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

[BMW Alpina]

This is also done a few months ago, I installed the Radiator Fluid Filler Neck (cleaned and painted in Red Anodize Paint) to the EVR Carbon Radiator Fluid Reservoir using ProTi Titanium bolts as usual:









Then add the brand new Cagiva Logo radiator cap, just for that OLD SCHOOL theme:




Next install the ProTi Titanium bolts for the Ilmberger carbon mudguard's brake hose holder:




Also bought some Titanium Bolt from ProBolt for the starter switch (ProTi did not make one that fit):


Add some UHU glue to secure the rubber pad for mounting the EVR Carbon Radiator Fluid reservoir:

 

[PanigalePilot]

Nice

 

[BMW Alpina]

Yes, this was a few months ago, I started installing the Samco hoses:



Started with the hoses to the EVR Carbon Reservoir:







Note that soon that bolt for the clamp will be replaced with Titanium bolt from ProBolt (ProTi did not produce the correct size):


Install on the frame:



Now, the Samco hoses going to the radiator:




Test fit the Airbox to make sure everything fits:

 

[BMW Alpina]

Time to connect the Samco Hoses to the cylinder head outlet (the RS aluminum machined outlet):


And to the Thermostat and Water Pump:

 

[BMW Alpina]

I then proceed to install the old wiring harness that originally came from this 998 bike when I bought it. Please note this was many months ago, so I did not have my brand-new 998 wiring harness yet. Now, this old wiring harness had been removed, and I am just going to store it for spare.
I started with the connector to the water temperature sensors:




Then to the cooling radiator fan, and throttle body:


and more connectors connected:




Please note that this old 998 wiring harness was in EXCELLENT condition except, the fuse block has a broken plastic which I fix with Epoxy:

It break when I try to replace the bolts with ProTi Titanium bolts. Of course it does not affect the strength, but me being me... feel this is not perfect.
After many hours of research (well, more than a week), I finally able to find REPLACEMENT fuse box. Just need to unclip and insert the spade into the new fuse box. The good thing is, the new fuse box has a nicer clear cover.
The process is quite complicated, involving removing the locking yellow tabs, but the pictures below should provide clear guidance in case any of you wants to perform the same upgrade:






The new fuse box came with it's own spades which I need to take out:




Then need to remove the spade/wiring from the old fuse box:

 

[BMW Alpina]

All spade/wiring had been pulled out from the old fuse box:


Here is the new fuse box with original fuse sticker from Ducati:


Install the hardware with ProTi Titanium bolts:


Everything is ready now:




Installed on the frame:

 

[BMW Alpina]

hmmm... looking back at these posts that I just posted here... this old 998 wire harness is already good enough for my project... but it's just me... I am never happy until it is close to perfect... anyway, more pictures below of the installation of this old 998 wiring harness:














But, there is an incompatibility issue because I was using 1198 coil on spark plug system, while the original 998 wire harness is using the old school separate coil winding technology.
Below is the 3 PINS connector from the 1198 coil on spark plug connectors:




And below is the connector from the wiring harness, which is the simple 2 PINS connector:


No worries, I already found the solution by making a customs adapter. I purchase all the required connectors, automotive-grade wiring, and race-grade RayChem insulators. The expensive parts, however, are the crimper tools needed. I will post here soon.

 

[BMW Alpina]

The other incompatibility is the original 998 generator have a longer cable coming out of the generator assembly.
Since my engine is 999 with 999 generator cover, and I want to use the newer 999 generator and flywheel design, that also means the cable coming out of the 999 generator assembly is much shorter.
However, I found out Ducati actually have "extension cable" for some of their Monster model application.
I just need to connect 2 of these Ducati OEM extension cables in series.







Time to install them:







However, even this solution is now obsolete because later I found an even better solution by ordering a custom 1 piece longer cable. Not to mention, it also allow the connector locking clip to function properly.
The 2 extension cables from Ducati have the wrong locking clip design (mixed up female and male for the locking clip), but this new custom 1 piece longer cable, has the correct locking clip.

 

[BMW Alpina]

I also purchased a thicker starter and ground wiring kit from the UK. But their ground connector was a 90-degree bend design, while the original factory ground wire was the flat design.
So I decided to connect this thicker ground wire to the vertical cylinder head instead:




Of course, this is not enough... and I am buying a ground wire from Panigale V4 and Streetfighter V4, which I believe is much thicker than the 998 ground wire. I will choose which one is better for the 998 application (between Panigale V4 and Streetfighter V4 ground wire), and use it to replace the 998 ground wire. This means I will have 2 thicker ground wires. First ground is the new UK ground wire going to the cylinder head, and the second ground is the Panigale V4 or Streetfighter V4 ground wire going to the battery and original crankcase mounting location.
This will ensure enough ground wire connection that will enable to starter motor to work more efficiently. Especially since my 999s motor has been bored up with high compression piston and 999R camshaft.

