Ducati 998s FE Final Edition (REPLICA but MODIFIED FAR BEYOND the Original) Build Thread

[BMW Alpina]

Some few small things I did last weekend was installing 2 ProTi bolts to cover the unused bolt holes for the original factory license plate bracket:



Install the ProTi Titanium bolts that hold bolt Motocorse silencer together:




And replace the regular hex socket bolt that came with Motocorse Rear Brake reservoir with the ProTi Torx Titanium bolt:

Below picture shows comparison between the regular hex socket bolt that came with Motocorse brake fluid reservoir to the ProTi TORX version:



I also finally able to install the Ducati Performance Carbon Fiber Clutch Cover (Satin clear coated) because the right length ProTi titanium bolts finally arrived:




Yes, they look PERFECT :

 

[BMW Alpina]

I also managed to do a bit more last weekend:
First, I want to install the EVR Carbon Fiber Coolant Tank reservoir (expansion tank), and I started by covering 3 unused threaded holes with some leftover Gold colored ProTi titanium bolts:


But I then realized, I don't have any of the extra parts needed like the filler neck, the filler caps nor the hoses... I somehow forgot to buy a brand new parts for it. You can see all the missing parts in the picture or the original tank below:





After looking at some supposedly brand new filler neck on eBay, I realized, even when it is brand new, their finish is ugly (rough and dull)...
so I decided to just used my current old filler neck but have my sons MIRROR polished it:


AFTER Mirror polished pictures below (my son spent a few hours mirror polishing it):



But then I realized I want 1 step further by painting it in an Anodized Red color, which my son did for me. He still will add a few more coats to it next week:


In the meantime, I ordered all brand new radiator filler cap, and hoses (including Samco hoses) for this EVR carbon fiber expansion tank/coolant tank reservoir which should be here in 3 weeks or so.

Last,
I install the rubber grommet for the stud where the fuel tank hold onto the carbon fiber airbox... This is not easy because the rubber grommet is large and made of stiff/durable rubber. It took me more than 30 minutes but I finally made it:




I am hoping this weekend will be another productive 998 weekend

 

[BMW Alpina]

Today, I am starting to identify all the "special" connectors on the main wiring harness. The factory 998 wire harness is no longer in Production, and I checked with Ducati dealers all around the world, from Asia, the US, Canada, Japan, Australia, and the EU. I even reach out via LinkedIn to Claudio Domenicali, the CEO of Ducati. He told me he would check, but there have been no more updates since then. So it's surely not available anymore.
I actually have 2 sets of full 998 main wire harnesses, one from my bike and one I bought used from Germany (the seller claims it is new from 998R, but it turns out it is NOT new, although it is in decent condition).
But I am not happy because almost every part in this bike had been replaced with brand new parts (except the main trellis frame, which had been refinished better than the new one). Well, very few other parts are also not new, but had been reconditioning better than new, like, for example, the coolant tank filler neck a few posts above.


Anyway, my plan is to have a wire harness specialist build a Motorsport Grade brand new main wire harness, but with Ducati's original connectors.
The wire harness will be based on the Raychem/TE Connectivity “System 25” Motorsport Grade material system.
Now I need to find the New Ducati original connectors, thus why I am starting today by taking pictures of these special connectors:

1. Below is the overall picture of the 998 main wiring harness. Please note that I already have 2 brand new fuse boxes that can be use to build my new wire harness:

b. Below are the pictures of the 19-pin round connector that will connect to the front sub-wire harness (lighting, dashboard, turn signal)



c. Below are the pictures of the 2 connectors going to the Magneti Marelli ECU:



d. Below are the pictures of the 2 connectors for the Fuel Injectors made by AMP:



e. Below are the pictures of the other 2 connectors (similar to the fuel injector connectors, but they are slightly different), one was made by AMP, and the larger one has no brand on it:


f. The picture below only shows 2 grey connectors, but in this wire harness, there will be 3 grey connectors needed:


g. The 2 pictures below show the last connector that I believe is difficult to find. I already purchased a brand new light switch that happened to have the same connectors like this on it that can be harvest/cannibalize:



The rest of the connectors are simple, basic types that are common.

 

[BMW Alpina]

Yesterday, the Post Lady stopped by and delivered this Samco Hose in Classic Black from Demon-Tweak in the UK. This Samco hose is for the coolant tank reservoir/expansion tank.




Then, I tightened the ProTi bolts that hold the Brembo T-Drive Brake Disk Rotor to 25Nm (with Loctite Anti-Seize):



I did the above because it's time to balance the wheels.
So, this beautiful Sunday morning, I started by setting up the ValterMoto balancing wheel tools.


