Diavel Debut Monster Project Voltage Regulator Swap Where

Diavel Debut Monster Project Voltage Regulator Swap Where
The Official Magazine of the Ducati Owners Club of the United States
Volume 9 Issue 2
Summer 2011
Diavel Debut
Monster Project
Voltage Regulator Swap
Where There’s A Will...
Engine Performance Upgrades and Tuning
Suspension Upgrades and Tuning
Machine Shop Services
BMW - Ducati - Triumph - MV Agusta
Ohlins Authorized Service Center
Full Service Dealer
Specializing in European Motorcycles
& Machining Services
Dynojet Tuner
SMC Inc.
Andy Rounds 408 Plaza Drive Harrisburg, NC 28075
(704) 455-2434 cell: (704) 309-6298 info@smcspec.com
Techno Research vehicle
diagnostics for all Magneti
Marelli components
731 Westinghouse Blvd.
(At I-77 Exit 1)
Charlotte, NC 28273
Tuesday – Friday 9:00AM – 6:00PM • Saturday 9:00AM – 4:00PM • Sunday – Monday Closed
SUMMER 2011www.USDESMO.com
Greetings from il Capo
ast issue the topic was snow and the upcoming riding
season. As I write this we have done one track day
and the oldest event for our club, the 16 Annual Ducks
Along the Blue Ridge or DABR as it has become known.
Our events are still experiencing lower attendance than
historically, but the trend is up from last year. That
coupled with the many cost-saving measures instituted
last year has put the club on firmer financial footing. For
now, the printed magazine will continue to be published.
TekTalk: Regulator Swap
by Michael Todd
Diavel Debut
Page 7
by Neale Bayly
Monster Project
by Bill Park
Page 11
Where There’s A Will...
by The Ducshop
A Few DABR Pics
by Jim Calandro
Page 19
The USual Suspects
Last year we did a first by introducing a calendar as our
fourth issue. It was greeted well, and we plan on doing it
again this year for the 2012 calendar. Most of the months
have bikes picked, but if you have some photos you would
like us to consider, please feel free to contact me and
discuss it. Keep in mind we need high-resolution photos
and watch the background so it does not to compete with
the bike for preeminence in the photo. Detail shots are
also important.
We introduced Tiny Tech Tips in the last issue and will
continue with it as a regular feature. If you have a simple
solution to an annoying problem that you can write up
in a succinct two or three paragraphs, please feel free
to share it with us. You can make someone else’s day
simpler and get your fifteen minutes of fame. One of our
future goals is to have an index of articles for all our past
years of Desmo Leanings. That way if you have an event
or a technical question, you can look it up. All past issues
are on line, and if you want hard copies contact me. We
have most but not all available for a small fee to cover
postage and handling.
Our Ducks Head West rally has always had very light
attendance. I am not sure why because we end up riding
some of the best roads in the Southeast, and at the
elevation we ride the temperature is warm but tolerable.
Come out and join us and make it a better event.
Piazza Del Mercato
Tiny Tek Tips
Page 25
il Capo
Battery Trick
Jim Calandro . . . . . . . . . . . . . il Capo
Clyde Romero . . . . . . . . Consigliere
Bob Lattanzi . . . . . . . . . Consigliere
Terry Wyse . . . . . . . . . . . Consigliere
Larry Haber . . . . . . . . . . Consigliere
David Grogan . . . Revisore di Bozze
Terry Boling . . . . . . . Redattore Technico
Lewis Kirk . . . . . Curatore del Sito Web
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Page 27
Cover photo by Ducati.
SUMMER 2011www.USDESMO.com
Piazza Del Mercato
2008 Ducati 1098S Black (Rare) $18500 4986 Miles, Like new with new tires, transferable
7500 mile service included by Motorcycles of Charlotte, meticulously maintained and
serviced, always garaged, synthetic oil, service records, no damage history, never
dropped. TERMIGNONI - Full 70mm Racing Exhaust w/ECU and Racing Air Filter. EVR
- Full Vented Clutch Cover Black w/Vented Clutch Pressure Plate Red. PIRELLI - Diablo
Supercorsa SP High-Performance Road & Track Tires. STOCK GOODIE BOX - Exhaust/
ECU/Misc parts, passenger accessories included. STANDS Ducati Front Stand and Pit
Bull Rear Stand included. CHICKEN HAWK RACING - Digital Pro-Line Tire Warmers (Red
front/rear) included. Motorcycle located in South Charlotte/Ballantyne area. Reasonable
offers considered. Jeff 704.661.3012
#1 Ducati Dealer in the Mid-Atlantic Region
2008 1098S Motor less than 1,600 miles on it. Street ridden only. Motor is complete and
includes oil cooler. This motor is in perfect condition and bike was dissembled by Ducati
Tech II. Also have radiator from same which includes dual fans and hoses.
Motor priced at $1,995. Will deliver within 200 miles of Charlotte, NC. Radiator priced at
$495. Call Jeff Dwyer 704.895.2859 or email me at madmanduc@hotmail.com
2008 Triumph Speed Triple Clubmans, Arrow 3-1,rear hugger, seat cowl & belly pan.
Bike has 3,900 miles and has a new Pilot Power dual compound on rear. Stock exhaust,
bars and mounts are included. Comes with rear Pit Bull stand and full bike cover. Asking
$8,500. Call Jeff Dwyer 704.895.2859 or email me at madmanduc@hotmail.com
1987 750 Paso Good condition, 9488 miles. All stock except for a Corbin seat and Dyna coils. New battery. Service
just done, set valves, new belts. etc. Like new 16” Michelin tires. Runs great! $2250.00 OBO
I also have another one with 8300 miles. It has been repainted yellow, service not done yet, make offer.
Contact Marvin Jensen, Bakersville, NC mjensen851@gmail.com 828.467.0167
1993 900SS parted out Frame (straight), $300.00 (NC salvage title)
Fuel tank, no rust, needs paint, complete, $200.00
Snowflake rotors from ST4S, excellent cond. $165.00
Spiegler Iron Full Floating rotors, good condition, $325.00
Stainless brake lines, front, rear, clutch, Goodrich brand with red coating, $75.00
Carrozzeria 6 spoke wheels, forged aluminum, black, excellent condition, $1250.00
Pro Italia billet rear sets, new condition. $200.00
Many other misc. parts available.
