Pocher 1:4 Ducati Superbike 1299 Panigale S Anniversario + Hardware-kit of Paul Koo [COMPLETED BULD]

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Chapter 20:
183 Hfst 20.jpg
Right Handlebar with Brake:

All the parts. With 2 tiny spring.
184 Brake.jpg

The parts for the brake lever and cylinder, with the tiny spring, fitted together:
185 Brake.jpg

The throttle can be rotated and is loaded with a spring.
From the Paul Koo manual:
186 Throttle.jpg
Fitted together:
187 Throttle.jpg
With the decals and the extra’s:
-most of the bolds where from the Paul Koo kit;
-1: cable for the brake sensor on the brake pump;
-2: cable for the starter switch;
-3: cable for the throttle control.
And:
-A: brake hose;
-B: steering damper rod;
-C: started button;
-D: switch lever;
-E: bleeder valve.
Also here the end of the bar painted black and the switch lever red.
And the reservoir cup filled with flued. I had to think for a moment how I would do that with this one. Because there are 2 mounting holes in the bottom and sealing both equally is not possible. The cap is screwed on from below.

Seen from the other (front) side:
188 Throttle.jpg

Regards, Peter
 
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Chapter 21:
189 Hfst 21.jpg
Fitting both handlebars and the Steering Damper.

The 2 bars:
190 Both.jpg

The reservoir of the clutch does not stand well. That was also with the previous model.
191 Both.jpg
Unscrewed and cut away a position cam.

The left handlebar fitted:
192 Left.jpg
Extra:
-1: the Damper got its sensor cable. The damper works speed dependent. Plus a Paul Koo Ohlins decal.
And:
-A: the hose for the clutch fitted.
- the reservoir in a better position. The bike is now on the garage bar. When it stands on his wheels, its coming more straight.

The working clutch lever, because of the little spring:
193 L-Working.jpg
I forgot the picture with the lever in its free position.

The right handlebar, with the working brake lever:
194 R-Working.jpg
And the working throttle. I put a arrow marker on the handle to show begin and end position:
195 R-Working.jpg

The view on both handles when you stand beside the bike:
196 Both.jpg

And now it looks more as a bike:
197 2021-05-29.jpg
But not ready for a test drive. A lot of hoses, tubes and cables must be fitted. And on the right side the brake pedal.

Regards, Peter
 
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Chapter 22:
198 Hfst 22.jpgRight Footpeg / Brake Lever / Heel Guard

The collected parts and Paul Koo bolts:
199 Foo7 Brake.jpg

The parts fitted together:
200 Foot Brake.jpg
Extra the banjo plug, clamps on the hose, painting some parts black and the Paul Koo bolts.

On the back side you can see the working brake lever:
201 Foot Brake.jpg
On the rotating points, which are not in view on the bike, you can see the black Philips bolts from the kit.
If those bolts were also mounted in the front, the look would be significant different.

The installing on the bike is later. Some brake hoses must be modified.

regards, Peter
 
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Hi Peter,
Amazing build, do the parts "just go together" or is there a fair bit of work needed before assembly?
Cheers,
Stephen.
Hi Stephen, thanxs for your likes, reply and interest.
In principle, you can screw everything together, straight out the box.
With filing some small edges from the parts wich you have to cut out the platic frames. The metal parts are largely neatly finished and provided with paint.
By the build of the first Duc, 4 years ago, 2 bolts broke off by me. Because the hole was not deep or wide enough. But most can be prevent by always adding a small tip of oil to the bolt. And pre screw in the hole in question, and with a little resistance, do not twist with force (what I did ;)).
In this construction, I chose to use the taps from the set that Paul Koo can supply with his hardware kit.
When you do the super detailing ..... then there is ‘a fair bit of work needed before assembling’ :).
Regards, Peter
 
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In the last chapter I was forgotten to show the last added extra detail on the brake light switch:
201a Foot Brake.jpg
A: the rear brake switch.
202 Foot Brake.jpg
A: the brake light switch cable.