First, adjust the feet and level the surface with this water level indicator:


Now leveled and ready, oh by the way, I upgraded the bearings on this ValterMoto tools with Ceramic Bearings for super smoothness:



Next, I prepared the shaft:


Insert the shaft onto the wheel center holes:



Then setup the cones:








Ok, now ready for balancing:



I marked the area opposite of the heaviest point on the wheel with blue painter's tape, then after several testing, found that 2 pieces of 5grams weight is the best:




Test again, and it is FULLY balanced:

 

[BMW Alpina]

Then it's time to balance the rear wheel.
First, I took out the Single-sided Swingarm Wheel Balance Balancing Truing Stand Adapter Tool Ducati from HDESA:



Install it on the Rear Marchesini Wheel:


Then install the Single-Sided Adapter - A from ABBA:



Then install everything on the ValterMoto wheel balancer:


On this rear wheel, I need to use 5 pieces of 5 grams weight. Oh by the way, this weight balancer weight is made by a company called Hofmann and it is the same parts as what Ducati used for my Panigale V4 916 25 Anniversario, looks very beautiful (the weight itself):


Perfectly balanced:


Install the BALANCED rear wheel/tire back on the bike... by the way, the Motocorse 60.5mm exhaust pipe really makes it super difficult to install the wheel/tire back, but I managed with some acrobat of the wheel positioning:

 

[BMW Alpina]

Threaded Insert from Ducati to be inserted into the crankcase and hold the 998R Carbon Belly Pan arrived, but they are seemed to small to be inserted into the hole on my 999 engine deep sump crankcase, so I am trying to figure it out how to install them now:

 

[BMW Alpina]

This week, I have been doing more research on the connectors for the Ducati 998 main wire harness. With the help from great members of both Ducati.MS and Ducatiforum.co.uk (the UK forum) I found the correct 19-Pin connector which needed to connect to the front light relays/and dashboard wiring harness.
I also purchased a brand new NOS Ducati ST3 wire harness so I can harvest the 2 Magneti-Marelli ECU Connectors. I also managed to find the source for the PIN of these ECU connectors and should be able to purchase them next week (when they are back in stock).

Some background story:
Almost two years ago, I was quoted around $4,000 from a professional wire harness builder. However, he did not have all the connectors, so I still needed to purchase some New Old Stock Ducati wire harnesses (from another Ducati model with the same ECU) to harvest the connectors.
Because of that, I asked if he could lower the price to $3,500 since I had to source some of the connectors myself, and he said no. So, I decided to postpone buying the wire harness until I am almost done with my bike build.

Fast forward 2 years later (present time), I am almost done with my bike build, so it is time to start this wire harness project again. However, this time, I decided to contact several other professional wire harness builders to see if I could get a lower quote (with the same quality material, of course).
So last week, I started contacting 5 professional wire harness builders, and only 2 responded.

One said they couldn't do it, and the other said he could, but he wanted to do more research on the connectors and asked me to also help him find the connectors.
What is funny (well, maybe not funny) is that even the second pro wire harness builder now does not respond to my emails and phone calls. I hope nothing bad happened to him because he was very eager and promised to get back to me the next day after he did his research.
He even gave me some rough pricing, and I already agreed to his pricing. Roughly maybe $3,000 to $3,500, including all the NOS wire harnesses I need to purchase to supply him with the connectors.

If by the end of next week, the second pro wire harness builder still does not respond to my email/call, I will build this wire harness myself. I think it would cost even less (or maybe about the same since I will need to buy a lot of crimping tools).
But I am determined to replace every part on my 998 build with brand new parts, and this main wire harness is the only part (except the frame and some very few other parts) that came from the old bike. This is a 22 years old wire harness, I think it's time to be replaced.

Having said that, I do have 2 sets of fully functioning 998 wire harnesses, one came with my bike, the second I bought from Germany ex 998R, but I still want to get a brand new wire harness build, just cannot stand the looks of used wire harness (dirty, tired and old)...

 

[BMW Alpina]

By the way, last weekend, I also installed the Brand New Front Ducati Red Mud Guard (Original Ducati part of course). Before I installed it, I covered the hole ex bracket for front brake like with ProTi Titanium bolt as usual, I just don't like the looks of an open threaded hole without anything covering it:



Next, I test fit to determine the correct orientation and height of the NCR mudguard bracket (yes from that NCR company):



Then once I know the right orientation and bolt height, I apply Loctite 243 (Medium) and attached the NCR mudguard bracket to the Motocorse Billet Lower bottom:



The NCR bracket looks proper racing setup, too bad, it will be mostly hidden behind the Mudguard:



Then, I still need to add spacer to space out the mudguard further so it will cleared the rotating tires. Noticed, I had different thickness of the spacer on the top and bottom to compensate for the slight curve of the mudguard:


The picture below just to further illustrate where the spacer is located, but of course it will be BEHIND the mudguard not in front like shown in the picture below:



And they were installed:

 

[BMW Alpina]

There was a lot of real progress last weekend, but it all started a few weekends ago.