Contact Marvin Jensen, Bakersville, NC mjensen851@gmail.com 828.467.0167
1998 916 three spoke gold rear wheel for sale. $100 OBO Jim capo@carolina.rr.com 704.843.0429
Classified ads are free for US Desmo members. Spring issue deadline is February 28. Summer issue deadline is May 31. Autumn issue
deadline is August 31. Winter issue deadline is November 30. Please provide an accurate description of about 500 characters, price and
contact information, plus a digital photograph. You can also list a classified ad on the US Desmo web site, www.usdesmo.com.
SUMMER 2011www.USDESMO.com
BMW Ducati Husqvarna
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Voltage Regulator Rectifier Upgrade
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By Michael Todd, Member # 01379
So my friends make fun of me. Maybe
it is because they are jealous. Maybe
it is because they have more reliable
motorcycles. Much like a beautiful Italian supermodel,
a beautiful Italian Supersport makes your friends wish
they were you. They see your popularity swell when the
crowd forms to gawk at your babe and her curves. Then
they wait to pounce when she has her annual hissy-fit 5
minutes later.
Yes, each year I spend in excess of $500 fixing what
ails my high maintenance Italian Supermodel. I try to
make the best of it and be a glass-half-full kind or guy.
Of course, it is all worth the trouble because the sex is
This time it was my charging system, a typical
problem for all the earlier Ducatis. When I asked for
opinions and read the blogs, I found that upgrades were
in order to make the bike work like it should have out of
the factory 15 years ago. Four main mods were in order.
New heavier gauge leads for battery, starter, starter
solenoid and ground was the first. A replacement highcapacity gel battery was second. A new regulator/rectifier
and a way to indicate low voltage was third. Last, I
needed a way to turn off the headlight to assist the
battery during starting and initial, post-start charging.
The original regulator/rectifier (R/R) unit for the
2 wire/phase system was not capable of handling high
charging current and the heat generated by that current.
These bikes are high compression and have thicker oil
(for air-cooled twins) and as a result, are harder to turnover. This is even more pronounced when the oil is very
cold. The starters are small (for reduced weight and
space) and draw higher current to turn. If your battery
Photo 1
Photo 2
SUMMER 2011www.USDESMO.com
larger than the original with more and deeper cooling
fins. It comes with an adapter plate for the existing
nutplates in the frame (Photo 4). This installation is
explained by Ducati Technical Service Bulletin 97003
and the bulletin comes with the kit. The kit is pricey
(over $300) and I did look into aftermarket alternatives,
but those all required cutting and splicing for different
connectors. I didn’t like that idea much, so I spent the
money on the Ducati Kit. These R/R’s are all shunt style
units that still generate a lot of heat and have limited
ratings for current flow.
There are folks out there selling MOSFET units that
are less expensive (aftermarket), solid state and produce
less heat with higher current ratings, but cutting and
Photo 3
is already weak, there is less current available to the
starter and it takes longer to start with more battery
discharge. When the bike does start, there is a resultant
high rate of charge to the battery. Can you say hot wires?
The wires and connectors can smoke themselves into
oblivion and damage the system.
The replacement R/R unit available from Ducati for
the ’93 to ’97 SS (PN 69920821B) and the ’94 to ’97 M900
(PN 69920831B) is the same 3 wire/phase unit produced
for the Desmoquattro bikes (PN69920841A), but it comes
with an adapter harness for the 2 wire systems. It is
battery/starter cables, I purchased a HICAP Starting/
Starter Upgrade Kit from Motolectric. Michael Heth is a
principle at Motolectric and sells the kits online at www.
motolectric.com and on ebay under the userid Nortomo.
He asked thorough questions about my bike and its
wire routing before assembling my kit. Motolectric uses
pure oxygen-free copper terminals and has designed
special battery terminal ends for the Supersports that
are solid, 90 degree angles to eliminate tank contact
with the wiring. The 3 new wires they supply are 4
gauge and include battery positive to solenoid, solenoid
to starter and battery negative to ground (Photo 3). The
main ground o nthe bike is relocated from the frame
to the main engine lug. You can read the details at the
website. The kit is absolutely fantastic and only minimal
adjustments need to be made to install it. I had to drill
out a few of the terminals to fit the fasteners. I also
Photo 5
splicing are also required with these units. I plan to see
how long my new, expensive unit lasts. I will consider a
MOSFET unit if I am disappointed with the Ducati part.
The Ducati kit installs in a snap. The harness is very
bulky, the plugs are large and the harness is longer than
required. I think the intent is “one size fits all”. It zip ties
to the inside of the frame with some folding and tucking,
but is hard to hide and would look bulbous and ugly on a
CR bike or Monster without fairing lowers.
I also needed a new battery as it was several years
old and failed a load check. I decided to purchase a higher
Photo 4
Photo 7
noViTa muLTiSTraDa 1200
Photo 6
capacity, vent-free gel battery. These batteries claim
to handle loads better and never “spill”. I purchased a
Bikemaster “Trugel” from the dealer. It is dimensionally
equal to the OEM and looks great, but I was disappointed
when it arrived and I found “made in China” on the case.
I paid way too much for this battery to see those words,
and I hope I will not be disappointed. Only the future will
reveal if it will perform as advertised.
To increase current carrying capacity of the main
TEL. 051/803070
pagina_pubblicitaria_1.indd 3
had to ream out the battery terminals as the included
bolts are larger than original and made of solid copper.
The kit includes new rubber boots to cover the solenoid
terminals. I had to trim them a bit to make room for
the plug between the terminals(Photo 1). The kit also
supplies a boot for the starter terminal, but I re-used the
OEM boot because it is deeper and pops over a recess
in the starter to seal out water. The post-modification
starting performance is fantastic!
