old, just that I've known them and ridden with them for a longer time than anyone else.



At anyrate, I got to looking at the clutch spring keeper and how the edges were beveled where they were rubbing on the clutch cover. Now, this isn't normally a "thing" on Ducatis. The covers, aftermarket and stock alike are made so there is no contact with the moving clutch parts with or without the gasket.



In this case the stock cover had been retained (why?) for some reason. I don't get why at all. It is obvious that it was damaged in a crash and was ground through around the edges. The Ducati logo was ground off along the way. Why not just buy a used open cover? It isn't like they're expensive. The stock cover was then repaired by welding the holes shut and reinstalling.



The only problem is, that was poorly executed and the weld bead protrudes through to the inner diameter of the cover. Thus, the spring keeper contact with it and the milling down of the keeper edges. Par for the course with this project though.

It was clearly evident a P/O had used a hammer to beat the inner part of the cover back out to gain some clearance. Again, poorly executed.....and a used open clutch cover was but a few bucks away. I'll try to get some pics tomorrow and post them to the PSS thread for the entertainment of all.....sean


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post #54 of 56 (permalink) Old 4-14-2019, 1:22 PM
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hammered from the inside...jeez. No doubt a Ninja owner, at one time or another. Jk

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**Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba.... Hunter S. Thompson**


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post #55 of 56 (permalink) Old 4-14-2019, 7:22 PM Thread Starter
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Originally Posted by ducatiman View Post
hammered from the inside...jeez. No doubt a Ninja owner, at one time or another. Jk
Awww man....I wasn't gonna insult Ninja owners like that!!....Now Gixxer owners on the other hand....oh....wait......I'm one of them too
Yeah, hammered. And welded. Now that you reminded me, lemme go take some pics.......sean


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post #56 of 56 (permalink) Old Yesterday, 10:38 PM Thread Starter
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pics of the cover


Here is the cover I wrote about previously. If you use the clock system, right about the 8 o'clock position is a spot where a hole was welded shut. If you look closely, you'll see several more of them. Like the bike was dropped on the right side and it slid some way down the road. That would go a long way to explain the need for a welded bead around the entire circumference of the clutch cover.




In this image you can actually see a couple of the hammer marks left from the beating given to the cover.






Above you can see the results of the heating process. Also some of the expansion from the hammer blows.




If you got the impression from these pictures that this cover was a mess, you'd not be wrong. The paint on it alone is a disaster. The cover has umpteen layers of paint. Complete with runs and all.



Doesn't matter at all in the bigger picture. It will be replaced with a vented cover of some description anyway. It is however a perfect illustration of the overall condition I found this bike in.......sean


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