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 M6x12mm 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?
I think that evaporated as soon as it was wheeled in to his garage I may be completely wrong of course
I have a very understanding dealer. That said I know the risks in terms of the warranty, but this is the fifth bike I have done now and "touchwood", none of them have ever given me a problem. Torque figures aside, every project I undertake, follows the workshop manual meticulously, so the bike goes back together, just as it would have done at Bologna, possibly to an even better standard, when I look at the way some of them have been assembled. Can safely say, if that was a concern, I'd never undertake the work involved.
and where do you get the workshop manual from on such a new model? The same understanding & helpful dealer?
Obviously not. I'm using a combination of workshop manuals I acquired from elsewhere. One is the V4R 2023 model and the other the V4SP2 25 Anniversario. Not all the information is pertinent (such as the eccentric swingarm adjustment on the R model or lack of electronic suspension) but that is irrelevant, as I cross check any torque settings between the two and any mounting instructions given, where they apply to this bike. There isn't really a whole lot of difference across the variants, in terms of assembly and where there are, they are taken into account. Most if not all the information has not changed significantly from 2018. Perhaps half a dozen items and torque settings but that's it.
Looks like my Cerakoted parts and those I sent off to the paint shop will be ready mid-week. Should allow me to make some decent progress over the weekend. No chance of doing much in the meantime sadly, as I am flat out at work with a lot of extra flights scheduled and covering for other crews. I've got a large batch order of ProBolt, Racebolt and RaceTi fasteners en-route and the TGP MotoRacing suspension linkage kit which has left Germany. Most should be here by the end of the week or early next week. Still have a few more parts to order but these can wait a while, as I don't need them at this stage of the build.
Here's a sneak preview of some of the clear-coated parts I am due to pick up at the end of the week. Matte carbon be gone! One of the winglets Drive chain shark fin guard Frame protector Dry clutch cover Termignoni main heat shield Rear silencer heat shield Cross pipe heat shield As for the rest of them, you will have to wait and see.
Picking up the Cerakoted parts tomorrow due to a change in work plans. Clear coated parts will be ready to collect on Friday, so that being said, you should start to see some significant progress in the build. Still waiting on the linkage kit from Germany, but that should arrive any day now, as well as some more titanium fasteners. I should have the bike back up on paddock stands within the week, fingers crossed.
Finally collected all the Cerakoted and clear coated parts today, in between flights. A few more Ti fasteners also arrived, so for now I have got plenty of parts to be getting on with and hope to make some real progress over the next week or two. The titanium rear suspension linkage bolts also arrived from Germany, which pave the way for me to now make the bike self supporting and remove the engine stand.
TGP MotoRacing Titanium Bolts Rear Linkage Kit. This is the sort of jewellery I like! And a little gift to boot. These bolts command different torque settings than those of the OEM bolts, so I won't quote them, as they are specific to the specs TGP MotoRacing use on their custom Panigale V4 builds and therefore irrelevant, unless you are fitting the MotoCorse kit. All in all, it's been a very long day at work so I'm taking the rest of the night off. Stay tuned for more.
Just as a matter of interest, how do you go about getting insurance for the road on such a highly modified bike? My last two insurers have had clauses severely limiting approved mods. My current policy only allows the levers to be changed!
