03 620 Dark - PLEASE help me figure out some starter mods

[ducjon]

I've noticed the clutch is really a tough pull, I rode a 695 and 696 and it seems wayyy easier of a pull.. My hands get crazy cramps around the city.. Is there a way to modify this cheaply? I'm thinking maybe aftermarket levers that are adjustable and give me a shorter distance to pull..


Or.

I just get used to it.

[Mojo S2R]

spidey wrapped it all up pretty good.

Couple other things. 
Lengthen and reroute the wire for the oil temp (I think that's what it is).

Length and reroute the starter wire.

Look for the forks/shock off a S2R1000 or S4.  Get them resprung/oiled for your weight.

+1
I've read explanations and seen pix (pic above is a nice example) of the starter wire reroute mod and plan on doing this myself.  I've read of the oil sensor wiring reroute mod but can't find any example pix or explanations of where the wiring is getting rerouted.  Can someone please point me in the right direction?  Thanks.

Another free mod that I don't recall being mentioned - flip the handlebars to lower the controls

[Privateer]

+1
I've read explanations and seen pix (pic above is a nice example) of the starter wire reroute mod and plan on doing this myself.  I've read of the oil sensor wiring reroute mod but can't find any example pix or explanations of where the wiring is getting rerouted.  Can someone please point me in the right direction?  Thanks.

Another free mod that I don't recall being mentioned - flip the handlebars to lower the controls

for the oil sensor wire, I just cut off the end, stripped a little off the wire, used a butt splice to mate on some more wire, routed it around the back of the clutch cover, put another terminal on, a little shrink tubing over the splice and the terminal, done.  use some zip ties to keep it tidy with the other wires and such running around over the clutch and down towards the rear brake.

[rule62]

I've noticed the clutch is really a tough pull, I rode a 695 and 696 and it seems wayyy easier of a pull.. My hands get crazy cramps around the city.. Is there a way to modify this cheaply? I'm thinking maybe aftermarket levers that are adjustable and give me a shorter distance to pull..


Or.

I just get used to it.

The 695, 696, and newer 620's (like mine) have the APTC clutch, which has a significantly lighter pull.  Your '03 does not.  That being said, I swapped my APTC clutch for a non-APTC.  I actually like the stiffer feel of the standard wet clutch and how it engages, over the APTC.  To lighten the pull effort for free, you could take the clutch-side engine cover off and then remove 2 of the clutch springs, opposite each other to keep things balanced.  More expensive would be to get an aftermarket clutch slave-cylinder.  

...and please revisit my post about the 14-tooth sprocket and lightened flywheel.  Seriously... best mods for the money... and the prices I paid were on the high side.

[teddy037.2]

Are not!

[ducjon]

...and please revisit my post about the 14-tooth sprocket and lightened flywheel.  Seriously... best mods for the money... and the prices I paid were on the high side.

Really? Can you tell me what exactly they both do for you? I read a little about a lighter fly-wheel, but I can get a good feel for what both mods would do together.

[teddy037.2]

Really? Can you tell me what exactly they both do for you? I read a little about a lighter fly-wheel, but I can get a good feel for what both mods would do together.

14 tooth front sprocket alters the gear ratio front:rear, giving you more usable low rev power (but buzzier, high revs, at like freeway speed)

lighter flywheel will help the motor itself spin up faster, and engine brake more (less mass=less intertia)

[Scooter Montgomery]

Mine. It now has a rear cowl on it too. This is the actual factory 1/2 dark color also.

[ducjon]

Looks great!

Can you list off real quick what you changed? It seems I want to do a lot of what you did (no balls for the open belts though)

Thanks!

[Scooter Montgomery]

Looks great!

Can you list off real quick what you changed? It seems I want to do a lot of what you did (no balls for the open belts though)

Thanks!

Lowered headlight and gauges
Cermic coated header
Cored stock exhaust and 4" chop
Tail chop
Dinky winkas signals
Suburban machinary bars
powder coated side covers
powder caoted the rearsets
stock rear hugger cut down
removed the side panels and relocated the crap behind them under the seat
The belt covers aren't open, they have lexan side them to protect the belts.

And I put 30k on it in the first 4 years of owning it.

Lots of the things I did are just stock part modified, to keep things cheap.

[sbrguy]

i have a 03 620.  did minimal mods.

unlike others i do not like the tail chop so i have a stock back, meaning beer tray, hugger, and seat cowl are all there.  i also kept the carbon canister on the bike.

termi slip on low mounts titainum, crg bar end mirrors, front bikini faring on the bike, top mounted matris steering damper (ok this is really just for bling), and i go thte oil cooler kit put on the bike, make sthe bike temp run20-30 degrees cooler.

unlike others i did not put any carbon on the bike.  also i took the fork reflectors off but keep them on if you like them, they make the bike look better.  crg brake lever adjustable but didn't put one on the clutch side bc honestly the stock levers feel a little more sturdy to me.  personally i like that the 620 has a slightly heavier pull than the 695 or 696 bikes, but that is a personal thing..  

[Monster Dave]

Hey it's nice to finally see some others of our rare color scheme for 2003. An interesting fact is that there were only 199 of our type sent to the US in 2003.  

Here's mine as stock:




And a few tasteful mods that I've done:





The Leo Vince pipes are AMAZING. Hands down the best that I've heard. Love'm.  

So, I did:

1) Clear Alternatives Smoke Tail Light
2) Tail Chop
3) Leo Vince Exhaust
4) Tail Hugger mod
5) CF seat cowl
6) Bar end mirror
7) 14t front sprocket
8 ) CF Tank Protector
9) Ducati Valve Stem Tops:



Here's the story on mine: http://ducatimonsterforum.org/index.php?topic=25682.0

[ducjon]

Mine. It now has a rear cowl on it too. This is the actual factory 1/2 dark color also.

How did you hide your cables and ditch the zip-ties? I really want to do this ASAP, but I'm afraid I'll do something wrong.

[ducjon]

Quick question for the guys with the 2003 620..

I had this strange thing happen today, on a stop-sign little rev..

It gave me almost a backfire... it didn't rev up, just got almost silent with a little "pop"... scared me, and it happened one more time on my ride today. Bike was around 230 on the oil temp, and i had just gotten gas. I can't really re-create it, but it only seems to happen on a really quick twist of the throttle..

[Privateer]

How did you hide your cables and ditch the zip-ties? I really want to do this ASAP, but I'm afraid I'll do something wrong.

you can't really do it wrong.  cut the zip tie, see where the wires droop, if at all, then zip them somewhere else out of site, or to another wire harness.

if it doesn't work out, then reapply the zip ties where the factory had them.