Whilst I wait for the Cerakoted parts to return, I need to check the clearance for the aluminium radiator pipe in between the frame and engine, as if it clears with the frame in situ, then I can fit the frame now and the pipe at a later date when it is back from the paint shop, which will allow me to make much more progress over the next few days. Not looking hopeful if I am honest. The alternative would be Wednesday at the earliest to refit the frame, which is very frustrating since I have a few days off work
So it looks as though the aforementioned clearance is good, which means I can fit the front frame. Hallelujah! First job was to sort out the all main wiring branches which need routeing a specific way around or under the frame, before securing it to the engine using some very special bolts (more on these later). Next I had to remove the frame brace to be able to access and connect up the front coil packs to the loom, then clip them to their dedicated mounts under the airbox. This brace was only introduced on later models, incorporating the cut-outs in the main frame. Here are the coil packs connected to the loom. After this I could attach the cyclone pipes to the engine and secure the 'Norma' clamps in place Re-fitted the front frame cross brace. Torqued to 23Nm as per spec. Retaining nuts are accessed through the frame cutouts. As you can see (with it fitted) it is difficult, to say the least, to access the wiring and connectors. In fact the service manual requires it to be removed when doing any work on the front cylinder head, as you can't remove the coil packs with it in place. I am hoping to get the forks back on in the next few days and once the linkage bolts arrive from TGP MotoRacing, I should be able to dispense with the engine stand. Lots more work to do with all the various wiring branches, so plenty of jobs to keep me busy
More from MotoCorse. Here's one of the four front frame plugs. These comprise of the main frame bolt, cap and allen retaining bolt. I have not tightened everything up yet so I will show you them in situ later.
A few more bits and bobs today. Fitted new pads to the rear caliper I transferred over from the previous project, then bolted it back onto the bike. Pro Bolt M8x20mm stainless steel bolts torqued to 25Nm. The pinch bolts were fitted during the previous project. The stock bleed nipple will be replaced with a Stahlbus bleeder check valve, once I begin fitting all the hydraulics back on to the bike. The garage lighting tends to wash out the colour, as it is a much deeper red than it appears here. Battery earth lead fitted. Pro Bolt M6x15mm stainless flanged head hext bolt and ACCU stainless serrated M6 washer. Torqued to 10Nm. RPM Pick Up Sensor fitted. Pro Bolt M6x15mm stainless flanged head hext bolt and ACCU stainless M6 spring washer. Torqued to 10Nm. Note that the steel blanking plug is no longer fitted to the later engine casings, which was previously used to inspect the gap setting of the sensor, as can be seen on the earlier model in the last picture.
Fascinating and admire your undoubted skills mate; very impressive and no doubt streets ahead of vast majority of "approved" ducati technicians. But what does all this do to your warranty on a new bike? Or is that irrelevant?
