Whenever I start a five minute job, it always turns out a little bit longer.
While re-routing the wiring through the air box, I was just about to connect the plug to the starter relay when I noticed this:
Maybe not the best picture, but the red and yellow wire had pulled out of the spade within the plug. I released all the spades and made sure the other two had a good solid contact before stripping the wire to re attach the spade. It had oxidised and I had to cut back a good inch or so to get to clean copper. At least that is one of the poor e-start mysteries solved.
Talking of electrical connectors, I really should have examined the motor and packing crate more closely when I opened it. Turns out one of the stator connectors had got cracked in transit somehow.
It made a good tight join, so I simply wrapped it in self annealing tape rather than try and cut and join the wires.
After bolting the engine in place and fitting the new silicone hoses, it was finally time to take the bike out of the workshop and see what she starts like. Just fill the rads and put some oil in.
As I was filling the oil, I noticed a line on the clutch case that I hadn't noticed before. The line turns out to be a crack.
Effing UPS have dropped the crate at some point. The double skinned floor has also got a crack in it, explaining both the clutch case and the connector. B*st*rds!
Luckily for me, as these cases are no longer available from KTM, I know where there might be a replacement. Assuming the owner is willing to part with it...…...
Thankfully, he was. (Cheers Craig!) Next morning I nipped over to collect it and hurried back to fit it.
The case is in similar condition than mine, corrosion wise, but with the added benefit of being oil-tight! After a discussion with Craig, I followed his advice and used a decent gasket sealant as well as the gasket, so couldn't put oil in it for 24 hours.
This turned out to be a blessing, as instead of going for a test ride I got the bike's documents out ready for packing. Better get an Mot before I do anything else!