620 Revamp Thread (SBK conversion, swingarm, etc, with pics)

[csorin]

Hey guys,

I've been asking a lot of questions on this forum regarding a front end rebuild and thought I'd post up my progress.  This all began after drooling over B's 620.  I was pumped to see someone rock their 'little' monster for more than 4 months, and not only that, put some good money into it.  Most of the parts were gathered here on the DMF.  I'll try to give call-outs to all those who were generous towards the project.

The bike as I bought it:



First I began the process of removing extraneous fairings, fenders, and covers.



Dyed the sprocket cover and belt covers according to forFreedoms excellent instructions: http://www.ducatimonsterforum.org/index.php?topic=43500.0.  





Replaced the silver swingarm with a black one from a 695:



At this point I had replaced the 620 seat with an 800 unit from Marvelous, and removed the side cover panels with help from SuzyJ's fantastic fork upgrade thread: http://www.ducatimonsterforum.org/index.php?topic=41414.0

I decided to go with a SBK clip-on style front end.  First up was dissassembling the headlight and controls area.  You might notice that my rear wheel is on the ground.  This was a result of the flat-sided rearstand slipping forward.  I jammed a wheel chock between the rear stand and the tire.  The fit was perfect and the bike is rock-solid in this configuration.



I packed all bolts and small parts in numbered zip-lock bags.  This way I could just count backwards for reassembly.  I also took notes and drew little drawings for myself.



The forks went on without a hitch.  Many thanks to bergdoerfer for the aluminum shims.  They fit perfectly.  Also, thanks to silvy1200 for the donated top triple.  In the end I went with a Speedymoto unit, so if anyone needs an extra top triple, just let me know.

With the aluminum shim, I had to slide the fork up, insert the shim from the top in the small diameter part of the fork, then slide the rest of the fork up through the shimmed triple.  Following this, I duct-taped a screwdriver and lightly tapped the shims back down into the triple.  The forks got slightly nicked, and if I were to do it again, I might use some kind of plastic clay sculpting tool.  



The Speedymoto clip-ons are a purchase from another Ducati forum (not the monster one ), and replacement bars from an online retailer.  Ca-Cycleworks provided the top triple.  

The clip-ons didn't come with the original titanium hardware, and at first I used too short of hex screws.  To my horror, I stripped about half the threads of the right clamp.  A trip back to Lowes for some longer screws, and a much more careful install resulted in a successful second attempt.



The forks are beauts.  2001 998 TIN coated units with GP suspension valving and .95 springs.  They came from a 7k mile bike and supposedly a 0 mile refresh from GP Suspension:



The new bar height:



So that's where I am.  Sitting on the seat, it is definitely an aggressive position.  I'm interested to see how it feels at speed with a little help from the wind.  I don't rest my hands on the bars and keep a pretty firm stomach/back while riding.  Very excited to set off.

Here's how she sits, awaiting TAftonomos' magic to be done on the headlight bracket: http://www.ducatimonsterforum.org/index.php?topic=16517.0  

[gOoIe B]

very nice work so far.  I wish I woulda jumped on those forks while they were still available

gotta love the 'lil monsters

[csorin]

Thanks man.  None of this would have happened without help and inspiration from the forum (is that a good thing? ).

The forks are from an eBay seller.  He buys Ducati's that are in good running shape and parts them out.  I've picked up a lot of parts from him (forks, shock, levers, random switches) and have never been disappointed.  He takes very large, detailed pictures.  An added bonus is that he starts his sales at $1, no reserve.  These forks were $220 shipped, and I just picked up a 748 Showa shock for $50 shipped.

PM me for his contact details, as I'd rather not advertise a non-sponsor.

[teddy037.3]

 

620s rawk!

[Bones]

nice.  I think SBK forks for my 620 is going to be my winter project.

[b.]

Lookin' good! 

