Advice please on rebuilding a 2005 Monster

03-09-2019, 09:52 AM

Hi Everyone,

My godson and I have just bought a 2005 Monster 620 Dark - 02, with a V5 & all the paperwork from the previous owner, in 4 large wooden crates.

We have unboxed everything and are starting to clean and label all the bits, ready for a full rebuild. It has been boxed for about 5 years.

The engine turns and it looks like we have a complete bike. We have ordered a Haynes workshop manual.

Our plans are:

Drain engine oil and replace. What oil please?
Replace cambelts, plugs, air filter, fuel pipes, battery? Where to buy these parts please?
Remove alarm to stop noise and immobiliser kicking in when we come to start it?
Replace 2013 dated tyres?
The spark plugs are old Champions RA6 HC & RA4 HC - are these correct, or can any UKMOC members suggest best plugs to buy please?
We need to replace 4 badly corroded exhaust studs. Cann we use studs from local nut & bolt shop?
Cambelts are labelled 190 187 5 208 DS & 153 5 208 DS - can we just order 2005 Monster belts?
Replace belt tensioners or service & keep?
The injector packs have been cleaned with carb cleaner - do we need to strip and rebuild like an old carb, or should they work OK with new fuel please?

ANY ADVICE WELCOMED PLEASE?

We live in Norfolk - Any MOC members live near us who would like a look at it over a cuppa and biscuits?

Thanks in anticipation.

Richard & Hamish

Mr Gazza · 03-09-2019, 10:28 AM

What sort of biscuits have you got?

mickj · 03-09-2019, 10:38 AM

Welcome to the forum Hamish

, good luck with your project and I'm sure there will be plenty of help forthcoming from the other members, hobnobs is always a good starting point

.

slob · 03-09-2019, 10:54 AM

+fuel filter

parts: Call Craig or Luke at Moto Rapido 01962 873981 (mention UKMOC for 10% discount on most parts) Super efficient mail order.

Mr Gazza · 03-09-2019, 10:56 AM

Drain engine oil and replace. What oil please? 10w40 Motorcycle specific semi-synth. Don't use car oil or the clutch will slip.

Replace cambelts, Ducati belts from Moto Rapido, or Exactfit from http://www.exactuk.com/about-exactfit-cam-belts/
plugs, Use NGK, not Champion, correct number will be in the Haynes manual.
air filter, and oil filter.. K&N from ebay
fuel pipes, Moto Rapido again.
battery? Motobatt.. Price doesn't vary much but shop around on ebay
Where to buy these parts please?
Remove alarm to stop noise and immobiliser kicking in when we come to start it? Pass!
Replace 2013 dated tyres? Oh yes definitely!!
The spark plugs are old Champions RA6 HC & RA4 HC - are these correct, or can any UKMOC members suggest best plugs to buy please? As above NGK
We need to replace 4 badly corroded exhaust studs. Cann we use studs from local nut & bolt shop? Yes, use stainless if you can.
Cambelts are labelled 190 187 5 208 DS & 153 5 208 DS - can we just order 2005 Monster belts? Order for 620.. As above.
Replace belt tensioners or service & keep? If they spin freely and are not rough, use again. Expect a little resistance from the seals
The injector packs have been cleaned with carb cleaner - do we need to strip and rebuild like an old carb, or should they work OK with new fuel please? Ultra-sound cleaner is best... Pop them in the one I currently have on loan from Utopia, a member on here.

ANY ADVICE WELCOMED PLEASE?

We live in Norfolk - Any MOC members live near us who would like a look at it over a cuppa and biscuits? See previous post..

Thanks in anticipation.

Richard & Hamish

slob · 03-09-2019, 11:00 AM

NGK DCPR8E

I'd use something like these on the exhaust studs https://www.ebay.co.uk/itm/Copper-Fl...r=561918993594

Mr Gazza · 03-09-2019, 11:09 AM

Quote:

Originally Posted by slob

NGK DCPR8E

I'd use something like these on the exhaust studs https://www.ebay.co.uk/itm/Copper-Fl...r=561918993594

Good call Rob.. Couldn't remember the number off hand, and not sure if same for 620.

