Advice please on rebuilding a 2005 Monster

[dacs]

Originally Posted by Hamish

Hi Gazza & Dacs,

Do you fancy a trip down the A47 this Sunday for a look at the rebuild?

Gazza - tea, biscuits & stottie cake at the ready.......

Hamish, thanks for the invite, given the forecast I have to agree with Gazza (he does not turn down a free biscuit easily). I should be at the breakfast meeting in a week's time, hope to see you.

[Grumpy]

Originally Posted by Hamish

Hi Gazza & Dacs,

Do you fancy a trip down the A47 this Sunday for a look at the rebuild?

Gazza - tea, biscuits & stottie cake at the ready.......

Originally Posted by Mr Gazza

Hamish. It's going to be peeing down all Sunday and I'm busy doing some woodwork for Dacs.

The Sunday after, we are meeting for breakfast at The Gin Trap, Ringstead.
That's near Hunstanton, so not too far from you.
http://www.ukmonster.co.uk/monster/s...398#post569398
Why don't you pop in if you can, and meet the lads?
We could follow on afterwards to look at your project if that's convenient for you?

Originally Posted by dacs

Hamish, thanks for the invite, given the forecast I have to agree with Gazza (he does not turn down a free biscuit easily). I should be at the breakfast meeting in a week's time, hope to see you.

I'm interested in coming along for biscuits...err I meant to have a look! Although I land at Stansted early hours of Sunday morning, returning from a break to Italy.
If I surface in time to head for the Gin Trap, will drop Gazza a text.

Hi Gazza and Dave,
Really enjoyed the Norfolk Branch MOC Meeting with you guys yesterday. Thank you for all your brilliant advice and thanks for coming to look at our 4 boxes of Monster 620 bits.
Utopia - Thanks for your offer of your ultra sound machine - Gazza has taken our injectors to clean them in your machine.

Thanks again all.

Hi Gary & Dave,

Thanks again for popping across to see us yesterday, and giving us some excellent advice. Your bikes sounded great as they went up the road. We managed to get the cam belts re-adjusted, fitted the shims in the rear swing arm, found the choke lever and fitted it and put the rear wheel back on.
We bled the rear brakes off the bike as suggested with the slave much higher than the master, and it works really well.

Thanks again.

Photos to follow.

[Mr Gazza]

Good to see you again and to meet Hamish.
You've made some fantastic progress and it's looking good.
Good news finding the choke lever... Even if it's really a fast idle lever with a choke symbol on it..

Till next time.. Keep up the good work.

Hi Guys,

Great to meet up with some of you for breakfast on Sunday. Thanks Gazza for the tank clip - very kind of you. Richard and I made great progress on the bike this weekend, please see attached photos for your entertainment, from boxes that were going to be shipped to Columbia to a Monster (that needs the wiring finished - so please ignore the messy wires everywhere)

Can anyone please advise where the pictured hose is supposed to be positioned (should it be connected to something or is it a drain)? Its about 18mm and has a strange rubber loop at the end.

Also, The wiring harness has coloured cables to help identify, but the components like the indicators and switches etc that connect into it seem to have no identifying colours on the wires into them. Does it matter which cable goes into which (ie are components like the indicators reversible)?

Thanks for all your help in advance, and I look forward to riding the bike to a meet up soon.

[Darren69]

Unfortunately you can't post pictures directly on here. You need to post pictures to a hosting site and link to them on here. PostImage or Photobucket or similar

[Mr Gazza]

[Mr Gazza]

The hose with the loop looks like a breather hose and could connect either to the crankcase breather catch tank or the air cleaner box.. Others will confirm.

If there are only two wires going into a switch or bulb holder, then unless it is an LED (read diode, polarity sensitive) it doesn't matter which way round they go.
With the indicators it looks like white/green and black to the right and white/black and black to the left.
That would seem to indicate (see what I did there?) that black is the earth.

There should be a downloadable wiring diagram somewhere.. Anyone know where to find it?

Thanks Gazza for your "indication"

Thanks Darren too.

[Darren69]

IIRC the wiring diagram is in the back of the owners handbook which you used to be able to download from Ducati.com for free, but I've just checked and they no longer go back that far.

If you can't find a link to download one you could alway buy a copy on CD of the full workshop manual from somewhere like ebay. I've seen these are about £10.

My godson Hamish just bought a 2005 Monster 620 Dark - 02, with a V5 & all the paperwork 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 over 6 years.

The engine turns and it looks like we have an almost complete bike.

Gazza and Dave have visited a couple of times and both have been incredibly supportive and encouraging in our rebuild, which we do about one weekend every 5 weeks.

