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I'm in the middle of rehabing a 916 and thought I'd post some of the progress and some pics. Of course, every little thing turns out to be a bigger job than expected. So far I put all the street lights back on (still trying to get some front blinkers). Trouble there? I was missing a little rubber thing that goes between the taillight and the back of the tail fairing. Once I got that and epoxied it in, the light sits a little crooked. So take it off and re-epoxy and....um, good enough. Put in a new speedo cable and a new throttle cable too. Then I filled the front brake reservoir and bled it, emptied the black fluid from the clutch reservoir and filled and bled it. Hm....brake is still a little spongy. I'll have to bleed the system again, but it's good enough for now. I'll bleed the rear too while I'm at it.

I added a new bracket to keep the stupid side stand from retracting every time I pick the bike up off it. Love that little $10 part. [clap]

Duct tape. Black duct tape. Right now it's holding the fairings together in a handful of places. Thank god for duct tape. I'm going to have to keep it like this for a while. I'm not going to buy shiny fairing yet: don't have the $ and don't want the bike being too attractive to thieves out here in Oakland. It looks a little rough, but also kind of mean. I don't think I would f**k with the owner.

OK, the tank. There's a little metal, um, protrusion at the front of the tank. Well, the tank had a makeshift one made from a bolt and nut, which did the trick but kept the tank perched a bit higher than it would normally sit, so that it rocked back and forth and didn't quite seat on the airbox seal. I swiped the part off a spare tank and got some of the rubber top mount screws that go beneath that tank. Now it seals and doesn't rock. It's on there pretty solid.

Rearsets. I was able to piece together a full set from the box of mix and match spares that I got with the bike. I had to machine a bolt/spacer part for the shifter to pivot on, which works like a charm. Of course when I saw George last night he gave me the stock part. D'oh!

Oh, right. Then when I fired the bike up for the first time I noticed a drip so I shut it down, lifted the tank to get a better look, and fired it up again...only to be hosed by a blast of spray coming from the hose. Hm. After I changed clothes [cheeky] I pulled the hoses from their quick releases at the bottom of the tank/fuel pump. Looked like an O ring was bad. So I picked some up from Munroe only to discover that it was the wrong part and wouldn't fit. So I got the right part from Desmoto but when I put the two O rings on each hose, they wouldn't fit in the fittings. Turns out that if you remove the rear O ring they'll fit and won't leak. Problem solved. Then I took as much of the gas out of the tank as I could as it had been sitting for a while. Not knowing what to do with the old gas I took it to the gas station down the street and the guy had a place for it, but he couldn't get the receptacle tank open without some pliers. He's been telling me he'll do it tomorrow for like a week. I'm going there tomorrow with some freakin' pliers, dumping the old gas, and getting my gas can back.

Picked up a front fender for pretty cheap but I had to BART out to pleasant hill and wait an hour to meet the seller. But the bike got the fender so I guess it was worth the trip. Radiator was hanging by one mount so I had to gently "encourage" the other mounting points to line up with the posts on the body. Picked up and installed a brand new battery from a place in Oakland called Battery Specialists. It was about $50, less than half of what I was quoted by either Desmoto or Munroe...can't remember which. Their office, however, reeked of pot.

Then I pulled the airbox tray and hosed it down. I pulled the FBF filter and ordered some stuff to clean it, should be here soon. Added the missing bolts to that tray, which is supposed to double as a member of the frame adding stiffness. I epoxied the ECU mounts which had sheared.

Nuts, bolts, fasteners. I've made 3 trips to the hardware store. And one or two to Duc dealers for weird Ducati parts like the pins that hold the seat assembly to the frame, little rubber parts, etc.

Finally sorted things out enough to take the bike for it's maiden voyage....to the end of the block for some gas. Sounded great, and was running strong, but I noticed a bunch of problem. Like the electronics. The turn signals didn't work in the rear, headlight didn't do high/low...only high. Neutral light was permanently on. So I spent about 2 hours with a wiring diagram sorting out the electronics. Now it all works the way it's supposed to.

I guess that about covers my progress so far. Next up: adjust the chain tension. The chain is hanging like...er, the only analogies that spring to mind are unsavory. Let's just say it's really loose. Bleed hydraulic systems again. Reinforce the ****ed up body work with fiberglass? Possible. Drop the ride height. George is like 6 feet tall, I'd say, and I'm 5'8". I'm sure there's more to do, but that'll get it in the ballpark. Oh, yeah, and register and insure it!

First pic is what it looked like when it came home, the other is from today.
 

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If those quick release fittings are plastic, save yourself some grief and replace them with metal ones.
And yes, they only take one O-ring, the other groove is for the lock plate thing.

About that front tank mount... put some blue loctite on the bolts.
Those bolts have been known to come loose.
If one of those bolts falls out, it goes directly into the front throttle body, usually with *disastrous* results.
 

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Discussion Starter #7
Speeddog said:
If those quick release fittings are plastic, save yourself some grief and replace them with metal ones.
And yes, they only take one O-ring, the other groove is for the lock plate thing.

About that front tank mount... put some blue loctite on the bolts.
Those bolts have been known to come loose.
If one of those bolts falls out, it goes directly into the front throttle body, usually with *disastrous* results.
Wow, thanks for shedding some light on the o ring snafu. Funny that nobody I talked to at Desmoto or Munroe knew that was the problem.... [laugh]
 

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It really warms my heart to see you putting that bike back together. This bike has the heart of a stallion. It will always treat you right, and bring you home. [thumbsup]
 

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Poor bike. It's kinda like a dog that's been beaten for years. Show it a little love and it'll be good to you.
 

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Using Fiberglass is fine, but don't use the fiberglass resin on ABS it wont bond..Sure it will last for a while but eventually it will just pop off. I used to use a two part resin we had in the shop, it took a while to cure under heat and was black in appearance. I don't think you can buy this same stuff at the store but there must be something similar for reinforcing ABS with fiberglass or carbon. I would ask at TAP plastics to see what resin they recommend.
 

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Thanks, Inglenook, but the fairings are aftermarket glass. I've done abs repair in the past, but it was a pregnant dog. Plastic welding, crazy epoxy products (I used a black one too but can't recall the name), etc. I will NEVER do that again. Thank god these are glass. [thumbsup]
 

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Almost done! New clutch, tank, skins, paint, battery, air runners, Nichols 6k, fluids, gaskets, fasteners, oil/fuel filters, fuel pump, lighting, Pilot Powers, front rotors, Ferodo pads, street bits, registration, and a hundred other little things I can't even remember. Phew, and it only took like a million hours! [thumbsup]

How's she look? Still got Ducati tank decals on the way...
 

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Were those stock plastics? I've been thinking of going either black or white for my Track Plastics... I might have to copy you guys and your header wrap I'm sure that keeps the leg radiant heat down a bit
 
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