Slar plenty of coppaslip round if you use stainless studs... You'll know how to slar it if you're true Norfolk...

03-09-2019, 08:31 PM

Quote:

Originally Posted by Mr Gazza

Slar plenty of coppaslip round if you use stainless studs... You'll know how to slar it if you're true Norfolk...

.....SPREAD, !.........I love a good quiz, you'll have to try harder than that Gary

Grumpy · 03-09-2019, 10:54 PM

Biscuits.....did someone day biscuits!

Flip · 04-09-2019, 09:15 PM

Quote:

Originally Posted by Mr Gazza

What sort of biscuits have you got?

Quote:

Originally Posted by Grumpy

Biscuits.....did someone day biscuits!

Trust you two!!!

Hamish and Richard, good luck with the rebuild- you know what they say when doing these things to always allow your budget, plus at least half again over?

That theory may be tested!

utopia · 03-09-2019, 11:58 AM

Yep, just to confirm that if Gazza is ok with it, you can certainly stick your injectors in my ultrasonic cleaner which he currently has on loan.

Is the fuel tank plastic or steel ?
If plastic, be aware that ethanol in petrol causes them to swell and not fit properly.
Draining and leaving them to dry out makes them shrink back to original dimensions.
I imagine its completely empty now, but worth making sure.

dacs · 03-09-2019, 07:27 PM

Hamish, welcome. I'm not that far from you, in Aylsham. You don't say whether this is your first Monster so the following may be superfluous but the hardest thing I found when fiddling with (sorry, maintaining) mine was dropping the assumptions that come with working on Japanese motorcycles - the design approaches are culturally different.
This link may help https://www.ducatiomaha.com/pages/ducati-oem-parts - drop down the page until you find the appropriate year and model for part numbers/exploded diagrams to supplement the Haynes manual.
Be aware that buying new Ducati bits will avoid the minefield of trying to find second-hand stuff on Ebay, which will fit A Monster but not necessarily YOUR Monster (don't ask how much I spent finding that out).
Ask on this Forum if you have a problem, there will always be someone who can give an answer in my experience. Best of luck with the 4 boxes of bits, I look forward to photos of the completed build.

Uncle Bob · 03-09-2019, 08:11 PM

Hello and welcome. I can guarantee you that I'll be absolutely no help to you technically, but I'll definitely be following your progress with great interest!

06-09-2019, 09:38 AM

All - many thanks for all your top tips.

Gazza - Thaats any biscuits you like old chap. Hobnobs, digsetives, custard creams. You name it.

Utopia - Many thanks for your offer of your ultrasonic cleaner, when Gazza has finished with it. I'll liaise with Gazza and lure him with Bourbons and stottie cake.

The fuel tank is plastic and has been empty for 5 years. If there's a fuel pump inside is likely to be gummed up with modern fuel additives, so could we ultrasonic clean that too, or just carb cleaner?

Mr Gazza · 06-09-2019, 10:15 AM

I'm very strict with my biscuits. I have exactly two chocolate Hobnobs every day as a special treat when I get home from work... I can eat only one Pringle too..

We'll have to sort a time to view this gestating Monster, I think Dacs and Grumpy would like a look too, so could be quite a party?

Regarding the injectors; 30 minutes in the tank should do the trick.
Regarding the fuel pump, not sure that ultra-sound cleaning would be ideal? But probably wouldn't do any harm provided it was thoroughly dried out afterwards, as the cleaning medium is mostly water. A quick dunk in some clutch and brake cleaner afterwards should get rid of the water come to think of it.
The best thing might be to just immerse it in clean fresh petrol to soften any residues, then just circulate them round in normal use, relying on the new filter* to catch anything thus loosened? Or in other words, just use it.

Any thoughts on that from the UKMOC think tank?

*Fuel filter = Mahle KL145. This is also a common BMW fitment, often listed a bit cheaper for beemers? Try Opie Oils, but shop around.

