Featured Grab Yourself Some Popcorn. This Might Take A While.

Yes I appreciate they serve that purpose, as well as providing a seal. I didn't mention it as I thought that was a given.

 

So as I wait for some fairly major parts to arrive, I managed to finish off a few little jobs today, the first of these being the cooling system and this the last pipe in the SAMCO kit. The diameter is too large to use the stock wire clips so I used JCS stainless steel 9.5-12 clips instead.



CNC Racing billet expansion tank cap



De-pinned the connector for the oil pressure sensor, in order to fit this "Amp Tyco" rubber gaiter. With this done, all the RHS lower wiring is now complete.



Took the opportunity to fit the newly clear coated clutch cover. Torqued to 5Nm.



Hopefully I should get around to fitting the fuel tank in the next couple of days, whilst I also tackle wiring up the bar end indicators and the rest of the front loom. Unfortunately I am waiting on some parts to allow me to fit the front wheel which means I can then remove the front paddock stand, as I need to be able to move the steering from lock to lock to check cable routeing and that there is enough free play and no snagging.

 

So with the tear down having started on the 23rd September, I am pleased with the rate of progress so far. 62 days in and counting, from a bare engine to where I am at now. I won't go as far as to predict a completion date, but this is shaping up to be the quickest build I have done thus far.

 

Not much opportunity to work on the bike today, other than fitting a "Throttle Spacers" kit, which removes any slop and makes a noticeable difference. I fitted one on the last bike and was very pleased with it.



I did at least receive a few more parts, so hope to have the tank on tomorrow evening.

 

The custom bracket to allow me to use the Evotech tail tidy with the Termignoni system, is currently tasked to a local engineering company, who have made one-off parts for me before. It might be that they opt to produce a new exhaust bracket (similar to the one I designed, albeit as a dimensional sketch) that attaches directly to the tail tidy or modify the design of the tail tidy itself (which means incorporating the bracket for the exhaust directly into it), either as a bolt on element or machining completely new tail tidy halves from billet using CAD, where the bracket is integral.

Currently only Rizoma make a tail tidy that is designed to work with the D200 exhaust system, but unlike the Evotech version, it is much larger and the wiring is exposed to the indicators, so it is not as neat and compact a solution. Deciding to stick with Evotech, has made the job a lot more complicated but I think it will be worth the effort.

 

Little bit more done today as still waiting on more parts. Fitted the MotoGadget bar end indicators which is a very fiddly job, as you have to thread the wires to each indicator through the handlebars and out through the 3mm hole I pre-drilled under the bars, then I bought some 3mm sleeving to protect the wires and routed them over the air intake duct. They will sit in the void under the front subframe so that there is enough slack in the wires when you turn the handlebars but I'll check this properly once the front wheel is back on.





Here's the wiring to the indicators, which will largely be hidden by the front subframe. Lots more to tidy up, but it is getting there. I've got to solder on the pigtail connectors so that they'll connect directly to the OEM plugs on the front loom, but that will have to wait until they arrive.

 

Thanks, yes slowly getting there, though there are only so many hours in a day and I'm juggling what free time I have between working on the bike and other commitments outside of work. First world problems but I do what I can, when I can.

 

Got to hope that tube of Parabond 600 I bought is still useable as I've a couple of Lieb Speed parts to fix back on the bike. Firstly the seat pad cover which, as with the subframe covers, I have prepped with some heat reflective foil tape onto which the sealant is applied before bonding the carbon cover on. There are all carbon versions but I found they flext too much when trying to lock them in position on the bike, so this option is a better solution IMHO.

 

Had an hour to spare so fitted a few more parts.

Pro Bolt perch bolts M6 x 25mm, torqued to 10Nm





Last few of the titanium fasteners from RaceTi. This time the subframe cover bolts, M5 x 12mm. Torqued to 2.8Nm.



Fitted a 21mm grommet in the Termignoni undertray.



Next up was the fuel tank...

Again RaceTi bolts. The front ones are M5 x 30mm, torqued to 6Nm



Then the rear two bolts. M5 x 10mm. Again torqued to 6Nm.





Next the seat bracket (which I had Cerakoted "Glacier black") fixed in place with 4 x Pro Bolt M6 x 10mm bolts, torqued to 8Nm and ACCU stainless steel M6 washers.





Next the two tank lines (formerly the one on the left would have gone to the now defunct EVAP canister and the right one was the fuel overflow), so the Y-join allows you to run a single line to the drain point under the bike. Secured in place with two new zinc plated clips.




Last job was to connect the fuel pipe. I discarded the OEM clip as it's made of swiss cheese and prone to fail, so I used a JCS 9.5-12 stainless steel jubilee clip. Tightened by hand, not too tight as the fuel delivery barb is only plastic, so gently does it.



And here's the tank finally back in place on the bike.