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

[BMW Alpina]

I continued with installing the original (New Old Stock) 998 radiator today. I posted in the past on how I further modified with AELLA protector, new OEM electric fans, and as usual all ProTi Titanium Bolts:




Insert the right mounting bracket into the right frame stud:





Then using all factory spacer, I secure the left side:












Then the last lower mounting point directly to the left cylinder block cover, using the special bracket and stud from Ducati, with Loctite as advised by the service manual:


And done:

 

[BMW Alpina]

Next naturally is the oil cooler,


First, I need to install the double stud that also acts as a cylinder head oil drain. This special double stud had been painted in Anodized Red by me:


Noticed I add cooper gasket for the oil drain side and Loctite:


Protect with painter's tape, tightened to 12Nm:


Install the cerakoted bracket with ProTi Titanium nut and screw:





On the left side there is a Ducati OEM aluminum spacer between the oil cooler bracket and the cylinder head:




Now attached the oil cooler to the oil cooler bracket:





After this, time to install the gorgeous satin matte painted original New Old Stock Ducati Performance Carbon Fiber V Cover:

 

[BMW Alpina]

Ok... I remember, the reason I decided to install the radiator/oil cooler this weekend is so I can test whether my Ducati Original Carbon Fiber Timing Belt Cover for 999S (with air intake) can fit behind 998 radiator/V-Cover.

You can see the air intake:



Unfortunately they hit the V-Cover so they can't line up with the crankcase:


As you can clearly see on the right side there is gap with the crankcase (well, actually cylinder head, not crankcase):




Out of curiosity, I still want to try the cover for the Vertical Cylinder because, I can always CUT/TRIM the intake of the horizontal cylinder cover,
But they also will not fit. The issue now is the clearance with the frame of the bike since the intake has "hump":


So soon, I will be selling my 999 original Ducati Carbon Fiber Timing Belt Cover:


The good news is, I already find and bought an original NEW OLD STOCK Ilmberger Dry Carbon Timing Belt Cover for 998. It should arrive in about 2 weeks, and I will test fit just to make sure.
If everything is good, it will then be Satin Matte Clear Coat again at Spooky Fast in Arizona

 

[BMW Alpina]

I had done a lot these past 2 weeks, I just didn't have time to post it here, so let's start...

This is the special oil cooler hose line only for 996R and 998R because on the oil cooler end, they use clips instead of nut to secure the hose:


These are Brand New Old Stock hoses:


Coat the Double O-Rings with Motul Engine Oil to protect them from damage during insertion:


Fully inserted:


Now secure with clip:


Time for the left side of the oil cooler inlet (by the way, the hose for 996R and 998R has different outlet/inlet then the non R model, it's just the way they cut the length of the hose that dictate this, but the oil cooler itself is bi-directional):




Now to connect the hoses to the Engine sides, this is the return oil hose and it's connected to the left side inlet of the oil cooler:


This is the outlet side of the hose, connected in a straight line to the right side inlet of the oil cooler:


More clear picture to show which hose goes where (again in Non-R models, the hoses are connected inversely):


Then, I am about to throw away the boxes that contain all oil cooler related items, when I found something flat at the bottom of the box,
Turn out, I forgot that the radiator protector kit from AELLA came also with oil cooler protector... I almost throw it away with that box:


So I install it:


And yes, it looks gorgeous, before and after picture below:




To be continue...

 

[BMW Alpina]

Next... I am comparing the hole diameter of the banjo bolt vs the banjo fitting for the braided oil line to the cylinder heads.


After many measurements, I realized that this braided hose is not your typical AN3 size brake line, but it is an AN4 size line (larger). Initially, I just wanted to replace it with a FrenTubo kit, but they told me their line is an AN3 size, so I decided to make a custom line myself.

Here is another test comparing several Titanium Banjo bolts that I have using pin needle:


The banjo bolt on the other hand is unique because after I ordered some stock Ducati banjo bolt, I realize, they are actually have small limiter to limit the flow of oil to the cylinder head... so contrary to my initial guess that I need to install the banjo bolt with the largest diameter.
I believe this is because Ducati want more oil flow goes to the crankshaft and other area around the crankshaft instead of the cylinder head.
Here are comparison of several Titanium banjo bolts that I have:

 

[BMW Alpina]

Now, it's CLUTCH time :



I found out that It's best to install the clutch side cover before installing the clutch itself and to prevent damage to the main seal, the Ducati service manual requires a special tool just so the main seal can glide smoothly over it.
Well, I found that no one (online) had the official Ducati special tool in stock, and I decided to just 3D print it below (well it was my youngest son who designed and 3D printed it for me of course ):


I tested fit the tool and it is PERFECT :




