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Gen2 tuono project build

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cheesy View Drop Down
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    Posted: 25 May 2020 at 00:49
Started building my project
Eventually I'll swap my bigbore motor over

Will be running gen1 electrics on this

Tuono 06 frame
Late gen2 motor modified for gen1 
New oil pump installed & couple of pain in the ass exhaust studs
Carbon front & rear plus usual pieces 
V4 diamond rearsets & yokes ready for radials
Racetorx chain adjusters
Homer ironbite airkit
Akrapovic evo6 system
Maybe a play with shower injection
Few more boxes to unpack


Working on making the gen1 loom fit this week 
04 Tuono Fighter
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 426hemi Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 00:59
Very nice, trick rearsets and the shower injection looks really good 👍
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Post Options Post Options   Thanks (0) Thanks(0)   Quote nitroargi Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 05:45
Love the huge carbon airbox! Show us more... TongueTongueTongue
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Pete 86 Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 07:53
Yes thats sexy.

How much was that injector setup mate?
And where from?
I have seen some pics of them they are very nice.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote NickyBoy1984 Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 09:52
Oooo, pornographic that is.....!!

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Post Options Post Options   Thanks (0) Thanks(0)   Quote IanG Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 10:08
Some very nice machining on display there Clap
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Looking forward to the next track day
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ice-mille Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 11:41
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Hangry Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 11:44
V.nice indeed going to like seeing the progress on this one Thumbs Up
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Post Options Post Options   Thanks (0) Thanks(0)   Quote redratbike Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 12:01
Nice project Chris

I thought about this myself seems the perfect combination of gen2 power and gen1 simple electronics ... I’ve had a gen2 motor for at least 2 years and done nothing with it .

The showers always look good but not sure on the actual gain probably at the top end of the Rev range no doubt ....but you’ll be in an exclusive club alright




One thing I have found 
Remember not every expert that tells you stuff works is right .... even worse if they are selling the stuff


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Post Options Post Options   Thanks (0) Thanks(0)   Quote IanG Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 14:26
Very true.
Some people will tell lies, others may not tell the whole truth to sell something and others may rely on others for sales word of mouth.

Buyer beware at all times.

Use your own common sense and if it sounds to good to be true then it probably is.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote cheesy Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 17:57
Originally posted by Pete 86 Pete 86 wrote:

Yes thats sexy.

How much was that injector setup mate?
And where from?
I have seen some pics of them they are very nice.

I bought it from German, that was the picture all fitted from the seller. 
I got all the mounting hardware, minus box & stacks
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cheesy Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 18:00
Originally posted by redratbike redratbike wrote:

Nice project Chris

I thought about this myself seems the perfect combination of gen2 power and gen1 simple electronics ... I’ve had a gen2 motor for at least 2 years and done nothing with it .

The showers always look good but not sure on the actual gain probably at the top end of the Rev range no doubt ....but you’ll be in an exclusive club alright




One thing I have found 
Remember not every expert that tells you stuff works is right .... even worse if they are selling the stuff

Being able to play around with the set up is a bonus & being able to do the mods is great. 

I had a shower kit years back & sold it when the tri colour went that I hadn't got round to fitting so this is another crack at it. 
Yeah think your on the money with more higher up but we'll see when the time comes

Very true sir
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cheesy Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 18:01
Cheers for the comments

I've been working on the wiring loom today making the gen1 fit the gen2

Will update shortly
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 19:39
Nice to see you post this up mate going to keep people interested great start to the build Thumbs Up
I started out with nothing and I've still got most of it left
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cheesy Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 20:07
Looms had an alarm previously, not taken out the best & some of the soldering is questionable. 
Can sort that. 
Need to wrap the cabling but the rear taking shape
Relocating the rectifier to the gen2 position

Got to work out fuse box mountings 

 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 20:18
That looks like a headache 
I started out with nothing and I've still got most of it left
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 2020 at 20:19
Looking super neat now 
I started out with nothing and I've still got most of it left
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Post Options Post Options   Thanks (0) Thanks(0)   Quote IanG Quote  Post ReplyReply Direct Link To This Post Posted: 26 May 2020 at 10:43
It's a good idea unwrapping the harness like that as you fit proper guage modern wiring and also custom wrap it after for much better routing Thumbs Up
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Post Options Post Options   Thanks (0) Thanks(0)   Quote wigginsjp Quote  Post ReplyReply Direct Link To This Post Posted: 26 May 2020 at 13:50
Great stuff 

Wanting your Gee tech stands also! 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cheesy Quote  Post ReplyReply Direct Link To This Post Posted: 26 May 2020 at 21:00
Spent today working on the front end

As most know the gen1 has both fuse/relay boxes at the front & trying to get them to fit a gen2
There's no room to hide anything really

So after a couple of messages to Adam checking on routings from his gen2 tuono. 

I set about stripping & relocating the boxes to the rear
Trial fitted a spare set of boxes I had. 
Close clearances but they clear
Got most wiring pulled from main loom where needs to be. 
Need to purchase some cabling to extend so routes back

Some more shoddy soldering on this loom I found 

But I decided while I had the headlights fitted looking at space I trialled the carbon fairing, rested in place. Will need a touch of fettling, manipulation but should look good. 

