Point-Seven-five wrote:+1 on Duck's removing the radiator cowl. I have yet to find a way to avoid that job when installing the belly pan.
Well having abjectly failed to re-mount the belly-pan back in October despite your, TacKler and MartinW's well-meant tips, I returned to do battle with the damn thing yesterday and STILL couldn't crack it.
Completely removing the rear tang and/or pan-mounted "slot" doesn't help locate the rubber bungs-cum-grommets into the cup holders on the bar beneath the crankcase. I have tried everything, including sticking the bungs in them first and
then trying to ease the holes in the pan around them, but that's impossible... And even getting the bungs in the exact position that then enables you to insert the hard plastic sleeves and
then line up the bolts so that they connect accurately with the threaded metal fixings is damn difficult, (though not impossible).
I also don't see how removing the upper rad cowling would help because it doesn't offer much more room to maneuver or, more helpfully, actually see what is going on when you're trying to locate the bungs! Oh, and neither soapy water or Vaseline helped either!
After 90 minutes of knuckle scraping frustration I gave up and on reflection the only possible solution I can come up with is to cut the bungs in half, insert the thicker halves in the cups, then find some stainless steel washers that are larger than the holes in the pan, find some rubber and/or fibre washers that will cover the holes on the outer edge and bolt through them into the threaded (loosely) captive fixings. Has anyone tried that?
By the way, I did think of taking the belly pan apart – it's in two pieces bolted together – then bolting it back together once
in situ, but that would leave you without the wire mesh that protects the sump from roadkill, which would rather defeat the purpose!
In the meantime, any other ideas - short of having three hands and X-ray vision – gratefully received... oh, and have a good Xmas.
Mark W