Next, apply the Ducati Liquid Gasket:


To the perimeter of the Clutch Cover:


Then apply lots of oil to the 3D printed special tool:


Also apply oil to the Main Seal on the clutch cover:


Then Apply Oil to the slot where one of the shaft will go into:


Then position O-Ring on the oil passage way on the crankcase side:


One more check before close the cover:


And closing the cover (I protect with blue painters tape) with rubber mallet tapping lightly:


Once fully inserted, the 3D printed adapter fell of by itself:


And the seal is properly placed smoothly without any damage thanks to the 3D printed special tool:


Then it's time to install all the Pro-Ti Titanium Bolt and test fit the Ducati Performance Carbon Fiber Clutch Cover (already matte painted):

 

[BMW Alpina]

After the clutch cover, I decided to install the Generator Cover, checking to make sure everything is installed on the generator cover itself:




Adding the 2 TITANIUM dowel/bushings:


Also check the front surface of it:


Clean all the mating surfaces with Alcohol:


Apply Ducati Liquid Gasket:


Install onto the crankcase:


Next install the Water Pump Cover:


Apply the Ducati Liquid Gasket, also ready the 2 steel dowel (original Ducati dowel that somehow I mistakenly thought already the Titanium dowel):


Clean the mating surface with alcohol and install the 2 steel dowel:


And install and torque the Titanium Bolts:



Well,... I was happy until.. I found out the 2 TITANIUM DOWELS that I suppose to use for this Water Pump Cover:


So, I took out the pump cover again and clean the dried Ducati Gasket:


Now the surfaces are cleaned and ready, and I install the 2 BLACK DLC coated Titanium Dowels:


Apply Ducati Liquid Gasket again:


And yes, it's PERFECT :

 

[BMW Alpina]

Now it's time for Coolant secondary reservoir. The left is the used that came with the 998 when I buy it. The right is a brand new Ducati original parts with red anodized painted bracket and Titanium bolts as usual:



Take out the bolts holding the rubber intake manifold flange:


And install the reservoir

 

[HKMP7]

This thing is coming along so nicely excellent job @BMW Alpina

 

[BMW Alpina]

This thing is coming along so nicely excellent job @BMW Alpina

Thanks so much @HKMP7


Now, I am installing the K-Bike Clutch rod:


Apply lots of oil and grease:



Then I decided to test fit the front sprocket and related hardware only to realize that I forgot to purchase the O-Ring behind the sprocket spacer, which I already ordered but not arrived yet.
By the way, below is the TITANIUM sprocket spacer :


Also, when I test fit the SITTA front sprocket, it just won't fit... then I realized it is made in China so the tolerance and quality is bad... causing it's inner hole too small to fit to the shaft...
I am not too happy since the Sitta rear sprocket is so beautiful and precise plus made in Italy...
So, I decided to order a NOS (New Old Stock) AFAM sprocket (520 size at 15t).

By the way, the KTM spark plug tools arrive and turn out I still need to grind it a bit to fit the small diameter inside the cylinder head, but everything is good, and I tighten the spark plug to 20Nm:




Then add the Titanium Stud to attached the 999S coil:


Add some red loctite and tighten the stud:



Add dielectric grease to the inner boots of the coil:


Insert the coil onto the spark plug:


Secure with ProTi Titanium Nuts:

 

[BMW Alpina]

I was busy leading my team to a trade show in SoCal last week, so I have done a lot. However, I do have some updates:

Install the Ducati original clip to hold the wire harness on the generator side:


Install Motocorse Titanium Oil Fill Cap:




I purchased 2 different sets of coolant inlet. 1 pair is blue anodized, the other pair is cerakote:


I also compare the weight:




In the end, I prefer the cerakote pair, plus they are lighter by 2 grams :






Then, it is time to install the Thermostat:



Finally the special bolt/spacer/stand-off for the battery tray:

 

[BMW Alpina]

 

[PanigalePilot]

I had done a lot these past 2 weeks, I just didn't have time to post it here, so let's start...

This is the special oil cooler hose line only for 996R and 998R because on the oil cooler end, they use clips instead of nut to secure the hose:
View attachment 13463

These are Brand New Old Stock hoses:
View attachment 13464

Coat the Double O-Rings with Motul Engine Oil to protect them from damage during insertion:
View attachment 13465View attachment 13466

Fully inserted:
View attachment 13467

Now secure with clip:
View attachment 13468View attachment 13469

Time for the left side of the oil cooler inlet (by the way, the hose for 996R and 998R has different outlet/inlet then the non R model, it's just the way they cut the length of the hose that dictate this, but the oil cooler itself is bi-directional):
View attachment 13470View attachment 13471