Below is the KTM speedometer cable that I purchased because I needed a longer one due to the "rotation" of the speedometer gear outlet caused by the Motocorse fork bottom's radial mount caliper style.


I even added an extra insulation using heat shrink tubing to protect the metal part of the speedometer cable end:



However, after I fitted this speedometer cable, turn out it had several issues:
a. It is too long overall (which is still manageable),
b. the cable end on one of the ends did not protrude long enough to catch the gear on the speedometer input, so the speedometer sometimes does not turn, which is a big problem.

So, after doing more research, I decided to purchase the speedometer from Ducati Monster, and turns out this is the PERFECT fit, both in overall length and Ducati Speedometer and Gear compatibility. Here are the pictures after the speedometer cable installed:







I also decided to test fit the switches on the original 998 handlebars. Note: I am using the original 998 handlebars with all the holes drilled, so I don't have to drill holes to fit the switches anymore. I did replace the handlebar to fork bracket with the bracket from Ducati 1299 though.

These original 998 handlebars had been cerakoted:






I install the left switches below along with the Rizoma Grip, but then I realized, not enough space to place the choke and the clutch master cylinder. The Ducati 998 original handlebars are too short to be used with 1299 handlebar to fork bracket !!!


So what should I do... stay tune, I will update soon

 

[BMW Alpina]

The solution is the Billet Handlebar from PerformanceParts.de Germany.

Initially, I want to plug the inner side of the billet handlebar with the Ducati 998 OEM handlebar plug, however, they are too big in diameter for the PerformanceParts.de billet handlebar



So I checked my 23mm Motocorse frame plugs (extra parts) and I found an idea to combine them with Ducati Rubber Expansion nuts:






Next, I need to test fit and make sure the Motocorse TITANIUM handlebar weight (from Motocorse JAPAN) fit this PerformanceParts.de billet handlebar:


Which they do perfectly:





But there is a problem,
The Ducati 998 (and 1299) handlebar had a NOTCH cut into them so they can be firmly held in place (and for spacing) with the second bolt on the handlebar bracket to fork, while the Billet Handlebar from PerformanceParts.de does not have... so what should I do about this...



Well, nothing that the good ol' Dremel can't do , but it got to be done properly.
First masked the area surrounding the notch to prevent accidental scratch:



Place firmly on the visegrip and start dremelling away:



Stop to make sure the first mm of cut is good:


And finally done:


Check the result without 3M blue painter's tape:

 

[BMW Alpina]

Looks good, time to test fit into the clamp bracket to the fork, and they fit perfectly:


Time to work on the other side:


And test fit the other side:


They are perfect length, longer than the original 998, pictures below to compare the length:


Still, more things to do for these handlebars... I will write more soon, got to eat my dinner...

 

[BMW Alpina]

Now, I need to determine the location of the holes to drill on the handlebar.

I started with the left by inserting the choke lever:



Then, the left-hand switch, the Rizoma Grip, and finally, the Motocorse Titanium end weight. Note that I did not tighten the left-hand switch because I have not drill the hole to fit the locating pin.
I just loosely located the left switch so I could determine where the location to drill the hole for its locating pin (both horizontally and rotational location):




Now I know the rough location; I verify further by matching the original 998 handlebars with PerformanceParts.de side by side (use the blue painter's tape to firmly hold them together) and mark the location to drill:



This is the tool to help secure the drill bit so it won't slip away drilling a smooth round handlebar tube:


The locating drill bit tool now securely mounted on top of the location to drill and drill baby drill:


Initially, I was thinking of using my drill stand, but then I figure, my hand will still be pretty stable, just have to do it slower:


And voila:



Next is the right side.
First I need to select the right pulley type for the Rizoma grip for throttle. The Rizoma grip for throttle came with 3 different pulley type.



Then measuring and located the location for the pin again. However, for the right handlebar, I need to drill 2 holes, the first hole for the kill switch locating pin, the second hole for the throttle assembly locating pin:




Two holes drilled:


So everything related to the handlebar is ready to be installed properly.

 

[BMW Alpina]

I then installed all the switches, Rizoma grip, Motocorse Titanium handlebar weight,... but how about the other end of the handlebar hole near the speedometer/fork?