03-09-2019, 09:52 AM	#1
Hamish Guest Posts: n/a	Advice please on rebuilding a 2005 Monster Hi Everyone, My godson and I have just bought a 2005 Monster 620 Dark - 02, with a V5 & all the paperwork from the previous owner, in 4 large wooden crates. We have unboxed everything and are starting to clean and label all the bits, ready for a full rebuild. It has been boxed for about 5 years. The engine turns and it looks like we have a complete bike. We have ordered a Haynes workshop manual. Our plans are: Drain engine oil and replace. What oil please? Replace cambelts, plugs, air filter, fuel pipes, battery? Where to buy these parts please? Remove alarm to stop noise and immobiliser kicking in when we come to start it? Replace 2013 dated tyres? The spark plugs are old Champions RA6 HC & RA4 HC - are these correct, or can any UKMOC members suggest best plugs to buy please? We need to replace 4 badly corroded exhaust studs. Cann we use studs from local nut & bolt shop? Cambelts are labelled 190 187 5 208 DS & 153 5 208 DS - can we just order 2005 Monster belts? Replace belt tensioners or service & keep? The injector packs have been cleaned with carb cleaner - do we need to strip and rebuild like an old carb, or should they work OK with new fuel please? ANY ADVICE WELCOMED PLEASE? We live in Norfolk - Any MOC members live near us who would like a look at it over a cuppa and biscuits? Thanks in anticipation. Richard & Hamish

03-09-2019, 10:28 AM	#2
Mr Gazza Lord of the Rings Join Date: May 2013 Location: Norwich Bike: M900sie Posts: 5,983	What sort of biscuits have you got? __________________

03-09-2019, 10:38 AM	#3
mickj Registered User Join Date: Jun 2018 Location: Clevedon Bike: M1200s Posts: 565	Welcome to the forum Hamish , good luck with your project and I'm sure there will be plenty of help forthcoming from the other members, hobnobs is always a good starting point . __________________ Keep the rubber side down. Mick

03-09-2019, 10:56 AM	#5
Mr Gazza Lord of the Rings Join Date: May 2013 Location: Norwich Bike: M900sie Posts: 5,983	Drain engine oil and replace. What oil please? 10w40 Motorcycle specific semi-synth. Don't use car oil or the clutch will slip. Replace cambelts, Ducati belts from Moto Rapido, or Exactfit from http://www.exactuk.com/about-exactfit-cam-belts/ plugs, Use NGK, not Champion, correct number will be in the Haynes manual. air filter, and oil filter.. K&N from ebay fuel pipes, Moto Rapido again. battery? Motobatt.. *Price doesn't vary much but shop around on ebay* Where to buy these parts please? Remove alarm to stop noise and immobiliser kicking in when we come to start it? Pass! Replace 2013 dated tyres? Oh yes definitely!! The spark plugs are old Champions RA6 HC & RA4 HC - are these correct, or can any UKMOC members suggest best plugs to buy please? As above NGK We need to replace 4 badly corroded exhaust studs. Cann we use studs from local nut & bolt shop? Yes, use stainless if you can. Cambelts are labelled 190 187 5 208 DS & 153 5 208 DS - can we just order 2005 Monster belts? Order for 620.. As above. Replace belt tensioners or service & keep? If they spin freely and are not rough, use again. Expect a little resistance from the seals The injector packs have been cleaned with carb cleaner - do we need to strip and rebuild like an old carb, or should they work OK with new fuel please? Ultra-sound cleaner is best... Pop them in the one I currently have on loan from Utopia, a member on here. ANY ADVICE WELCOMED PLEASE? We live in Norfolk - Any MOC members live near us who would like a look at it over a cuppa and biscuits? See previous post.. Thanks in anticipation. Richard & Hamish __________________

03-09-2019, 10:54 PM	#9
Grumpy record breaker!! Join Date: Apr 2006 Location: Peterborough Bike: M1200R Posts: 2,155	Biscuits.....did someone day biscuits! __________________ It's not the destination, but the journey that matters Definition of a motorbike, a devise for overtaking cars!