The old, original R/R unit contained an internal
voltage sense circuit and output wire to the instrument
cluster for low voltage annunciation. The superceded unit
does not have this circuit or wire and the kit includes a
plug to seal off the output wire to the annunciator (Photo
2). A low voltage warning is necessary and I think Ducati
dropped the ball on this issue. Your choices are limited to
aftermarket voltmeters that, whether digital or analog,
are huge, ugly and not waterproof unless you slather
them with Silicone. I am not into hack jobs, so I dug
deep for an alternative. I found one in Glasgow, Scotland
selling over ebay under userid “sparkbright_products”.
Dr. Andrew Ferguson owns Sparkbright Products and
produces miniature tri-color (green, yellow, red) LED
08/12/10 14.02
SUMMER 2011www.USDESMO.com
voltage indicators controlled by miniature Printed Circuit
Boards (PCB’s). The unit I purchased requires a single
14mm hole and snaps into position. It easily fits in the
RH dash panel. There are 2 wires to install to a switched
source (Photo 6). I spliced in some aviation grade Daniels
connector pins and inserted them into the back side of
the general relay which is right next to the RH dash
I am an aircraft technician and had access to the
pins. I also own the crimp tools. Any suitable, bladed,
crimp connector should slide into the relay, or you can
an appropriately rated in-line switch somewhere on the
bike for the headlight. I didn’t like the “somewhere” part
of that option or cutting into my harness. I could have
purchased an aftermarket switch from CA-Cycleworks,
but they also required some wiring and soldering to make
it operate like the original. Another option was a used,
clapped out, European OEM switch on ebay….but for
some reason, folks are way too proud of their junk. The
prices were absolutely ridiculous for old, faded, scratched
up hardware. I decided to order a new OEM European
switch (PN 036138456) for $130 (Photo 8). That’s about
Words by Neale Bayly, Member #01174. Photos by Ducati.
cut into the wiring and install a 3 way splice. The voltage
thresholds on the indicator can be custom designed, but
Andrew’s initial set-up is fine for my bike or any other
12 volt bike. It is very tasteful, very affordable and while
not absolutely waterproof, can be sealed with minimal
silicone and replaced easily and affordably if it fails.
(Photo 5)
My last desire was to be able to switch off my
headlamp during starting and initial post-start battery
charging to reduce demands on the system. The
European bikes have a headlamp switch, but thanks
to our DOT, not so in the states. I could have installed
$30 more than what the ebayers wanted! In the end,
it looks and operates correctly and was plug and play.
I might not recommend spending the kind of money I
did on items like this if my bike was “track day only” or
rough around the edges, but my bike is a clean example
of the species and to me it was worth it.
The bike starts and runs fantastic with these
modifications and I highly recommend them. In the
future, I hope to break down alone with my cell phone as
my only companion. Then I can call my brother to come
get me and avoid spoiling the image everyone has about
my hot Supermodel.
ith my feet tucked up in a semi-race
position, arms stretched out in front of me
like a Streetfighter, and the Spanish road
dividers beside me traveling backwards at over 120
mph, it feels more like being in the latest Tron movie
than out on a test ride. Futuristic electronic gauges
feed me information as we carve effortlessly through
the Andalucía countryside. Big fat tires, loud raucous
engines, and a pack of leather-clad riders around me fuel
the excitement as we blast along the interstate heading
for the slower, more scenic mountain roads that will take
us towards the town of Rhonda. Riding on the all-new
Ducati Diavel is like nothing I have ever experienced in
over a decade of testing motorcycles around the world,
and my brain is in stimulation overload.
It’s a naked standard. It’s a custom cruiser. It’s
a sporting muscle bike. No amount of shuffling and
juggling with existing motorcycle terminology is going
to help me adequately pin a definition on the latest
Ducati. That the word Diavel is an Italian derivative for
Devil is about the only thing that makes any sense as I
peel through a triple-digit sweeper and let loose all 162
horsepower again to keep pace with my group.
For the launch of their radical new Diavel, Ducati
picked the town of Malaga in the south of Spain. As
a central spot for the world’s press to converge, it
affords beautiful views of the Mediterranean Sea with
challenging climbs up in the mountains that frame out
the coast in this area. With fast, open interstate sections,
slower crawls through town, and a couple of hours
bend-swinging as we made our way for coffee in the
mountains, Ducati gave us a chance to test the Diavel in
a wide variety of different conditions.
The Ducati launch wasn’t just essentially dealing
SUMMER 2011www.USDESMO.com
with new graphics, styling, or minor upgrades like a lot of
intros lately, and the press brief was enough to make my
head spin. Jet-lagged and on some weird time schedule
and sitting in a warm, dark room is normally the kiss of
death for staying alert and attentive. Not so this time,
as the Ducati designers, engineers, and marketing staff
told their stories. The new Diavel is so totally new and
fresh, and jam-packed with such a plethora of advanced
electronics, it actually ended up being a fairly long affair
as we learned all the intimate details. From anti-lock
brakes to multiple-position traction control, different
ride modes, keyless ignition and all the custom parts, the
connection to the Tron movie actually started before I
even rode the bike.
While the majority of the espresso-bar conversations
about the new Diavel are undoubtedly going to focus on
the styling, the most impressive part of the beast to me
was the engine. Using what is called the Testastretta
11—referring to the degrees of crankshaft rotation
during valve overlap—it’s also a lot more civilized than
Ducati’s own Streetfighter: a machine that is darn
right unfriendly on an open throttle unless you are
on a deserted road. This doesn’t make the Diavel less
exciting, as the big desmodromic twin is still kicking out
162 Italian stallions, it’s just able to mind its manners
at low speeds before you get too rowdy with the throttle.
Now get that throttle pinned, and you had better be
holding on, as the Diavel can apparently accelerate from
0-60 mph in 2.6 seconds. I’m told it feels very similar to
the new Multistrada, but I’ve not ridden it yet so can’t
I have no reason to doubt this acceleration claim, as
yanking open the throttle pins you back in the seat and
demands your full attention. Using Ducati’s Ride-byWire (RbW) system, this acceleration is immediate and
flawless and really starts to build once you get past 6,000
rpm. There is a choice of three different maps, or riding
modes, and if you don’t want this full-power version, you
can step down from this sport level to a touring mode.