Chapter 23:
203 Hfst 23.jpg
Installing Right Footpeg Bracket and all the Brake Hoses.

Some parts were already installed in previous chapters, because you could do better then.
Just 3 left for this chapter:
204 Brake.jpg
But the amount of work is no less.

Paul Koo advises to adapt the brake hoses to the original. There are pieces of metal tube in 2 places.
I pre installed the cover to adjust the 2 pieces of tube in the rear brake hoses:
205 Brake.jpg
With the hose clamps of course.

At first a overall view from all the work in this chapter:
206 Brake.jpg
But there are so many details, I show them in 2 separate pictures with indications of what is where.

The rear part:
207 Brake.jpg
1: brake hose from rear brake caliper banjo to ABS-unit with metal section brake tube;
2: ABS-sensor cable from rear wheel to right electric panel;
3: brake hose from brake master cylinder to bottom of brake fluid reservoir;
4: brake hose from brake master cylinder to ABS unit;
5: brake light switch cable via connector to the electric panel;
6: oil pressure hose via switch to electric panel;
7: metal sections brake hose;
8: Lambda probe oxygen sensor cables from front cylinder tube to electric panel;
9: Lambda probe oxygen sensor cables from back cylinder tube to electric panel;
On the picture below:
10: brake hose from front brake caliper banjo to ABS-unit with metal section brake tube;
11: brake hose from front brake handle to ABS unit.
Finally installed the tube cover and the engine side cover.
With the same numbers, the front part:
208 Brake.jpg
The other hoses were installed in other chapters.
The electric cables are connected in chapter 26 and 27.

And a picture from a different perspective:
209 Brake.jpg

Regards, Peter
 
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Pocher…..definition = Long Haul, challenging, wow factor, accomplishment! Your build, attention to detail and clean approach is most excellent. I have not built any of their new kits. But the older ones….many. The prices are staggering now! I am working on probably my last Pocher Project. The Alfa Spyder Touring. Paul Koo, great individual. Looking forward to more.
Rick
 
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Pocher…..definition = Long Haul, challenging, wow factor, accomplishment! Your build, attention to detail and clean approach is most excellent. I have not built any of their new kits. But the older ones….many. The prices are staggering now! I am working on probably my last Pocher Project. The Alfa Spyder Touring. Paul Koo, great individual. Looking forward to more.
Rick
Hi Rick,
Thanxs for your kind words and compliments. I had the Alfa Spider also on my list, but the Bluenose came passing by. So I now divided the time between the Duc and the BN.
Regards, Peter
 
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Chapter 25:
This chapter is in the manual divided in 4 parts. So first 25-1:
213 Hfst 25-1.jpg
Front Airbox Intake + covers.

The parts:
214 Airbox.jpg
With the correct decal from Paul Koo and the metal-look surface.

Fitted on the Duc:
215 Airbox.jpg
The holes for the 2 hex-bolds on the top of the airbox intake, has to be tappad to 2.5 mm.
Advise for Paul Koo: To fit the bolds on the under side of the 2 covers (blue arrows), you have to cut them shorter. Because the holes are very shallow. I have drilled them deeper and tapped them.
Regards, Peter
 
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Before I went on, the horn has to be wired:
226 Horn.jpg
Then I could start with collecting all the wires to guide them neatly through the fairing covers.
On the left:
227 WiresL.jpg
On the right:
228 WiresR.jpg

And to get an impression of my (temporary) photo studio:
229 Studio.jpg
The inside of the cover box of the Pocher kit. Also good for a nice white-balance by adjusting the pictures. :)
Regards, Peter
 
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Chapter 25-2:
220 Hfst 25-2.jpg
Instrument Cluster + Front Tank Cover + Ignition Switch.

The parts:
221 Ingition.jpg
The Instrument Cluster fitted together:
222 Dash.jpg
And on the Duc:
223 Ingition.jpg
The Keyhole painted alu and the Key some Ducati-red.
224 Dash.jpg
Amazing how tightly the parts fit together. It is quite a complex construction.
That was also the last metal parts. We are now on 5.4 kg.
Regards, Peter
 
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Chapter 25-3:
225 Hfst 25-3.jpg
The Headlight unit.

