The weather has been really crappy lately, Spotty and I almost froze to death in his garage working on the GPZ1100 on Saturday. I was looking around for something to do at home last week and I remembered that the Ducati 916 S4 desperately needed new fork seals. Now I've probably done 50 fork seal changes on conventional forks over that many years, but until now, I've never done upside down forks with internal damping rods and adjustable rebound.
I didn't have a workshop manual and of course, no special tools, but ignorance is bliss, so I very carefully raised the front of the bike and used a couple of car stands and a long socket handle to hold it in a slightly less precarious position, then removed the wheel, fender, fork legs and brake calipers, that were both soaked with fork oil, and dropped the complete calipers into my ultrasonic cleaner. Disassembling the forks was a PITA, as was reassembling them, requiring some redneck engineering (tie down straps to compress the springs worked really well)
Ducati fork fixing by
Terry Prendergast, on Flickr
Ducati fork fixing 5 by
Terry Prendergast, on Flickr
And I also had to machine up some fork seal drivers as you can't just replace the fork seals on these forks with the tubes out, like you can do on conventional forks. Happily, it worked.
Ducati fork fixing 3 by
Terry Prendergast, on Flickr
So after 3 days of farting around with them, I reassembled the front end, gingerly lowered the bike after cleaning the calipers, blowing them out with compressed air, flushing them with brake clean, and finally bleeding them. The weather yesterday was cold and overcast with rain threatening, but I had to go for a ride to make sure that everything was working fine. It did, and I had a magnificent ride. After riding my VMax I was thinking that the power of the little 916 engine wouldn't excite me, but it was quite the opposite, I hit 220 KPH (140 MPH) a few times, and found myself going around corners at 20-30 MPH faster than I would on most of my other bikes.
Ducati Monday 2 September 2025 by
Terry Prendergast, on Flickr
All up I did just under 120 miles, and only really turned around when my fingertips started to go numb. Great day!
Ducati Monday 2 September 2025 1 by
Terry Prendergast, on Flickr