We are not trained mechanics or engineers, just keen, and certainly don't have the skill and ability of 'Buzzer', Gazza or Dave.

Thanks again to everyone who has given us tips.

[Mr Gazza]

Bingo! Well done to both of you..

You have reaped the reward for patience and thoroughness. I hope she gives you many years of good service and joy..

Hello All,

Hamish’s Monster 620 passed its MOT last week after a full rebuild from 4 crates containing 1000s of pieces, which had been lying around for several years.

A huge thanks to Gazza & Dave for all their help and advice over the last year of hard work. Hamish has a design background, not an engineering background and he has found the full rebuild very interesting and he has learnt a lot about rebuilding motorbikes, which was the aim for the project. I thought his favourite part of the rebuild would be learning about the TDC markers on the cams and how to replace the cambelts, but his favourite part was using a large piece of cardboard to make a facsimile crankcase to keep all the crankcase bolts in the right order.



When Covid -19 is all over, Hamish is keen to take the Monster back to his house near London, and I’m hoping he will tax and insure it from 1 July 2020, so either he or I can bring it to the next UKMOC meeting, especially if it’s going to be at Wendling & Beston Airfield Memorial. If it is there, I might even ask my wife to come along in a car with some thermoses full of piping hot tea & coffee………and of course some biccies for Lord Gazza.

Just in case anyone is thinking of doing the same sort of project, here are some notes from the last 9 months:

We bought a Haynes manual, which proved very useful.

We slowly built up the frame, added the forks, then the swinging arms and wheels. The chain had been cleaned in brake cleaner (Gazza’s favourite) and left in a bath of fresh oil over the winter 2019/2020.

We bought and replaced many nuts and bolts, including those for the handlebars, rocker covers, swinging arms and crankcases.

The exhaust pipes were cleaned and new O rings and new stud nuts fitted.

Both brake calipers were stripped, cleaned and rebuilt with new pads.

We removed the rocker covers and checked the valve clearances, which were all good, so left them alone. We also sprayed lots of fresh oil around the rockers & cams, as they had been dry for over 6 years.

The engine was fitted to the frame and she started to look like a Monster.

We did an oil and filter change using Motul 10w40 Ducati Motorcycle specific semi-syn.

We replaced the cambelts, plugs, air filter, exhaust studs and fuel pipes.

The fuel injectors were badly gummed up, so when Gazza & Dave visited us, Gazza took them away and used Utopia’s ultra-sound gizmo to clean them. (Thanks also to Utopia)

We had a look at the wet clutch to find it very worn and it had a crack on the inner drum webs. We found a Ducati dealer online who was clearing out old stock and bagged a brand new clutch drum at half price. We also renewed the seals on the clutch operating rod.

We bled both brake systems and the clutch, ensuring all the 6-10 year old brake fluid had been fully flushed out.

We fitted a new battery, switched on the ignition and were amazed when most items lit up for the first time in over 6 years.

The old Datatool alarm/immobiliser was past its best and kept sounding off randomly, so it was removed.

We had one leftover wire and no neutral light, so made a quick call to Gazza, who advised to look at the back of the engine. After close inspection of the engine, we found the connector covered in grey duct tape. The light works fine now. The indicators were intermittent, so we took off the handlebar switches, dissembled them, cleaned them and all good now.

Various relays looked grimy, so we removed them, cleaned the posts and re-assembled.

Both tyres had lost pressure whilst standing idle for 6 years so were inflated and date checked. The front tyre was date marked 25 12, and the rear was 03 13, so both about 7 years old. It was decided to keep them on, just in case the MOT revealed some other expensive faults.

to be contiued........

continued from last post:

STARTING

We had a final look around to make sure everything was in order, then put some fresh petrol in the tank and hoped that after 6 years, the internal electric fuel pump wasn’t gummed up. A final check of the fuel lines, and all was looking good, so we took her outside the garage and turned on the ignition. The internal fuel pump ran for 4 seconds, which sounded promising.

Choke on, press the start button and after a bit of coughing, she fired up on both cylinders and kept running.

There was a small oil leak from the rocker covers, so new seals were fitted.

She passed the MOT in June 2020, but has still not been more than 5 MPH or out of first gear for over 6 years.

Gazza has agreed to give her a shake down (safety) ride, as he is used to Monsters.

So, what does she owe us, not that Hamish will sell her?

Hamish paid £700 for the 4 crates and all the items mentioned above add up to £400, so she owes us £1100.

An update to follow when she is taxed and insured………