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999s Restoration & Rebuild

18211 Views 97 Replies 15 Participants Last post by  edgar999s
10
Hi all, and welcome to curious visitors from Chromeheads also ;)

Thought I'd share my restoration work on the 999s. Once hailed as the 'ugly duckling', many buyers are now waking up to its timeless design. I was one of them, receiving this 2003 model with 987km in June 2020. I had little to no information to go on other than photos and the seller's word, and unfortunately the bike turned out to be a lemon, though not entirely the seller's fault - he probably just didn't know any better. I had hoped it was in good condition on the basis of the very low mileage, but that wasn't the case. Was a lot of back and forth on that sale.. Anyway, long story short, I eventually stuck with it and got a partial amount of my money back, allowing me to move forward.

Here's how she looked online -
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Day of loading up for her journey -
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And arrived 3 days later -
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Bike was known to not start. While I wasn't looking to mod or enhance it in any way, it did need a lot of my attention. Here were the early stages of me diving in, slowly opening up the can of worms. End of diagnostics concluded -

  • dead battery
  • rusted spark plugs
  • rusted vertical cylinder spark plug tunnel
  • rusted horizontal cylinder intake valve + seat
  • badly rusted fuel tank
  • ruined fuel pump
  • clogged injectors
  • worn + rusted clutch disks, basked chewed, fractured spider spring
  • evidence of crash on left side
  • spoiled oil cooler
  • degraded sound dampening material
  • leaking fork seals
  • expired stator unit
  • aged upholstery + worn rubber components
  • scratched/broken bodywork and carbon fibre components
  • bent rear brake lever bolt
  • once engine was running, coolant was found to be mixing into the oil - bad vertical head gasket

Other areas to address -

  • air filters
  • oil + coolant change
  • timing belts
  • brake + clutch bleed
  • chain + sprocket set
  • brake pads
  • tyres
  • valve adjustment
  • upgraded earth + starter wiring
  • exhaust manifold ceramic coat

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Oil drain plug magnet, not too bad -
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She's been sitting pretty in the lounge the whole time. With that, the battery got a bit sluggish and her starts became laboured. Bought a much better battery charger/maintainer the other day and now she's good again 馃槉
She's been sitting pretty in the lounge the whole time. With that, the battery got a bit sluggish and her starts became laboured. Bought a much better battery charger/maintainer the other day and now she's good again 馃槉
Good stuff. I think mine will end up in the lounge over winter, it's already cooling down here and I've got two other bikes I can ride (and pay for registration for!) over winter. It'll be a nice ornament for when we're watching MotoGP and WSBK :D
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My girls stay in the house. It's safe there.
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I just picked this 2006 999 Bi-Posto up this weekend. Not running. Immobilizer enabled and preventing bike from starting. Came across this discussion thread while researching for known issues for this model. WOW, cs363 and edgar999s have absolutely inspired me!!!!! Luckily, I have a little experience with these "older" Ducs as I just restored my 1999 996s (#187) and 2007 Aprilia RSV1000R and am somewhat familiar of what to watch out for. A friend owns a 999s that I have helped to mechanically sort out and get back on the rode for him. I look forward to rereading this entire discussion for tips on this 999. Cheers!


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Still here and always eager to help. Have you got the complete service manual? Immobilizer can be bypassed I believe, it gives instructions in there.
Still here and always eager to help. Have you got the complete service manual? Immobilizer can be bypassed I believe, it gives instructions in there.
I have found the throttle twist instructions and will give that a go tonight after work. Otherwise will need to solicit advice on sending out the Instrument panel or ecu to unlock/bypass the immobilizer. Thank you!
Happy to report it was just the Immobilizer antennae came loose in the housing!!!! Now on to the next issue(s). The starter solenoid only clicks鈥..
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Happy to report it was just the Immobilizer antennae came loose in the housing!!!! Now on to the next issue(s). The starter solenoid only clicks鈥..
And the lithium battery had a bad cell. Replaced battery and she now cranks over! Reinstalling the clutch pack and fuel tank. May have a running bike tonight!
And the lithium battery had a bad cell. Replaced battery and she now cranks over! Reinstalling the clutch pack and fuel tank. May have a running bike tonight!
She鈥檚 alive! Not sure how to post the video but the bike fired right up!!!
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Woohooo!! That was quick! The loose antenna is a very common issue from what I've read.
Woohooo!! That was quick! The loose antenna is a very common issue from what I've read.
rode it today and she has issues. Won鈥檛 rev past 4k rpm under load. Time to inspect fueling components.
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Found two clamps missing at the pressure out from the pump and the inlet pipe at the filter. Thinking it is possibly bleeding pressure internally. My 996s was also performing similarly with a cracked pressure hose inside the tank.
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Reassembled the pump into the tank using the questionable integrity of the pump base oring. And no surprise, the oring leaks. Ordered a couple of new orings and now have to play the waiting game鈥.
And while replace the damaged horizontal cyl ignition coil, discover a previous attempt to repair a broken off insulator. Are you kidding me?!!!!
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And just like that, it now runs and rides as it should!! I鈥檓 super excited now to order tires and complete this bike so I can really give her a go!!
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Well folks it looks like I'll be starting on a 10/1198 build as my next project 馃憖馃檶 this time I won't be working from an existing bike but rather building from the ground up, spare parts only, as and when I am able to get them 馃檪 will create a new thread accordingly. The 999 is out with a sprag repair at the moment but otherwise all good 馃槃
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Well folks it looks like I'll be starting on a 10/1198 build as my next project 馃憖馃檶 this time I won't be working from an existing bike but rather building from the ground up, spare parts only, as and when I am able to get them 馃檪 will create a new thread accordingly. The 999 is out with a sprag repair at the moment but otherwise all good 馃槃
where are you in South Africa
where are you in South Africa
In the crap hole they call East London haha.
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