[Duc Buz]

Nice 

[csorin]

Thanks guys.  Super small update today.  Work has slowed as I'm waiting for my new-fangled and now finished bracket to come in.  Damn this three day weekend!  Probably shouldn't wish it away just for a bracket

I placed my controls and grips.  Master cylinders from UglyDucky's S4, levers and brake switch from my eBay seller. 

The levers were a pain in the ass.  Apparently, the pin and barrel that pushes into the master is next to impossible to find.  You either buy a set of OEM levers that will include the pin and barrel, or buy aftermarket parts that are insanely expensive ($25 a side!).  Luckily, my guy had a take off set that I specifically asked to include the pins.  The levers are kinda sloppy, but were still cheaper than buying a set of replacement pins and aftermarket levers.



Plans for the weekend include shining up the exhaust (http://www.ducatimonsterforum.org/index.php?topic=43917.0), and general detailing (http://www.totalmotorcycle.com/restoring.htm).

[csorin]

All finished up



Bracket came in from Taft (fantastic work here), and the front end was buttoned up.  Only snag was stuffing the stock brake lines behind the light.  That took some creativity and total trust in the fittings holding.  All lines have plenty of slack, no binding to be found.

I took the bike to BMW of Plano and had Chuck adjust the suspension.  The difference was astonishing once the front and back were more in balance.  I was running 24mm sag at first, and we got this up to 32 for the street.  He got things dialed in about as good as could be with the .95 springs of the SBK forks, and suggested I go to .90's at some point.

Pre-load waaaay out:



Overall, stoked on the suspension feel so far.  The bike is less wallowy, and in turns it is rock solid.  One strange effect has been an increased sense of acceleration.  The rear end no longer drops, and I could swear the tire hooks up more efficiently.

The S4R master's are incredible.  Faster to take effect, much stronger, and much more progressive than the coffins.  I can't imagine needing more power, and the gold looks fantastic with the rest of the stock brembo bits.

The clip-ons are taking a bit to get used to.  I am honestly wondering if it was worth it at this point.  Yes, I've only given them a whole three days, but holy shit, you are committed to a very aggressive position.  When things get speedy, and lots of turns are involved, it's a beautiful thing.  The other 80% of the time, especially decelerating into stop lights, is awful.  Hopefully it's only a matter of giving my body time to get used to the new position. 

[teddy037.3]

good stuff! 

it looks like there miiiight be enough meat to mount your clip-ons over the triple if you need to.... clip-ons were always way too much of a reach for me

[b.]

Good work!  Any pics of the whole bike?

[csorin]

Hey B, I'll try to get some pics up this weekend.

Truly though, the clip-ons might not be for me.  Riding around town has become not so much fun.  I'm going to try putting them above the triple, but if that doesn't work out, I'll probably go back to a stock bar setup.

For those who have used Speedymoto Tallboys, how do they compare to the stock riding position?  They apparently offer them in a 53mm diameter now.

[teddy037.3]

Truly though, the clip-ons might not be for me.  Riding around town has become not so much fun.  I'm going to try putting them above the triple, but if that doesn't work out, I'll probably go back to a stock bar setup.

if you go back to bars, give a serious look at suburban machinery. IMO, absolutely perfect compromise between forward lean ergos and the more upright stock bars.

[Artful]

How tall are you? At 6'1", above the triple zero rise clip-ons are MUCH better for my monkey arms than the stock bars.

[csorin]

I'm 5' 10".  Just put the clip-ons above the triple on my lunch break.  Raised the forks about a 1/2", and just transferred the clip-ons to the top.  I have my bike back   A million times more comfortable.  Still fairly aggressive, but shit, I'm not dying anymore around town.  Pretty stoked. 

The stock brake lines are kinked something fierce with the lowered gauges.  I'll have to invest in some new lines down the road. 

For now, everything is feeling decent.  I might give the stock 620 seat a go again, see if the lowered height brings my arms even closer to the bars.  I do like the extra room the 800 seat provides for my knees though.  We'll see.

She's not as pretty as she was with the clip-ons below the triple, but she's much more comfortable to ride.