This will still give you the full 162 horsepower but with
a more progressive delivery. Finally, there is a city mode
that limits the Diavel to 100 horsepower, and after
letting loose all the horses in the full-power mode, trying
out the city mode just didn’t feel like fun, so I never used
it again.
Besides, the new Diavel comes complete with full
traction control, so worrying about putting too much
power to the floor is never a problem. The sandy Spanish
roads near the coast were as slick as anything I’ve ever
ridden on and were almost as polished as a concrete floor
in places. Twist the throttle any time and the traction
control immediately kicked in, keeping the Diavel moving
forward without drama. You know it’s working, but you
also know it’s not spinning, and that’s very comforting
with so much horsepower on tap.
Called DTC (Ducati Traction Control), there are
eight levels of traction control to choose from. These are
set with one being the least invasive for sport riding and
with eight being the most invasive. The DTC is pre-set
to a specific level in each of the three riding modes, but
you can easily change this to suit your needs, or you can
access the set-up menu found on the lower display and
custom set each mode to your desired level of traction
control. If you want to leave your choices, that’s fine, or
there is a default option available that puts everything
back to the factory pre-sets when you turn the bike off.
The secondary display molded into the fuel tank
uses TFT (Thin Film Transistor) technology to show you
which riding mode you are in and what level of traction
control is active. It also has a gear-position indicator as
well as mileage and trip counter. You will be familiar
with TFT from your experience with cell phones and
computer screens, and the display is so incredibly vivid
you wonder why no one has used it before. Of course,
in keeping with the futuristic nature of the Diavel,
the display will adjust between a black and white
background depending on the light available.
While we are talking lights, there is no departure
from the unique for the Diavel with either the headlight
or the taillight. Up front a large aluminum body houses
high- and low-beam double reflectors, with an additional
strip of LED positioning lights for extra night vision.
Once you’ve seen the Diavel coming at you, you’ll never
forget it, or mistake it for any other bike. In the rear,
you’ll find two clear, vertical LED strips for tail light,
braking light, and turn signals, and these are integrated
into the under-seat paneling for a cleaner look and
SUMMER 2011www.USDESMO.com
is an attractive LCD display attached to the handlebar
risers. This also houses all the usual warning lights
as well as the time and temperature. It requires fairly
good eyesight to keep up with the fast-moving electronic
display, but it will be very familiar to existing Ducati
owners. These risers also hold a set of wide, tapered
aluminum bars that hold a pair of forged-aluminum
mirrors. It’s all very sparse and minimalistic, and
the mirrors actually let you see most of what’s going
on behind, minus the usual amount of elbow. The
switchgear took me a while to get comfortable with as
you have to slide the kill switch cover up to engage the
starter button the way you would use a trigger catch on
“That the word Diavel is an Italian derivative
for Devil is about the only thing that makes
any sense as I peel through a triple-digit
sweeper and let loose all 162 horsepower
again to keep pace with my group.”
greater visibility. This part of the bike looks somewhat
similar to my buddy’s Desmosedici, but as much as
I tried to like it while following the group of Diavels
around all day, it just always looked unfinished to me
compared to the rest of the bike. Just my two cents, but I
heard it from a couple of other scribes during the day, so
clearly I’m not alone in my thinking.
For the more mundane stuff, like how far over the
speed limit you are and how close to the rev limit, there
a gun. The turn-signal switch also doubles as a scroll
button for changing the riding mode above and as a
navigation tool for the control panel below.
The last time I rode toward Rhonda, it was pouring
with rain with the clouds so low we couldn’t get out
of second gear for lack of visibility. During the Diavel
launch, there was barely a cloud in the clear, blue sky,
and the air was so fresh and clean it felt sharp enough
to cut. Swinging through one perfectly manicured bend
after another, with the accompanying sound track of the
booming V-twin engine and the occasional sound of the
SUMMER 2011www.USDESMO.com
hero blobs marking their territory, the Diavel threw the
next set of pre-conceived ideas out of the window. Even
though it has a 62.6-inch wheelbase, and a 240-series
rear tire, it can really hustle through the curves. Now
a sport bike it is not, and you always have to remain
conscious you have a long bike to turn, so more thought
is obviously needed. But as we carved our way up the
beautiful mountainside, I realized I’ve never gone faster
on a bike with this sort of riding position and comfort.
My friend Arthur Coldwells, the owner of Ultimate
Motorcycling, was riding with me, and we’ve put on some
crazy miles around the world together. So when we got
to the coffee stop, after profusely manifesting that we
a long-wheelbased, fat-tired motorcycle handle way
better than it has any right to—better also than I had
expected from looking at the spec sheet before our ride.
get aggressive. It lacks the initial bite of something like
the 1198, but that’s fine for the street. It’s also got a nice
sweet-spot for trail braking with all the power you need
for getting the 456-pound Diavel under control when you
pull a little harder. The rear brake is also very strong,
and this setup comprises a two-piston Brembo working
on smaller 265mm disc.
Suspension is a mix of Marzocchi forks up front and
a Sachs shock in the back. A black-bodied 50mm inverted
setup comes equipped with pre-load, compression, and
rebound settings, and is held in place by a beautiful,
cast-aluminum, slash-cut triple clamp. These are blacked
out and certainly add to the Diavel’s looks. In the rear,
absolutely weren’t pushing it, his big shit-eating grin was
all I needed to back up my feelings about the Diavel’s
excellent handling.
Heading back down the mountain, we were taking it
just as easy as I left progressively more foot-peg metal on
the Andalucía tarmac. This gave a wonderful opportunity
to put the brakes to the test. Looking like they were
lifted straight from Ducati’s Superbike, there are two
4-piston Brembo Monobloc calipers up front clamping
down on 320mm discs. Fluid makes its way to the pad
via a radial-pump master cylinder stored in a uniquely
styled reservoir. The lever is adjustable, and the setup is
not so strong that it overwhelms the front fork when you
the spring holding your butt off the wheel is mounted
horizontally under the chassis. It features an external
adjuster for setting pre-load as well as compression and
rebound damping adjustment.