View attachment 13472View attachment 13473

Now to connect the hoses to the Engine sides, this is the return oil hose and it's connected to the left side inlet of the oil cooler:
View attachment 13474

This is the outlet side of the hose, connected in a straight line to the right side inlet of the oil cooler:
View attachment 13475

More clear picture to show which hose goes where (again in Non-R models, the hoses are connected inversely):
View attachment 13476View attachment 13477

Then, I am about to throw away the boxes that contain all oil cooler related items, when I found something flat at the bottom of the box,
Turn out, I forgot that the radiator protector kit from AELLA came also with oil cooler protector... I almost throw it away with that box:
View attachment 13478

So I install it:
View attachment 13479

And yes, it looks gorgeous, before and after picture below:
View attachment 13480View attachment 13481

View attachment 13482View attachment 13483

To be continue...

Fantastic

 

[BMW Alpina]

The Ilmberger NEW OLD STOCK Carbon Fiber Timing Belt Cover arrived, and as you can see in the fabric pouch, it still has the OLD (decades ago) graphic. New Ilmberger fabric pouch is not in black color as this and don't have too the colorful graphics:











I must say their quality is higher than the factory Ducati carbon fiber parts of the 998 era. Also the shiny finish is super glosy and super fine, that I decided not to paint them satin matte anymore and leave it as is.

Next, time to install them, start with the center cover:




Oh, the Ilmberger cover only utilize 3 out of 5 bolts per cylinder, but I don't like empty holes, so I cover them with some left over Titanium bolts from Melotti Racing as pointed by my fingers:

 

[PanigalePilot]

After the clutch cover, I decided to install the Generator Cover, checking to make sure everything is installed on the generator cover itself:

View attachment 13520View attachment 13521


Adding the 2 TITANIUM dowel/bushings:
View attachment 13522View attachment 13523

Also check the front surface of it:
View attachment 13524

Clean all the mating surfaces with Alcohol:
View attachment 13525View attachment 13526

Apply Ducati Liquid Gasket:
View attachment 13527View attachment 13528

Install onto the crankcase:
View attachment 13529

Next install the Water Pump Cover:
View attachment 13530

Apply the Ducati Liquid Gasket, also ready the 2 steel dowel (original Ducati dowel that somehow I mistakenly thought already the Titanium dowel):
View attachment 13531

Clean the mating surface with alcohol and install the 2 steel dowel:
View attachment 13532

And install and torque the Titanium Bolts:
View attachment 13533


Well,... I was happy until.. I found out the 2 TITANIUM DOWELS that I suppose to use for this Water Pump Cover:
View attachment 13534

So, I took out the pump cover again and clean the dried Ducati Gasket:
View attachment 13535View attachment 13536

Now the surfaces are cleaned and ready, and I install the 2 BLACK DLC coated Titanium Dowels:
View attachment 13537

Apply Ducati Liquid Gasket again:
View attachment 13538

And yes, it's PERFECT :
View attachment 13539View attachment 13540

Ti dowel s excellent

 

[BMW Alpina]

Now it's time for the rear carbon mudguard from Ilmberger. I custom ordered with Ilmberger matte paint (it was only available in glossy, but Ilmberger was willing to do this one-off matte paint for me).

The Ilmberger rear carbon fiber mudguard also function as chain guard. The factory plastic chain guard came with metal backing plate to further protect in case the chain broke.
I decided that I also want this extra protection for the Ilmberger Carbon Mudguard/chain guard. Unfortunately, the metal backing plate does not fit without modification, the hole for the bolt holding it, not aligned, as shown in 2 pictures below:




But hey, this is Ducati MODIFIED, so , I took out my trusty laser guided SKIL drill:


As a result:


It fit:


However, there is still 1 problem... I will post more soon

 

[BMW Alpina]

Here is the problem, it hit my Ohlins rear shocks. Please note, this is NOT the stock Ohlins that normally came with 998 this is the DU143, higher spec, thus the provision for mounting stroke sensor that hit the rear Ilmberger mudguard:


So... I decided to just cut a hole in the Ilmberger :


I grow the hole slowly :


Finally:


However, the tire now rubs the top part of the Ilmberger... so what the heck... just cut more holes :




and Done:


Next, I apply polymer resin on the cut area to make sure it will seal the fiber from moisture and prevent de-laminating:




More updates coming soon

 

[BMW Alpina]

I finally have time to do work on my 998 today:

First, somehow I lost the important M5 screws and washer for the STM clutch kit. I checked my old pictures, and they were in the package, but I must have misplaced them, thinking they were just some of the steel/washer that I am replacing with ProTi Titanium bolts.
I realized I lost them a few months ago, then I had to order from Europe, and it took almost 2 months before they arrived. I don't want to replace them with ProTi Titanium since this M5 is a grade 12.9 or far stronger than Titanium from ProTi, which only goes to grade 10.9 equivalent.
I can of course order from Accu in UK, but this time, I just want original STM sourced bolt, but they finally arrived. Pictures below. What annoying is, turn out the bolt package already include washers, so I accidentally bought an extra serrated washers... oh well :




