Another successful weekend. The 2-1 collector that needed modification by my tig-welding guru was completed, so I went about completing the exhaust install. I utilized an old steel suspension dogbone from some long-forgotten project to fabricate an exhaust bracket which mounted the 2-1 collector and headers to the engine, with a rubber bushing. The only type of bolt I could find in the coarse M12x1.75 was a hex nut, but it will do fine for now. Exhaust bracket mount fabricated and welded in place. The complete exhaust: While it was still on the cold side (wiring sheaths get stiff) I did some work on the harness. I wired in the koso dash into the power leads, as well as the two idiot lights -- the oil pressure warning light, and the neutral indicator light. Everything switches on and off with the main 20A rocker switch on the dash. Both lights on -- the oil is red, the neutral is blue... both are so bright they overwhelm the filter on my phone camera. Neutral light off as transmission is clicked into first. The digital readout on the tach is for oil temp, but I did not plug that lead in. Still need to run the wire for the tachometer signal, which plugs into the ignitech.
My split FCRs have come in from overseas. I've also ordered a set of adjustable intake manifolds from Ducati Aprilia Kämna. I decided to take the carbs apart (the photos looked like the carbs were really clean) and as advertised, there were some new gaskets installed. I tried to set the float height to the recommended 9mm, but I was miles off. Luckily I decided to check out the float seat (which was new) and realized it was for the wrong FCR. I believe it's for an FCR-MX. Luckily Frank! MXParts out of Europe has the correct pair and those, too have been ordered. I doubt I would have gotten it to run properly as it was! I have the Chinese FCRs on the table for comparison. For what it's worth, the intake snorkel from the pukka FCR was damaged in shipping. The Chinese one fits.
A bit more progress. I had to wheel the bike off the hydraulic lift in order to jack up the front end -- I was planning on installing the spacers and the pair of rotors that I originally got when I started the project. However, the rotors did not fit the 636 front wheel. I confirmed it was the correct model year front wheel, and so realized that my original parts haul that started this project has ultimately left me with just one set of yokes, a left fork leg (right was so buggered I had to find a new one), front axle, and two calipers (both of which needed to be rebuilt). The rotors are a mystery and not suitable. Oh well -- either the guy I bought them off buggered me over, or he didn't realize he'd bought mismatched parts. I'll find a solution! In more productive news, I was able to wire in more of the harness -- I fabricated a mount for the reg/rec out of aluminum, and then plumbed the wiring back to the battery box. Over top of the belt cover is perhaps an odd solution, but quite common when upgraded reg/recs are added to Ducati superbikes. While I was at it, I also installed the ignitech ignition module. I also added a wire feed to pin #15 for the tachometer signal. Thanks to Liam at Fastbikegear for sending me some replacement pins. With the help of a welding rod, I was able to feed the wire (the blue/yellow one) through the original shroud up to the front of the bike for the tacho. After confirming the schematic with Liam, I cut the wires to length and fitted them to the coils he also provided. As I'm converting an FI bike to carbs, the signal from the alternator is plug and play -- you can see the OEM connector at the 2 O-clock position from the coils. I also fitted a 900ss/monster belly pan. I did need to modify the underside to clear the pipes. I also snagged a Ducabike 30mm clutch cylinder. It should help with the OEM 12mm clutch lever. The aforementioned brake calipers -- stripped and rebuilt with new seals, and then painted with caliper paint and baked in the $15 toaster oven for an hour. I wonder how durable it will be?? Note the leaking fork -- new seals to come for sure! Bike seems "long and low", but that is likely due to fact that there are no tires mounted! Wheelbase is 55", +/- rear wheel adjustment. Looking a bit racey...