Ducati quote figures of 28 degrees for rake and
130mm of trail with a 24mm offset. Somehow, the people
who have recently won a MotoGP world championship
and more World Superbike championships than any
other manufacturer have figured out how to juggle the
numbers to achieve the impossible here. They have made
Parking the Diavel for coffee and sitting back to enjoy
its visual footprint, I couldn’t help being attracted to the
custom 14-spoke wheels. Looking more like something
Bobby Fisher at Roaring Toyz would accessorize one
of his custom bikes with, it’s going to be a tough job
convincing people they come stock on the Diavel. The
rear is a massive 8x17-inch rim, while
the front is a more sporting 3.5x17. Of
course, the bike rolls on some specially
designed Pirelli Diablo Rosso II tires.
With a more rounded profile than a
traditional cruiser tire of this width,
they no doubt contribute heavily to
the bike’s handling manners, and it’s
nice to know you have such high levels
of grip available when riding with
Mr.Coldwells at speed.
The two exhaust pipes hanging
out off the right-hand side of the
Diavel beg to be removed and
replaced with something smaller
and more compact. Ducati already
has this covered, and we got to see
a Termignoni carbon, full exhaust
system on the full-carbon display bike
in the hotel. A must for new owners,
I’d say. This fully accessorized Diavel
adds $3,000 to the $16,995 entrance
price of the standard Diavel; if you can
call a bike like this standard?
The bike uses keyless ignition:
just put the fob in your pocket, hop on
the bike, press the starter, and go. It
comes in a choice of red or black, and
Ducati are seeing big things for the
Diavel in the American market. It’s
wild, futuristic, and like nothing I’ve
ridden before, and that’s what’s going
to make it so appealing to the lucky
few who buy one.
SUMMER 2011www.USDESMO.com
’07 Ducati S2R1000 Monster
Two-into-One Exhaust System
Bill Park, Member # 01055
Race & Track-Day Bike
Fabrication & Setup
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We specialize in Ducati
Greenville, South Carolina
y Project Monster was born of necessity. After
years of riding my beloved 996, the all-time
number one production superbike, in my
esteemed opinion, I knew it was time for a change. The
riding position of the 996 is dreadful to wretched on
straight roads with traffic. On the other hand, Ducati’s
Monster series has a riding position in the classic
motorcycle style that has endured over many decades,
a riding position more
in line with my current
requirements. And the
Monster series was created,
designed, and manufactured
as a springboard of
inspiration for those
motorcyclists who wish for a
bike customized to their own
unique vision and style. So in
my humble opinion, starting
with a stock ’07 Ducati
S2R1000 Monster would
be the perfect project. I’d
owned several other, smallerdisplacement Monsters, all
of which had been modified
by their previous owners.
That’s a nice, safe, and
less expensive way to own
a Monster, but not what
I wanted to do this time
around. I planned on making
this bike my very own,
personal, custom Monster.
This would be a long-term
project—a work in progress,
so to speak. This bike would
work well as both a canyon
carver and as a low-country,
back-woods road racer. Besides, the wife would never
agree to add a fourth bike to the already overflowing
stable. Something had to give.
After selling the 996 locally and purchasing the
Monster from Igor Shafran of Staten Island, New York,
I decided to try it out on the US DESMO trip to Erwin,
Tennessee—Ducks Head West—as a trial run. The
Monster did everything well, but a 996 it is not, so plans
to modify the bike started to form in the hardwired
portion of my cerebellum. I found myself lusting—no,
a better term would be appreciating—Jim Calandro’s
custom Monster. By the time I got back to home base, I
was already making my list and checking it twice.
Back home with the Furtive Riders Anonymous, I
got a chance to take a closer look at Della’s 750 Monster.
Jeff McIntosh had just installed a set of CRG levers and
removed two clutch springs with the intent to relieve the
effort required to operate
the clutch. One squeeze of
this trick CRG clutch lever
and I knew I was a goner.
Back at the shop, I ordered
a set of CRG levers, an Evo
hydraulic clutch slave kit,
and a fender eliminator
kit. I found good pricing
and delivery with Bobby
at Houston Superbikes,
aka DesmoPorsche, www.
But the real
modification that stuck in
my mind was the neat twointo-one exhaust system of
Jim Calandro’s Monster.
The look and sound of a
low, single pipe was just too
much to contend with. The
stock mufflers and exhaust
system must weight, at the
very least, a metric ton.
Getting rid of all that mass
could only be beneficial,
not to mention the added
horsepower from the freeflowing exhaust and a remapped ECU. So as the
cold arctic air started making its presence known in and
around the Grand Strand, I started surfing the web for
bits and pieces needed for this big project.
I worked on a basic concept that eliminating the
catalytic converter as well as the two large factory
mufflers would reduce weight and improve exhaust
flow. The system would rely on a single 304 stainless
steel “Y” as a junction for the two head pipes. Then a
few additional 304 stainless-steel tubing bends work
SUMMER 2011www.USDESMO.com
to fill in the gaps. All of these tubing pieces came from
Burns Stainless Steel, Costa Mesa, California, www.
burnsstainless.com 949-631-5120. Vince, one of their
knowledgeable staff, was super helpful in lining up my
parts and getting them here in time to make the project
a success. Now I decided to go in search of the actual
muffler and build the rest of the system around a really
nice, light-weight unit.
My search started by taking a look at our local
motorcycle salvage yard, Myrtle West, www.myrtlewest.
com, out on Highway 9 just west of Little River, South
Carolina. They had a good selection in their used parts,
but nothing that really grabbed my attention. So many
of the mufflers these days look like parts from an alien
spaceship. But what did catch my eye, on the new parts
shelf, was an M4 GP stinger muffler designed for a
600cc bike. It looked perfect, and the more I pictured
it sweeping up from under the bike, the better it got,
so I went back to the computer and started searching
for an M4 designed for a liter bike. I found a used unit
from a ZX10 Kawasaki. I quickly snatched it up, and it
arrived in a few days from A J Salvage Cycles. Check
out their eBay store, which is out of Pennsylvania. They
were easy to work with and shipped my parts out on the
same day, with tracking numbers. The muffler was well
packaged to boot.
