Monster 900Sie 50000mile refresh.

[dunf]

Originally Posted by Mr Gazza

Well I certainly would never have considered a Vespa or Lambretta part!
I'm game though if you think the fittings would be compatible, and thanks for the heads up.
Looking at the Gutsibits site they seem to measure the length of the inner, so 895mm would be perfect, 900 would be great.

Close but maybe they are just a little too long. Have a look. This particular site is in Germany but I linked it because they rather helpfully list the cable length and drive square dimension in most of the description titles. If you did identify a suitable cable then you can buy it anywhere. (I also do build custom scooters and have an account with this place).

https://www.sip-scootershop.com/en/s...%20speedometer

I used an extra length lambretta cable to replace the broken handbrake cable in my old van. Renault wanted £145 for a cable. The lammy one was £3.50 and was still working fine 5 years later when i sold it.

[Mr Gazza]

Thanks for the link Dunf.
That's a big list of cables! I got quite exhausted wading through it looking for a suitable one.
I ordered an XS650 one from Motorcycle Products last night as it looks just right and Jerry reckons Yamaha ones fit Ducati.
Besides I discovered they are a local family run business based in Bungay nearly next door to my mate. They sell quite a few Ducati bits too at very competitive prices.

https://www.motorcycleproducts.co.uk...0-parts/2/5692

[Mr Gazza]

It's been quite a hectic couple of weeks with work and I've been too knackered in the evenings to get into the shed!
However I managed to round up all the bits and pieces to make the forks and brakes all fit together. Correct wheel spacer for the axle, a washer to go beneath the spindle nut, Ti caliper bolts, 4.5mm disc spacers and a speedo cable for an XS650 that will fit the bill.
Today I dry assembled everything to have a proper look at it all.
Getting the disc bolts out proved harder than I thought it ought to be! The steel button heads I used don't have a very deep Allen socket, so I went for grinding paste in the socket from the start. Even so I only got two out and chewed the heads out of the rest.
I got them out by grinding slots in the heads and using an impact screwdriver on them.

Meanwhile Dacs phoned and asked why I wasn't using any heat, I complained that I didn't really have anything that had a small enough flame, to which he suggested boiling water.
This is like getting your own advice back, and I didn't think it would be hot enough, but it's silly not to try. Needless to say the bolts on the other side all came out after a dousing of boiling water with not one head wrung out. Thanks for the nudge Dacs.

The disc spacers fit perfectly, but the new Ti standard length disc bolts are left wanting, they could do with being 20mm instead of 15, but this will do for a trail fit.
I thought I would just offer the speedo drive into the wheel before I attempted to put it in the forks and this revealed a problem. The gearbox won't sit in the wheel properly with the disc bolts in. I had to take two out to get the gearbox to seat properly and obviously the wheel would not turn with the the others in place, so I'm afraid that somewhat kills the project, as I'm not changing the speedo or messing about with hall sensors and extra cabling.

I still carried on with the dry fit without the speedo drive to make sure everything else was good, which it is, and it looks good too.



The adjusters look good. The forks are set flush just as a simple means of getting them level, they would normally protrude above the yoke by about 20mm.



7.5mm spacer is perfect on the right side.




It will need the larger spacer on the left side to make it fit a bike without a speedo drive now, as I'll be moving this whole set up on to a post 2002 Monster owner.
The washer under the nice ally sleeve nut does the business.



So with the exception of the left hand axle spacer, I have all the parts to change the entire front end.
Hybrid Monster/1098 forks with new seals and oil (Goes straight into Monster yokes.)
Front axle with spacer, nut and washer. (Needs the LH spacer.)
Precision alloy disc spacers @4.5mm
Pair of Brembo radial callipers, with new piston seals and half seals about 3000 miles ago.
Stainless pinch bolts.
Banjo bolts with bleed nipples.
Pad pins and clips present with spares.
Set of 8 new EBC 4HH sintered pads (one for each piston) (+ a pair of matching new rear pads if required)
Titanium caliper bolts.

Add the spacer and 4 copper washers for the banjos and this is plug and play for a Monster with an electronic speedo.
Price upon application.

P.S. Standard Monster front mudguard goes straight on, no mods. I just thought, you'll need 12 @ M8 x 20 disc bolts too!

[Nasher]

Looking good Gaz.

Unfortunately of course both the bikes I've fitted the forks to have electronic speedos drive off the back wheel.

I'm a bit surprised you need to change the brake lines.
I used the standard lines on both my bikes with no issues.



Although strangely, when I put a set of 1098 Radial Caliper forks in my 999, I had to buy longer brake lines.

[Mr Gazza]

Thanks Nasher.
I'll have a better look at the lines when I drain the system and can offer them up properly. At the moment they look just a bit too short, although I had thought that they ought to fit like yours obviously do.

[jerry]

I have found that for speedo cables on monster that Honda and Yamaha cable fit too

[Mr Gazza]

Thanks for that Jerry. That's what I needed to know.

[Nasher]

Oh Fek Gaz

How much lower profile would the heads of the disc bolts need to be for clearance?
I'm sure some are very low profile dome heads.

And could a small amount be taken out of the body of the speedo drive to help?

[Nasher]

For example these later bike ones have lower profile heads and are 20mm long:
https://www.stein-dinse.com/de/ducat...7913991A-.html

[Mr Gazza]

Well. I don't think I could take anything meaningful off the gearbox, the bolt heads foul it everywhere.
The heads would have to be no higher than a thick washer. I pictured a flat head about 2mm thick at most with an Allen socket going down into the actual bolt. More or less like a grub screw with a head.
The other idea I had was to countersink the disc carrier and use countersunk screws, but not sure that's good practice on a disc? I've never seen countersunk ones before, but I'd only have to do one side.

Actually thinking about it, countersinking might have legs? Unless there is some engineering objection? I certainly wouldn't be able to grind slots to get them out if they were stuck. (milder locktite me thinks?)

[Nasher]

I'm not sure about countersinking them.

The loads on the heads of the bolts will be different.
Pulling them out rather than simply in shear.

When I put the ST lighter wheels in my 900SS I had to make the speedo drive narrower.
I took at least 4mm off the outside edge in my lathe.
If the same could be added to the inside edge of the inner sleeve, and the drive flange made wider, plus using the bolts I linked you'd probably have enough room.

[Nasher]

Does anyone have a spare, even knackered, 25mm spindle speedo drive they'd sell me and get to me quickly so I could have a play?

I'm convinced my 999 has the bolts that I linked to, so I'll measure them in the morning and see how much lower they are.

I'm sure we can sort this.

[Nasher]

Your other option could be some 748R/998R discs.

I'm told they are 6 hole 320mm diameter, but have a 15mm offset rather than 10mm.

Your discs would be 1/2mm offset in your calipers, but that's not going to matter.

I know somebody who has a pair, I'll get them to measure them. I'll also pop out to measure some stuff in my garage in a bit.

[Mr Gazza]

You're on fire Nasher!
I really don't think that altering the speedo drive will achieve anything, it's ludicrously tight in there.
I'll get a picture when I've done some chores and can get to it.

I had similar doubts about countersinks.

15mm offset discs sound like a much better solution all round as it's the spacers that are causing the problem. My discs have seen better days to be honest but I hadn't budgeted for new discs, they certainly don't need replacing just yet.

I think I can see the financial event horizon!

[Mr Gazza]

Just seen discs listed for 748/998 and they are stated as also fitting Monster 900 ect.
So I assume a 10mm offset?
Also seen them with 6 and 5 hole versions for 748 ect, so very I'm confused!