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Here's A Good Place To Start - Monster 620ie

Discussion in 'Technical Help' started by davidoffadventures, Jan 26, 2020.

  1. Hey all,

    I've had a 2002 monster 620ie for about a year now, it came with lots of little issues. I've been fixing them as I went along, but it's been neglected a bit whilst I replaced a head cylinder on my van. It's got a list of issues which I'll tackle, but if anyone can give some tips /advice that'll be greatly appreciated

    1# biggest issue is the dash/speedo, rain got in and nottin works really. No Speedo or milage, the screens are borken. I'm happy to customise this bike, so not looking for exact replacements. Has anyone replaced theirs with an analogue Speedo? And what issues would I likely encounter?

    2# the bike loves to slip gears whilst riding and wake me my heart up. Would you recommend changing the clutch plates? Or there any maintenance I can do?

    3# the electrics in general on this are shocking, I believe the coil pack is exposed to the elements, any nifty mods people have done? I'm thinking of rewiring the loom and hiding them as tidy as I can.

    #4 I've got an oil leak on left side, around the gear leaver. If I was to replace gaskets for this area could anyone recommend a place to get them and what to look out for?

    #5 ive just got some timing belts so I'm going to change those and check the valve clearances, I understand Ducati use desomdronic, which sounds like a time consuming faff to check, but if anyone's got some tips, that would be welcomed

    #6 rear brake light mount is snapped, and rear indicator on the brink too. I'd like to just change them all with LEDs and remount them without that beesting rear mudguard. What LED relays have people used for these bikes?

    Here's the bike (if attachments work)

    IMG_20191220_114044_112.jpg
     
  2. Be careful with the clocks as iirc most of that era have a matched ecu and clocks, so unless code matches it won’t work. You may be able to disable it in the ecu.

    it’s worth a google on belts change. There are ple gulf guides and occasional video out there.
     
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  3. With belts there is a load of stuff online. here is one of many:

    With my ST2, there seemed to be two main ways: vibration frequency, or twisting. I used a combination of both. I think that the factory tool is available to rent from the DOC if you join.
     
  4. Welcome to the Forum David :upyeah:

    1. If the speedo on that model is digital and reads off a magnetic pulse off the rear wheel I’m sure you’ll have the space on the front hub for an analogue one.

    2. I cant see how changing the clutch will prevent jumping out of gear, that sounds like a gearbox issue. Ducati gearboxes in my limited experience are normally very good, how many miles has yours done?

    3. big job to rewire the complete bike of it were me I’d tidy up the existing and waterproof as much as possible.

    4. crankcase covers are sealed with tri-bond or whatever it’s called, a liquid silicon sealant. The gear change shaft protrudes through a hole in the crsnkcase cover that has a seal in it, it may this that’s shot & is leaking, a photo would help.

    5. what Perry said above about belts

    6. LED lights usually come with a built in resistor and are plug & play straight into the original wiring IME, no need for extra relays.
     
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  5. I'm not an expert by any means but AFAIK the clocks contain an air temp & pressure sensor for the fuel injection system, so replacing the clocks for aftermarket is not a simple bolt on. You shouldn't rely on my info, but use it to check with someone who does know.

    Great pic!
     
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  6. If you’re using fully synthetic oil, try semi. I found mine has less clutch slip and worked better, especially when hot. I have had a couple and they both were typical Ducati ‘full of neutrals’ boxes but very very rarely jumped out
     
  7. #2...Do you mean it jumps out of gear or that the clutch slips whilst it’s in gear?
     
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  8. Amazing help here guys! thank you!

    #1 I'm looking at replacing the speedo/dash cluster. Already ordered the cables to disable the immobilizer in the ECU. I work with software, so hopefully the disabling wont be an issue, just the rewiring of an aftermarket dash will be a mare!

    #2 unfortunately I cant see mileage, but just checked the last MoT listing (2017!) it was at 22,805k miles - I changed battery, oil, filter, spark plugs, chain sprocket and chain when I got it last year.

    It slips out of gear at high gears, I've found some interesting posts about the type of oil to use and frequency they slip out of gear. Will look more into this (maybe purchase some performance oil) but I quite fancy change the clutch cover with one of these see through covers :D

    #3 Ah I really lost faith in the wiring at the moment, i think its been exposed to water too much overt the years, I'll take back all the sleeving and just check for my own sanity then tidy it up. But i'll be doing quite a bit with wiring the new dash.

    #4 I'll grab a photo, only one I had are from when I cleaned it all up with gunk engine cleaner, planning on seeing where it comes from next time. Looking at getting a gasket set if i'm taking lots of covers off though.

    #5 I'll be attempting the belts and timing this weekend, thanks for the video link. Fingers crossed I don't balls it up - ive just completed rebuilding my vans engine, and its sounding super sweet, but that was a pleasure to work on as the engine was inside (mazda bongo)

    #6 no wonder i couldn't find led relays for it , never owned led lights. Just got some incoming from flea bay :D thought I may have to add my own resistors :')
     
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  9. Superb photo btw, light, composition, hobby?, profession?, luck?
     
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  10. The oil leak may be clutch fluid if you have a slave cylinder on the left as with bigger bikes.
    Jumping out of gear is usually a result of not having gone in properly, which might be to do with lever adjustment
     
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