I then contacted Bobby at Houston Superbikes and
picked his brain on my options for obtaining an ECU
that would work with this very low-restriction exhaust
National Best Service Dealer 2008/2009
All Ducati Certified Technicians
Master Tech, Level 1 and 2
Desmosedici RR
has this gift. So with both of us doing the 3D thing, it all
started to fall into place. After some consideration, the
first few parts were welded and put in place. Starting
with the rear head pipe, we brought the front cylinder’s
head pipe back to meet it. We decide to make a slip-on
connection in the front-cylinder head pipe, about halfway
Only EXCLUSIVE Ducati Dealer in Florida
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system. I opted for the re-flash of my existing ECU.
Bobby does the official Ducati programs, and he had one
just for my S2R 1000 twin-plug Monster’s engine. This is
a racing program, which could be done the same day the
ECU arrived on his doorstep.
Now, equipped with parts and a game plan for the
ECU, the real fun began. It was a cold, wintry Saturday
in January. It was definitely not a riding day, but a great
day for working on your bike. I had removed the bulk of
the exhaust system the day before and had all the new
bits and pieces laid out and ready to go. I removed the O2
sensor and labeled the wires before cutting them. The O2
sensor would have to be relocated farther back in the new
system, after the two pipes became one. The catalytic
converter was then ready to be removed. The head pipe
from the front cylinder was cut with a reciprocating saw.
The head pipe from the rear cylinder was disconnected
via the existing factory clamp, using a ratchet with an
extra long extension and 10mm socket. I removed the
two hanger brackets, and the cat was then set aside for
a trip to the metal recycler at a later date. Now comes
the creative aspects of this project. One by one, different
bends are utilized to get some idea of where to start and
how to keep the flow as smooth and straight as possible.
Cut and tack weld a few parts at a time and then hold
them up under the bike to see how they will line up.
Cutting and fitting is the name of the game. This trial
and error type of work is the only way to build a custom
exhaust. No one has made a road map for you, and there
is no computer program that will tell you what to do
next. Eric Campbell, an excellent free-lance welder, is
very good at this. I call it seeing in 3D, and not everyone
from front to back. This would make life much easier
when removing and reinstalling the exhaust system.
A major consideration, as a system that can’t be easily
disassembled is not a real system at
all. Most bikes will need to have the
exhaust system removed at some
point in time, and you don’t want to
have to cut the system into pieces to
remove it. In my book, this is called
engineering 101.
Once the final pieces were
tacked in place, we stepped back
and admired the system. Getting
all the bends and twists as
smooth flowing as possible is very
important. It’s now obvious where
the O2 sensor will need to be, and
we tuck it just behind the foot-peg
guard. The wiring will come last,
after all the welding and supports
have been finished. Also, at this
point it becomes obvious that the O2
wiring harness will require a radical
new route. The harness only needs
about six added inches of wire, but the connections will
need to be weather proof. While we’re at it, the charcoal
canister, evaporative emissions controller is removed
and set aside, for good. This shed a few more ounces and
removed some dense plumbing from under the tank.
Things are starting to look very good indeed.
SUMMER 2011www.USDESMO.com
After a couple of trial installations and removals of
the entire exhaust system, the go-ahead is given to weld
up all the seams. This is another area where Eric shines.
He has that touch and steady hand, afforded him by his
youth, that makes his TIG welds look like they were
done by some space-age robot: smooth, seamless welds
with no blobs, globs, or blisters. And no leaks, either. A
new threaded boss for the O2 sensor is made from 316
stainless steel, and installation is completed during the
final welding process. The threads for this boss are 18mm
x 1.5mm pitch and we just happen to have the tap in our
extensive inventory.
The M4 Moto GP muffler is just a fuzz too loose for
my liking. So a quick trip to Main Street Auto Repair
In the entire Arai Helmet Company, only 15 men make helmet shells.
only 15 men.
Imagine the knowledge, commitment, expertise, and fanatical
attention to detail it must take to earn that right.
only 15 men.
You’d think there’d be hundreds of men and machines cranking out
Arai shells for the world. But that’s not what a rider who buys an
Arai expects. An Arai rider expects handmade care and attention, and
that’s what you get. You can get mass-produced helmets anywhere.
You get handmade ones here.
only 15 men.
Understand that these 15 have to make every shell for all of Arai’s F-1,
Indy car and NASCAR helmets, motorcycle racers and riders helmets
for the whole planet. One at a time, by hand.
only 15 men.
It gets even better. Arai’s obsession with excellence is so extreme that
the composition of the resins used to bond the shell components can
be changed several times in a single day - just to compensate for
changes in ambient temperature, humidity and barometric pressure
inside the factory that could affect the bonding properties. Yes, we’re
serious. Because a rider must be able to trust what’s under Arai paint.
Finally, every single Arai shell is measured for thickness and weight
to conform to Arai’s rigorous tolerances. (No easy random or batch
testing around here.)
The result of all this is that you get to wear one of the ones
that makes it.
(Put a price on that.)
Convince yourself at www.AraiAmericas.com
For a copy of Arai’s new 40-page color catalog plus an Arai sticker pak, please send $4.00 in cash or stamps
($5.00 U.S. Currency if outside the U.S.) to Arai Americas, Inc., Dept. 15MEN2010, P.O. Box 9485, Daytona, FL 32120.
Specifications subject to change without notice. ©2010 Arai Helmets.
The Official Helmet of the Daytona 200.
in downtown Conway, South Carolina, and the 2-inch
ID connector pipe that the muffler slips over is swaged
oversized, just slightly, and bingo, the fit is perfect.
Amazing what you can do with the right tools.
Okay, the wiring is done, the exhaust system has
been reinstalled, and all the connections are nice and
tight. The re-flashed ECU is installed, and the battery
is reconnected. You must do this in this order, or you
may fry your re-flashed ECU. The engine fired on the
first revolution, and the melodious sound of a 90-degree
V-twin filled the shop. People came running from all over
to see what was making such beautiful music. Most of us
are gearheads around here, so it doesn’t take much to get
this group excited. But the sound is great. Just what the
doctor ordered.