Well, it's time for the Motocorse 23mm frame plug hole combined with Ducati rubber expanding nut to be installed:




This is how they look:

 

[BMW Alpina]

Hmmm... my 998 need to look alive, so I decided to install the headlight :

This is a brand new headlight housing, I was lucky that I bought it before Ducati stop producing it. All bulb had been upgraded to LED:



Start by connecting the main connector of the headlight:


Install the headlight adjuster bolt, but upgrade with ProTi Titanium as usual:



It is alive, it open it's eyes :

 

[BMW Alpina]

Next is the Brake and Clutch Master Cylinder.

I decided to use the original Brake/Clutch MC from my DUCATI Panigale V4 25° Anniversario 916 because it came with super nice Rizoma levers with Ducati laser marked on it from factory. I also upgraded all the bolts with ProTi Titanium.
I could replace them with RCS Corsa Corta MC. However, I want to keep all the stock switches of the 998, so this stock-looking MC is a perfect complement.

Let's start with the Brake MC:


I also upgrade the clamp with the Billet Clamp from Brembo and below are the pictures of it installed:







Then the Clutch MC, which has the switch that not needed for 998, so I remove that switch:




Clutch MC Installed:






Again, I think they really complement the stock 998 switches:

 

[PanigalePilot]

Next is the Brake and Clutch Master Cylinder.

I decided to use the original Brake/Clutch MC from my DUCATI Panigale V4 25° Anniversario 916 because it came with super nice Rizoma levers with Ducati laser marked on it from factory. I also upgraded all the bolts with ProTi Titanium.
I could replace them with RCS Corsa Corta MC. However, I want to keep all the stock switches of the 998, so this stock-looking MC is a perfect complement.

Let's start with the Brake MC:
View attachment 14171

I also upgrade the clamp with the Billet Clamp from Brembo and below are the pictures of it installed:
View attachment 14172

View attachment 14173View attachment 14174

View attachment 14175View attachment 14176


Then the Clutch MC, which has the switch that not needed for 998, so I remove that switch:
View attachment 14177View attachment 14178

View attachment 14179

Clutch MC Installed:
View attachment 14180View attachment 14181

View attachment 14182View attachment 14183

View attachment 14184

Again, I think they really complement the stock 998 switches:
View attachment 14185View attachment 14186

Great work
I like the instrument cluster
The levers look great

 

[BMW Alpina]

Great work
I like the instrument cluster
The levers look great

Thanks so much @PanigalePilot

 

[BayAreaMotoDegenerate]

Amazing build.

 

[BMW Alpina]

Thanks so much @BayAreaMotoDegenerate


The next thing I did (2 weeks ago) was installing all the sensors. (Just FYI, at this moment, I have made much more progress, such as the custom Goodridge oil line to the cylinder heads with hundreds of pictures, but I just need to find time to post it here), airbox test fit, throttle body fitted with JetPrime velocity stack test fitted etc...)

I installed the Neutral Gear Sensor on the Crankcase a long time ago before I shipped it to Bruce Meyer to build the engine, but I removed the wiring to the Neutral Gear Sensor.
Luckily, I still can find this wire underneath tons of other parts, and I installed it:


After that, the Oil Pressure sensor:


It require a special Crush Washer from Ducati and larger-size 15/16" (yes, it is NOT metric) socket wrench:




Then, the Sensor for coolant temperature:


This sensor needs special Loctite sealant and the 3/4" (not metric) socket wrench:






Then, the second coolant sensor (more like a Thermistor or an on-off switch):


It uses a regular cooper crush washer and 13mm socket wrench:


Next is the RPM/Timing pick up sensor (Bosch):





This RPM sensor needs to be finely adjusted (air gap) with 3 different custom washers.



After measurement with special gap tools, I initially choose the thickest washer:





I will show the Air-Gap measurement process on the next post soon...

 

[BMW Alpina]

This is the feeler gauge tool that I bought to measure the air gap. Please note, you need to make sure your feeler gauge tool is the "slim" design like this one since the hole to insert and check the air gap is not that big. My previous feeler gauge was to wide, thus I need to buy a new feeler gauge below:



After I check with feeler gauge and determine the best washer/spacer, I start lubricating the o-ring with rubber grease to make it easy to insert the Bosch RPM sensor (and prevent damage to the o-ring). Also notice those 2 green O-Ring are actually 2 different diameter and thickness O-ring


I installed the Bosch RPM sensor with the correct washer/spacer and tightened the Titanium bolt:



Next, install the cover for the timing air gap check holes (apply loctite and gasket)


And all sensors are done