The parts:
226 Light.jpg
It's important to fit the parts in the right order together. Paul Koo has on his DVD a extra manual for the basic assembly. Here some pictures together from the different stept:
227 Light.jpg
With this result:
228 Light.jpg
With under the glass the air intake with channels to the air-box.
On the back side, the channels comes together:
229 Light.jpg

Regards, Peter
 
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Chapter 25-4:
230 Hfst 25-4.jpg
Assembling the Light Unit and the bottom trim plate.

Only 2 parts to compleet this chapter 25:
230 Parts.jpg
In the Pocher manual, this placement is done separately. First the unit, then the cover. But then you can hardly reach the middle bolt in the back of the cover plate. Then the front wheel is blocks your hand and screwdriver. Paul Koo puts the 2 parts together first and then places them both at the same time. That is then just as well fitting, measuring, turning and sliding/push into place:
232 Front.jpg
231 Light.jpg

The 'state of affairs' from different points of view.
Right in front:
233 18-06-21.jpg
A real Bully. Active on the front:
234 18-06-21.jpg
And a overview:
235 18-06-21.jpg

In the next 2 chapters, all the electrics are mounted on the panels on either side of the bike.
I first sit down and make a plan to get all the wiring in the right place.
But Paul Koo's manual is very helpful. He takes you step by step through this whole process with clear pictures.
Regards, Peter
 
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Chapter 26:
236 Hfst 26.jpg
Left Hand Electrical Panel.
From the Pocher-kit, only one wire must be attached: RF-10. Thats the wire to the spark plug of the front cilinder, attached there in chapter 12.

The parts:
237 Parts.jpg

A lot of the extra added electrical wires comes together in and on this part of the bike. And are connected to the various components.
It is a little bit complex, but Paul Koo added a nice overview picture on his DVD:
238 Paul Koo.jpg
It is from an original Panigale where Paul Koo signed his information.
What can I tell more …….

Here the wires added to the components in 3 stages:
239 Wires.jpg
On the picture in the middle, you see on the left side the ’painters crepe tape’. I made it mat black with a permanent marker. Cut small strips of 3 mm to imitate the ‘cloth tape’ around a bundle of wires.
The picture on the right is from Paul Koo. I forgot to take a picture myself.

The panel, components and wires all fitted together:
240 Wires.jpg
Most of it is done using 2 tweezers. But a thin strip of tape sticks to everything..... relax....... take your time.....
Some parts of the components are painted grey or made from white Evergreen.

With a picture of the completed left side of the bike, before the fairing is attached.
241 Links.jpg

Up to the right electrical wires
Regards, Peter
 
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Chapter 26:
View attachment 243494
Left Hand Electrical Panel.
From the Pocher-kit, only one wire must be attached: RF-10. Thats the wire to the spark plug of the rear cilinder, attached there in chapter 12.

The parts:
View attachment 243495

A lot of the extra added electrical wires comes together in and on this part of the bike. And are connected to the various components.
It is a little bit complex, but Paul Koo added a nice overview picture on his DVD:
View attachment 243496
It is from an original Panigale where Paul Koo signed his information.
What can I tell more …….

Here the wires added to the components in 3 stages:
View attachment 243498
On the picture in the middle, you see on the left side the ’painters crepe tape’. I made it mat black with a permanent marker. Cut small strips of 3 mm to imitate the ‘cloth tape’ around a bundle of wires.
The picture on the right is from Paul Koo. I forgot to take a picture myself.

The panel, components and wires all fitted together:
View attachment 243499
Most of it is done using 2 tweezers. But a thin strip of tape sticks to everything..... relax....... take your time.....
Some parts of the components are painted grey or made from white Evergreen.

With a picture of the completed left side of the bike, before the fairing is attached.
View attachment 243500

Up to the right electrical wires
Regards, Peter
amazing, well done Exclamation-Mark :) Thumbsup
 
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