I Test fit these bolts:



Then I was looking at the STM install manual, and it is in the Italian language... so I decided to just follow the picture diagram... little that I known, the back side of this install manual, there is an ENGLISH version which I found out later...
It had been a while since I am working on my bike so my brain need to be recalibrated


If I follow the install manual, I suppose to install O-Ring behind this spacer, but since I did not,... well, right now, I install without O-Ring, but please bear with me...


Then I install the main clutch housing:


Next, I see there suppose to be 6 ball bearings, but I can't find it,... I am so worry I might lost them again, so I decided to disassembled the Drum Hub Group (which was pre-assembled from STM):


And I am so glad that those ball bearings are still in there (just hidden):


So I reassembled the Drum/Hub Group back. Also, I did tried to find ProTi replacement of that small M4 locking bolt in this picture, but that bolt is special with a head diameter of just below 6mm and I can't find any ProTi titanium equivalent with a head diameter that small so I reuse the original steel bolt,
add loctite 243 medium and tightened to 3.5nm



Next, I grab the ProTi Titanium M8 bolts I prepared to hold the main clutch basket to the crankshaft:


Test fit 1 bolt, and it is perfect (with slight over lap, but that's ok), however, upon reading Ducati service manual to find the torque (35Nm), I was surprised that Ducati require Lock 4 or Loctite 510, which despite my variety of Loctite collections... I of course don't have...
hmmm... so piss off. so now I have to order and wait for the Loctite to arrive in around 10 days before I can install this clutch...


But... the heck... I want to finish TEST FIT all the STM clutch to make sure I am not missing any parts to finish the install so I continue with more ProTi bolts install at finger tight only:



Yes, they looks gorgeous, but ... hahha those bolts will be hidden from view soon... but hey. at least I know I have them installed :

Next, install the Drum Hub assembly:


Then the Secondary Spring Support, and after that the Secondary Spring itself:


Now, it's time for the sintered clutch plate followed by steel clutch plate until they consist the full set:


Continue below:

 

[BMW Alpina]

Steel clutch plate and then full stack of clutch plate set:


I also bought the titanium clutch nut, however, they only work for stock clutch so I am going to use the aluminum clutch nut from STM:


That is because the STM clutch nut has a special raised area to hold the serrated locking washer:


However, I am also buying the original Ducati OEM serrated washer, because it might be a good fit for the Titanium Nut...


This is how the nut installed, but of course, I made another mistake... I need to install the Evoluzione Spring first...


Ok, this is how it should look like:


Then... I realized... wait a minute... how the clutch rod can push the clutch plate to release... hmmm... there must be some parts from the original stock clutch that need to be reused with the STM...
Then I go to the spare part catalog, only to realize, I still need to get the BEARING, which of course I forgot to buy ...
Well, so I just ordered the bearing and the o-ring on eBay (I already have the STM clutch push pin), and I will also order Loctite 510 from Amazon.
I guess it will be another 10 days (most likely 2 more weekends) before the STM clutch is done

At least now I know how to install Ducati Dry Clutch (STM verzione)

But, yeah, it looks awesome

 

[PanigalePilot]

Steel clutch plate and then full stack of clutch plate set:
View attachment 13695View attachment 13696

I also bought the titanium clutch nut, however, they only work for stock clutch so I am going to use the aluminum clutch nut from STM:
View attachment 13697View attachment 13698

That is because the STM clutch nut has a special raised area to hold the serrated locking washer:
View attachment 13699

However, I am also buying the original Ducati OEM serrated washer, because it might be a good fit for the Titanium Nut...


This is how the nut installed, but of course, I made another mistake... I need to install the Evoluzione Spring first...
View attachment 13700

Ok, this is how it should look like:
View attachment 13702

Then... I realized... wait a minute... how the clutch rod can push the clutch plate to release... hmmm... there must be some parts from the original stock clutch that need to be reused with the STM...
Then I go to the spare part catalog, only to realize, I still need to get the BEARING, which of course I forgot to buy ...
Well, so I just ordered the bearing and the o-ring on eBay (I already have the STM clutch push pin), and I will also order Loctite 510 from Amazon.
I guess it will be another 10 days (most likely 2 more weekends) before the STM clutch is done

At least now I know how to install Ducati Dry Clutch (STM verzione)

But, yeah, it looks awesome

Great work
Good news is the aluminum will be lighter than the
Ti nut