 

[BMW Alpina]

Last to be connected is the wiring harness going to the dashboard and lighting. I also have to carefully relocate the lighting connector since I use the LED lighting from IPF for both low beam and high beam, which has extra electronic modules (those 2 black plastic boxes):

 

[BMW Alpina]

In the meantime, I found a BRAND NEW 998R front mudguard in Italy, which I will recoat with a SATIN MATTE finished to make it more "modern period correct". and not 1990's period correct . I know some people prefer to keep their 916 996 998 looking originals, while I just want them to look UPGRADED, UP to DATE and MODERN. Yes, I will have 2 front mudguard, the Red Plastic and this Carbon Fiber 998R. So I can switch from time to time when I am bored with either one of them.

 

[BMW Alpina]

A few weeks later, I also found a BRAND NEW 998R Carbon Lower Belly Pan in Japan.
So far, I bought 4 carbon belly pans:
1. 996R Carbon Belly Pan (slightly used, and I already sold it)
2. 998R/S Carbon Belly Pan (brand new and I have already coated with satin matte finish and will keep it)
3. 998R/S Carbon Belly Pan (slightly used), and it is now for sale on eBay
4. This latest 998R/S Carbon Belly Pan (brand new), and I plan to paint it in Red Paint with the original racing stickers kit from the 998s Final Edition.

The 996R Carbon Belly pan does not have an extra mounting tab to mount it to the lower crankcase.
The 998R/S Carbon Belly pan has an improved design with an extra mounting tab to mount it to the lower crankcase.

That is why I prefer a 998R/S Carbon Belly Pan. And since I am lucky enough to find 2 BRAND NEW 998R/S Carbon Belly Pans, I have decided to sell my slightly used 998R/S Carbon Belly Pan on eBay.
Below are the pictures of this latest 998R/S Carbon Belly Pan from Japan (Brand New):

 

[BMW Alpina]

Later (still a few months ago), I am test fitting all possible AN Goodridge/Earl's fittings for my fuel pump Staubli drybreak quick disconnect that will not hit the cylinder head (the space between the vertical cylinder head and the fuel tank/fuel pump base is very tight.
I am happy to say that I found the best fit configurations, and had bought all the needed parts.... I just have to find time to install them and will post it here.

 

[BMW Alpina]

Oh, did I mention I found a super nice looking front sprocket from Motocorse Japan? Yes, it is made by Gandini, POLISHED finished and sold by Motocorse Japan.
I already bought a nice brand new AFAM 15T sprocket, but of course not as nice looking as this Gandini sprocket... so the AFAM will be taken out and replaced with this Gandini:

 

[BMW Alpina]

I purchased the original clip for brake reservoir hose from Panigale V4. I like them because they have black color finish. But I forget they are way too small and hard to install... so this become a waste of purchase.
Just want to warn you guys not to buy these clips:

 

[BMW Alpina]

I had many brand new Goodridge 700 series Aramid Fiber Braided brake hoses from my Panigale V4S 916 25 Anniversario projects that have incorrect end fittings (Goodridge builds it wrong, and they end up giving it to me for free) or because I change the configuration since I am now using the Motocorse Lower Triple Clamp that no longer have mounting provisions for brake line distribution block.
So, I decided to try to use this brand new Goodridge 700 series hoses, but with adapters here so I can connect them properly.
Turns out, they all can be reused and I will post more details later, but for now, I need to test fit to determine the type of banjo fittings and bolts I need to purchase.
At that time, my new Brembo GP4-MS has not arrived yet, so I was using my Brembo GP4-RR caliper to test fit the Goodridge 700 series hoses:


Below are the end fittings going to the front brake master cylinders which I need to test fit to find the right angle for the banjos:

 

[PanigalePilot]

Oh, did I mention I found a super nice looking front sprocket from Motocorse Japan? Yes, it is made by Gandini, POLISHED finished and sold by Motocorse Japan.
I already bought a nice brand new AFAM 15T sprocket, but of course not as nice looking as this Gandini sprocket... so the AFAM will be taken out and replaced with this Gandini:
View attachment 15147View attachment 15148

H that sprocket may be lighter too. Look at all the lightening holes. If you get time weigh both you may save a few grams being turned by your engine.