Now for a visit with Mark Gillotte at Moto Gizmo,
Columbia, South Carolina, www.moto-gizmo.com, for a
quick balancing of the throttle bodies and setting of the
CO. Something we used to do by ear and unisync in the
pre-fuel injection era of carburetion. Mark Gillotte, owner
and mechanic, is a stickler for details and a perfectionist
when it comes to Ducati motorcycles—well, for that
matter, any bike. Mark found some flies in the ointment
but was able to get the bike set up and running great.
The power from the racing program is obvious, now that
the system has been dialed in.
Now with a few days of running time, the system is
uninstalled and packaged for a quick trip to Jeff Howell
at Jet Hot, www.jet-hot.com, located in Burlington, North
Carolina, for a heat-resistant coating of all the parts,
even the clamps and head-pipe flanges. Nice to have a
great high-temp coating process center in our own back
yard. I chose the black coating to help make the system
disappear against the dark asphalt, making the bike look
even leaner and meaner. Jet Hot covers the spectrum
from a shiny aluminum color to a jet black finish. Check
out their web site for more info.
With the system coated and reinstalled, I still had
two things left on my project list.
First, have some real photographs
made of the Monster with its new
pipe by my good friend and hand
surgeon, Dr. Stewart Haskins. He
can fix your carpel tunnel and do
your portrait with equal prowess.
I’m his poster child for his carpel
tunnel surgery technique, and his
photos grace this article.
Last but not least, a quick
trip to KWS Motorsports of North
Charleston, South Carolina, www.
kwsmotorsports.com, for a dyno test
for rear-wheel horsepower. Sorry
I didn’t think to do this before we
started the Monster project, but I
am told on high authority that it is
difficult at best to get an accurate
before-and-after measure of the
rear-wheel horsepower. I’m told that
there are so many factors such as tire and chain wear,
bearings and brake pad drag, and engine and clutch
condition that all factor into the equation. The chances
of getting any concrete information are, at best, a real
The cycle magazines like to see rear-wheel
horsepower to help clear the air, as crankshaft
horsepower comes from a wide variety of methods. I’m
told that some manufacturers remove exhaust systems,
stators, and anything that may cause drag and reduce
the final number. So, for what it’s worth, the rear-wheel
horsepower, with the new two-into-one exhaust, came out
at 102. This surprised even me.
Now looking ahead, I can see additional projects
with the Monster as a base starting point. I can also
see contracting custom exhaust systems for street and
racing applications. Options for Ducati, Aprillia, and
MV Augusta non-superbike applications are limited at
best. So, if you’re in the market for a customized exhaust
system, then check out my Project Monster and give me
a call.
Next installment for Project Monster: some
suspension work with Rick Tannenbaum at Cogent
Dynamics. Stay tuned.
SUMMER 2011www.USDESMO.com
TinyTekTip #2
Oh for a Better Day, or How I Solved a Short Problem
by Jim ‘il Capo’ Calandro, Member #00001
Whenever I get a new bike—well, most of them are used but they are still new to me—I install a hookup for a
battery tender. I use it both to keep the battery charged and to connect up my electric vest. Over the years I have
done this on about 20 bikes, and each one provided its own challenge. The main problem is that by adding
the extra eye connector, the mounting screw is a little short to reach the nut. Most batteries have a post that is
hollow and has five holes in it: one on the top and four around the sides. The nut that holds the bolt in is usually
a very crude flat piece of metal that just slides in from the side of the terminal, and you have to put the screw
down through the top hole and catch the nut. Well, without any wires attached it is simple. When you add more
than one wire connector, it becomes more difficult with each one. This is a result of the top of the terminal being
taller than the screw is long, and once it has two or more eye connectors under it, the length will not allow it to
reach the nut.
For years I had tried various small, flat-bladed screwdrivers to attempt to lift the nut. The problem is the
space around the battery does not always allow for this. One day I had an epiphany. Why not put an “O” ring
under the nut? I found one that was just about as thick as the space between the nut and the top of the terminal.
Pushing it under the nut raised the nut up to the bottom of the post where the screw could reach it. The real
advantage is it holds the nut in place so you do not have to grow a third hand to hold wires and nut and turn the
screw. The hole in the “O” ring allows for the screw to go in as far as necessary to make a tight connection. One
of those simple fixes that makes you slap your forehead and say, “Why did I not think of this years ago?”
We have a ton of these TinyTekTips, and we bet you do too! Send us your favorites and we’ll print ‘em and
collect ‘em on the web site.
story by The Ducshop
We are committed to making your Ducati dealer experience as satisfying as your Ducati riding experience.
Decades of passion and know-how have come together to offer you the most knowledgeable and friendly
service you will find anywhere. We’re here to make a difference...
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t took six of us to get Mark onto the race track: three
to hold the bike, one to put it in gear, one to strap his
legs in, and another to ride behind, but among us we
helped a paralyzed man ride his Ducati again.
Mark Brereton became paralyzed four years ago
when he crashed at Barber Motorsports Park while
practicing for an AMA race. The doctors believed Mark
would never walk again, but this past weekend Mark
defied all the odds and not only walked but rode his
Ducati 748 around Barber for three 20-minute track
sessions with SportbikeTrackTime.
The 38-year-old gained limited use of his legs two
years ago and is able to stand and walk short distances
with the aid of a walker. With this limited ability, Mark
approached Ducshop to add a thumb shifter to his 748
so he could shift gears and finish the lap he thought he
would never be able to.
Mark Sutton worked tirelessly to have the bike
finished for the SBTT weekend, and all of Ducshop’s
regular track-day-goers were on hand to help get Mark
onto the track to ride.
It was a harrowing first session, but with much pride
and jubilation, and to the cheers and tears of his family
and friends, Mark Brereton rode his Ducati again.
Mark has quite a list of people to thank: Richard
Harris and all the crew at SportbikeTrackTime
for sponsoring his track time; Brian Van of
SportbikeTrackGear.com for decking him out
with leathers, back protector, and gloves; TJ at
ridersdiscount.com for the boots; Pirelli for providing his
tires; Lee McCurdy for donating a Baxley stand; Neil
Hodgson for donating the helmet; and Mark’s wife Sam,
daughter Olivia, and son Devin for all their support and
frayed nerves.