03-09-2019, 10:54 AM	#4
slob . Join Date: Jul 2003 Location: East London Bike: Multiple Monsters Posts: 9,736	+fuel filter parts: Call Craig or Luke at Moto Rapido 01962 873981 (mention UKMOC for 10% discount on most parts) Super efficient mail order.

03-09-2019, 11:00 AM	#6
slob . Join Date: Jul 2003 Location: East London Bike: Multiple Monsters Posts: 9,736	NGK DCPR8E I'd use something like these on the exhaust studs https://www.ebay.co.uk/itm/Copper-Fl...r=561918993594

03-09-2019, 11:58 AM	#11
utopia No turn left unstoned Join Date: Jun 2010 Location: leicester Bike: M750 Posts: 4,561	Yep, just to confirm that if Gazza is ok with it, you can certainly stick your injectors in my ultrasonic cleaner which he currently has on loan. Is the fuel tank plastic or steel ? If plastic, be aware that ethanol in petrol causes them to swell and not fit properly. Draining and leaving them to dry out makes them shrink back to original dimensions. I imagine its completely empty now, but worth making sure.

03-09-2019, 07:27 PM	#12
dacs Registered User Join Date: Dec 2014 Location: Aylsham Bike: Multiple Monsters Posts: 200	Hamish, welcome. I'm not that far from you, in Aylsham. You don't say whether this is your first Monster so the following may be superfluous but the hardest thing I found when fiddling with (sorry, maintaining) mine was dropping the assumptions that come with working on Japanese motorcycles - the design approaches are culturally different. This link may help https://www.ducatiomaha.com/pages/ducati-oem-parts - drop down the page until you find the appropriate year and model for part numbers/exploded diagrams to supplement the Haynes manual. Be aware that buying new Ducati bits will avoid the minefield of trying to find second-hand stuff on Ebay, which will fit A Monster but not necessarily YOUR Monster (don't ask how much I spent finding that out). Ask on this Forum if you have a problem, there will always be someone who can give an answer in my experience. Best of luck with the 4 boxes of bits, I look forward to photos of the completed build. __________________ NFN

03-09-2019, 08:11 PM	#13
Uncle Bob Registered User Join Date: Jan 2017 Location: Milton Keynes Bike: M1100evo Posts: 233	Hello and welcome. I can guarantee you that I'll be absolutely no help to you technically, but I'll definitely be following your progress with great interest!

06-09-2019, 09:38 AM	#14
Hamish Guest Posts: n/a	All - many thanks for all your top tips. Gazza - Thaats any biscuits you like old chap. Hobnobs, digsetives, custard creams. You name it. Utopia - Many thanks for your offer of your ultrasonic cleaner, when Gazza has finished with it. I'll liaise with Gazza and lure him with Bourbons and stottie cake. The fuel tank is plastic and has been empty for 5 years. If there's a fuel pump inside is likely to be gummed up with modern fuel additives, so could we ultrasonic clean that too, or just carb cleaner?

06-09-2019, 10:15 AM	#15
Mr Gazza Lord of the Rings Join Date: May 2013 Location: Norwich Bike: M900sie Posts: 5,983	I'm very strict with my biscuits. I have exactly two chocolate Hobnobs every day as a special treat when I get home from work... I can eat only one Pringle too.. We'll have to sort a time to view this gestating Monster, I think Dacs and Grumpy would like a look too, so could be quite a party? Regarding the injectors; 30 minutes in the tank should do the trick. Regarding the fuel pump, not sure that ultra-sound cleaning would be ideal? But probably wouldn't do any harm provided it was thoroughly dried out afterwards, as the cleaning medium is mostly water. A quick dunk in some clutch and brake cleaner afterwards should get rid of the water come to think of it. The best thing might be to just immerse it in clean fresh petrol to soften any residues, then just circulate them round in normal use, relying on the new filter* to catch anything thus loosened? Or in other words, just use it. Any thoughts on that from the UKMOC think tank? *Fuel filter = Mahle KL145. This is also a common BMW fitment, often listed a bit cheaper for beemers? Try Opie Oils, but shop around. __________________