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508 viewsConnect the ignitor wires to the bulb. One thing I did to make this wiring install easier is to remove the weather seal that holds the 4 wires. Since everything is contained within the headlight bucket there's no need for the wiring seal. Carefully use a sharp blade, like a crescent X-acto blade, to cut the seal and remove the wiring.
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508 viewsPush the power supply wires into the original headlight bulb connector.
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507 viewsMy fingers are pointing to the two pins that fit into the two rubber grommets that are part of the upper triple tree (visible in the foreground).
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506 viewsUse a drift to tap out the push rod.
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506 viewsHere's how the clutch basket looked. Those streaks are LOTS of thread locker applied at the factory. It leaked out the back side as well. After removing the eight retaining bolts I had to use a drift and tap a couple of the ears on the basket to gently break it free.
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506 viewsPush in the power supply spade connectors into the headlight connector. As can be seen in the picture, I put the black wires together and the red wire with the white wire.
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506 viewsFor safety I wrapped each connector in electrical tape and then wrapped them together as well.
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505 viewsThis is the flapper opened 1/2-way. So some heated air will enter the cabin and some will exit to the atmosphere.
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505 viewsThe end result, push rod out.
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505 viewsPermatex 2A gasket silicone is what I smeared on the mating surfaces of the case half instead of using a gasket.
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504 viewsHi-risers and controls installed, ready to put the bike back together.
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504 viewsI placed a friction plate back in to measure the gap. I had to use an Allen wrench: 2.5mm. Not good. Max gap is supposed to be no more than 0.6mm!
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503 views"Tool tray" needs to be removed for tucking the wires in on the right side. There are six of the 4mm fasteners holding it down.
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503 viewsRemoving the one-way retaining washer is a pain in the butt. Chances are very good that you could end up breaking the pin...not that it's a big deal if that happens, honestly. I did this on the left side to remove the turn signal electrical connector away from the rest of the harness, then pushed the retainer back on.
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Getting the power ready for the turn signal LED array.502 viewsUse a BLUE wire tap-in like what I show. The ones that are RED are for smaller wire sizes and the YELLOW ones are for larger wires. I prefer these because when you insert the insulated male connector it makes a positive fit and keeps the tap locked on to the wire. -- Left side: Tap into the white wire with the GREEN stripe. -- Right side: Tap into the white wire with the BROWN stripe. -- FYI for both lights: The black wire [on the outside] is ground, the middle wire is the parking light and the other outside wire is the turn signal.
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502 viewsLower bolt. Use a 10mm Allen wrench to remove the bolts. Though they already have molyb (grease B using Ducati nomenclature) smeared on them I (later) added a little bit more.
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With film applied.502 viewsHeadlight and running light off.
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