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Title: 05 Monster 620 starts then dies Post by: The ModFather on October 08, 2017, 08:15:26 AM Removed the alt and clutch case covers for powder coating which I've done in the past without issue. This time after reassembly the bike starts idles slow and rough then dies after about 5 seconds. If i open the choke up or give it some throttle I get some big backfires. I've got it on a battery tender Jr and it was green when I tried starting it switches to red after the unsuccessful attempts. I think I can hear the whine of the fuel pump priming when I turn power on. I've been combing through previous posts but havent found any answers yet. Any thoughts?
Title: Re: 05 Monster 620 starts then dies Post by: Speeddog on October 08, 2017, 11:24:33 AM No PC on the mating surface of cover to cases, and the mounting surface of the rpm sensor, yes?
Title: Re: 05 Monster 620 starts then dies Post by: Howie on October 08, 2017, 01:14:11 PM Also, did you use a gasket or a sealant like tribond?
Title: Re: 05 Monster 620 starts then dies Post by: The ModFather on October 09, 2017, 04:21:25 AM No PC on the mating surface and I used the Motowheels Gaskets.
Title: Re: 05 Monster 620 starts then dies Post by: ducpainter on October 09, 2017, 04:30:53 AM If it didn't have a gasket before, I'm betting the ignition sensor need's re-shimming.
Personally, I'd just lose the gasket and use 3-bond. Title: Re: 05 Monster 620 starts then dies Post by: Howie on October 09, 2017, 05:04:13 AM The sensor air gap needs to be .6 -.8mm. It is much larger with the gasket in place. Two choices. Measure the air gap and shim to correct or get rid of the gasket. I agree with dp.
Title: Re: 05 Monster 620 starts then dies Post by: The ModFather on October 09, 2017, 09:44:17 AM So in experimenting with the shim (used a washer to increase the shim size by about 2x bike wouldnt start. Removed the shim completely and now it's idling normally and keeps running.
Am I at risk of damaging the sensor without a shim? How do you measure the Sensor AirGap and get the right size shim? Title: Re: 05 Monster 620 starts then dies Post by: ducpainter on October 09, 2017, 10:31:05 AM Use a caliper. Use the depth function. Then measure the sensor.
It's impossible to say if you're in danger of ruining your sensor without measuring. Title: Re: 05 Monster 620 starts then dies Post by: Howie on October 09, 2017, 01:36:14 PM Below and perpendicular the sensor there is a bolt. Remove the bolt. You can measure the gap with a non-magnetic feeler gauge. The shim has only one job, estabish the air gap. You got lucky. Less than 0 gap = smashed sensor.
Title: Re: 05 Monster 620 starts then dies Post by: The ModFather on October 13, 2017, 04:51:47 AM So apparently the paper based gasket was thicker than the Hondabond gasket I had applied about 4 years ago ??? as now with the shim I'm at about 2mm and the bike dies without the shim I'm at about 1-1.2mm. Without the shim it's running just as it was before but I cant help but feel like I'd like to see how it runs with the proper .6-.8mm air gap. I dont see how that's possible without using a longer sensor.
Title: Re: 05 Monster 620 starts then dies Post by: Howie on October 13, 2017, 07:40:44 AM First, ditch the gasket. There are different size shims, .6, .8 and 1mm.
Title: Re: 05 Monster 620 starts then dies Post by: ducpainter on October 15, 2017, 02:57:32 AM Listen to howie.
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