 

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Post Options Post Options   Thanks (0) Thanks(0)   Quote blacklines Quote  Post ReplyReply Direct Link To This Post Posted: 29 May 2020 at 14:17
That wiring is a right mess! The soldering equivalent of a granny knot ha. Front end looking good though. Only downside is having to take the tail off to get to the fuses and relays but you don't need quick access to them do you.

Originally posted by wigginsjp wigginsjp wrote:

Wanting your Gee tech stands also! 


Was thinking they are much nicer than the Halfords jack stands I use.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cheesy Quote  Post ReplyReply Direct Link To This Post Posted: 30 May 2020 at 19:57
Originally posted by blacklines blacklines wrote:

That wiring is a right mess! The soldering equivalent of a granny knot ha. Front end looking good though. Only downside is having to take the tail off to get to the fuses and relays but you don't need quick access to them do you.

Originally posted by wigginsjp wigginsjp wrote:

Wanting your Gee tech stands also! 


Was thinking they are much nicer than the Halfords jack stands I use.

Yep, the loom has certainly had the blind leading the blind on it before. 

On a O.e gen2 there fusebox is in the back but about half the size compared to the gen1's
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cheesy Quote  Post ReplyReply Direct Link To This Post Posted: 30 May 2020 at 20:00
The delivery came of the new cabling.
So I've made way & got the fusebox end all boxed off. 
I'm half way through the relays, but I need a few more metres of 2 different colours. 

Here's the fuse box ready for mounting once I've wrapped the wires in fabric tape

 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ice-mille Quote  Post ReplyReply Direct Link To This Post Posted: 03 Jun 2020 at 11:37
Good work so far, fun fixing old bad wiring pfuuffhh..
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cheesy Quote  Post ReplyReply Direct Link To This Post Posted: 10 Jun 2020 at 18:43
The rear part of loom from fuel pump area back is done.

Fusebox & relay box, all mounted & wiring finished. 
Moved a few wiring routes to make it better. 
Need the uprated starter cables to finish that part. 
1 connector to attach on indicator cable needed.
I've moved the diagnostic wires to a switch mounted on rear subframe & rewired the derestriction wires ready to install to a switch for dual maps. 

Continuely fixing any bad bits, as shown

Clearance on the boxes is more than originally thought  which is a bonus.
I may have to shorten some of the original loom that's still left as think there will be a bit of overlenght trying to tuck away. 

Passed the new cabling from the boxes upto behind the clock area to connect up. 
Then it'll be time to wire the switchgear plugs back in. 
Probably a couple of custom runs around the inside of frame for them. 

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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 10 Jun 2020 at 18:58
Making Great progress mate I'm envious of your leccy skills. 
I started out with nothing and I've still got most of it left
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cheesy Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jun 2020 at 19:32
Well the soldering iron has bit the dust so replacement is on the way.

Paulw dropped of the donor gen1 motor ready for me to ride for the rest of conversion parts to go on the gen2 motor.

Set too with that so,
Flywheel, stator & case fitted
Front cam sprockets
Cam sensor & made the groove in head to pass through. 
Removed the extra metal so the gen1 cam cover fits
Blank replaced with 2nd temp sensor
Couple little bits, neutral light switch, magnetic drain, switched to short filter
Upgrade the slave. 
Started on reattaching some of the water pipes.

Hopefully have all boxed off this week then it'll be back to the loom
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Post Options Post Options   Thanks (0) Thanks(0)   Quote redratbike Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jun 2020 at 20:35
Originally posted by cheesy cheesy wrote:

Well the soldering iron has bit the dust so replacement is on the way.

Paulw dropped of the donor gen1 motor ready for me to ride for the rest of conversion parts to go on the gen2 motor.

Set too with that so,
Flywheel, stator & case fitted
Front cam sprockets
Cam sensor & made the groove in head to pass through. 
Removed the extra metal so the gen1 cam cover fits
Blank replaced with 2nd temp sensor
Couple little bits, neutral light switch, magnetic drain, switched to short filter
Upgrade the slave. 
Started on reattaching some of the water pipes.

Hopefully have all boxed off this week then it'll be back to the loom


Chris I must do my gen2 motor

Any pics of the head work ? Do you remove the head or just the cams and block all the passages /gaps up ????


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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jun 2020 at 20:42
Nice work buddy loving this thread 
I started out with nothing and I've still got most of it left
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cheesy Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jun 2020 at 22:14
Mark,

I haven't, just need to make sure no sharps but may look a touch rough at edges if makes sense but it isn't seen

I'll be honest once you have all the parts to swap over in the same place it's a piece of cake.
Having the engines side by side I could compare where & how much needed removing

Crank was already locked
I secured cams to chain & removed
Blocked/covered as much as possible 
Then basically the piece to remove vertical cut either side then horizontal to then remove the piece. 
Dremel, hacksaw blade & drill in my case
I cleaned out everything, hoover, brush, compressed air. 
Then pulled the buckets & cleaned them down for piece of mind too
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