Mark would also like to thank all the Ducshop
people who helped him on the day, including Sean
Massey, Peter Runyon, Cliff Clarke, and Lewis and
Trudy Guthrie. But most of all he’d like to extend a
big thank you to Mark Sutton for preparing his bike
to ride.
SUMMER 2011www.USDESMO.com
Ducks Along The Blue Ridge 2011
Tom Rolland • 2808 Prenda de Oro NW • Albuquerque, New Mexico 87120
email: trolland@webtv.net • http://www.webgrafex.com/ducatibeltbuckles/
Ride Like the Wind
Marvin Jensen heads out to test the route.
Bill Park on a loaner BMW from Moto Gizmo. Quite a diversity of bikes at the rally.
Bill Park is a metallurgical engineer and small business
owner, manufacturing high performance trim tabs for
offshore racing boats and a self taught artist. His is
an avid motorcyclist, gear head, and a fan of World
SuperBike and MotoGP. His automotive and
motorcycle art works are highly sought after
by collectors around the world.
View the gallery and
purchase prints at
Bill Park
843.234.9500 • 153 Winyah Road, Conway, SC 29526
Our stop in Independence, VA before we start the long trek on Hwy 58. Notice all the Guzzis this year.
Motorcycle chain and wheel work made easy.
Wheel and Tire Cleaning
Chain Maintenance
Valve Stem Positioning • Tire Inspection
Patent Pending
Proof that is does not always rain at DABR!
Have Monster will travel.
SUMMER 2011www.USDESMO.com
Bench Racing
Tall tales of fact and “friction”
Down Shift: A moment of weightlessness
by Neale Bayly, Member #01174
aralyzed by perception, the call confirming I
would be riding Valentino Rossi’s Moto GP bike
sent seismic waves across the phone lines, rocking
and shaking the fabric of my known world. Seconds
turned to hours, minutes to days, as every heartbeat
began ticking down the time ‘til I would take the ultimate
motorcycle challenge. How could one motorcycle strike so
much fear in my heart, and so categorically undermine
every component of my life that represented stability
and security? Not cut from the same cloth as Rossi, nor
possessing the heart of a lion or the courage of David,
But as the inline four-cylinder engine roared
violently to life, and the mechanic blipped the throttle
to warm it for me, there was no more room for thought.
Slipping the M1 into first gear, sliding out the clutch, and
tiptoeing onto the Valencia racetrack under the brilliant
Spanish sun, I found the weeks of expectation were
over. Even as the battle of reason and terror still waged
in my mind, mercifully I had enough pre-programmed
motorcycle responses left to navigate the famous circuit
for my four allotted laps. Riding slowly and cautiously,
there was a release from knowing that I had won the fight
“Even as the battle of reason and terror still waged in my mind,
mercifully I had enough pre-programmed motorcycle responses
left to navigate the famous circuit for my four allotted laps.”
there was no machine I had ridden that could have
prepared me to ride his personal steed. Lifting the front
wheel of an AMA Superbike at 170 mph, setting a land
speed record of 202.247 mph on a nitrous-oxide devouring,
two-wheeled beast, or twisting the throttle of Rich Yancy’s
insane, 260 mph, street-legal, turbocharged Hayabusa
seemed hopelessly inadequate as qualifiers for this test.
Factor in a value of over one million dollars, or
that the number 46 emblazoned on the hand-made,
carbon-fiber bodywork belongs to possibly the greatest
motorcycle racer ever sent by the gods to taunt us fragile,
fallible humans, and at least there was valid justification
for my fears. Valentino Rossi is without doubt blessed
with superhuman abilities, but the marvel of modern
technology that sits beneath him should not be overlooked
in this equation of world dominance. Producing 250 tireshredding, blood-sweating Ferghana horses, propelling a
package weighing 320 pounds, and hiding a Pandora’s box
of electronic and mechanical secrets that contribute to its
phenomenal achievements on the world’s toughest stage,
just the chance to see this machine at close quarters is an
honor and highlight that could last a motorcycle lifetime.
and climbed into the saddle of doubt on the horse of all
my fears. And there on the long front straight with the
throttle pinned to the stop and the inline four cylinder
shrieking its blood-curdling battle cry at 15,000 rpm, I
found salvation. Experiencing the sound, feeling, and
mind-altering exhilaration of Valentino Rossi’s Yamaha
M1 at full power was my once-in-a-lifetime opportunity to
sit at the feet of the gods, if only for a brief few moments.
Fifteen minutes later, I was standing in the Yamaha
pit. Laughing from the very fabric of my conscious
being, my inner happiness reflecting in crew chief
Jeremy Burgess’ face, I felt an incredible moment of
weightlessness. I was a lover hearing the words “I do,” a
father holding his newborn child, or maybe Vale himself
climbing the top step of the podium, his foes vanquished
one more time and his place amongst the gods secure. I
won’t ever win a world championship, but this brilliant
memory will last forever. And, as the years pass, I will be
able to relive it as I recapture a few of those indescribable
moments. I had ridden and experienced the world’s
fastest, most famous race bike and, contrary to my
perceptions, lived to tell the tale.
Endless Transformations
Multistrada 1200.
A dream Ducati: 4 bikes in 1. A sport bike, long-distance tourer,
urban machine and an adventurous enduro are now all one click away. With the
Testastretta 11° engine, the Multistrada 1200 is a masterpiece of sport, comfort, safety
and handling, ready to transform itself for every new ride, for every new thrill.
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Ducati Monster 1100EVO
The Ultimate Monster
Evolution equals unprecedented thrill. With the 1100EVO we’ve perfected the formula that has defined the
Monster as the worlds most iconic naked motorcycle. The 100 hp Dezmodue Engine coupled with the
Ducati Safety Package, including ABS and Ducati Traction Control, provide an exhilarating, yet smooth
and controlled ride. The low-slung exhaust and improved ergonomics enhance both style and comfort.
Monster 1100EVO: The performance is undeniable. The thrill is something you must experience for yourself.
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