2003 Monster 620ie w.72 miles - Getting it running again

[Mr.Maim]

Greetings DMF'ers!

I've got a 2003 Ducati Monster 620ie Dark with 72 miles on the odometer.

Yes, 72 miles. GF's bike. She bought "pre-Mr.Maim"    and it's too tall even with a lowering link installed. Not sure to keep or sell so it's been sitting since new either under a carport with a heavy duty motorcycle cover (first four months of its life) or in my garage (sixten years ago to present). Never seen rain. Never exposed to UV. Never in the cold. Rubber is pristine, paint is fine, it almost got knocked over once NOT DROPPED (slight scratches on L.exhaust sleeve). Other than that, it is just really dusty.

I'm sick of looking at a Ducati just SITTING in my garage. It's a crime. So I'm getting it going and then the GF can decide if she wants to keep it and have some seat scalloping done or sell it once and for all.

About me: I'm an occasional rider. Always had Japenese bikes (Hondas, Kaws, 'Ukis) and currently have a Kawasaki KLR650. I've always done my own work unless I had warranty coverage. I'm a wrench and a gearhead so getting some grease under the nails is not a problem. Plenty of tools and a good lift.

The purpose of this thread will be to post questions related to getting this bike running again after not having been run in... jeez 10 years. I'm going to post questions and pictures as they arise, instead of 100 things all at once.

And now the pictures as it currently stands: (yes, I am bluring out all the crap in my garage  )

[Dirty Duc]

Timing belts, oil, tires, brake and clutch fluid, re-install mufflers, lube chain, check brake pads, check lights, ride.

Welcome to the board 

[Mr.Maim]

Also want to note that while I have owned motorcycles for the better part of 20 years, I have never had to deal with one that had not run for an extended period of time, and I have never dealt with a Ducati.

That being said: first order of business: THE FUEL TANK

Took the tank off the other night and of course it will 1/5 filled with green gasoline. Drained and disposed of the gasoline. Now to deal with the tank.


1) Looking at the pictures below, does this rust need to be dealt with? I have had bikes in the past that had rust in the tank but it wasnt an issue if the bike was in use and the tank kept gassed to prevent further rust. Also keeping an eye on the fuel filter for particulate matter.

[Mr.Maim]

Timing belts, oil, tires, brake and clutch fluid, re-install mufflers, lube chain, check brake pads, check lights, ride.

Welcome to the board 

(writing all that down) Thanks! I'll get to all those items in short order and will have questions about a few of them. Thanks for the "Welcome" !!

[ducpainter]

I'd not worry too much about the tank interior.

It can be dealt with if she decides to keep it.

I would change that fuel filter while you have it accessible.

NAPA 3032 is an inexpensive substitute for the OEM filter.

[Mr.Maim]

Really? That's good to hear. I've been shuddering at the thought of trying to get all that crap out of there prior to some kind of strip and re-coat, but had thought I could "let it go for now" as I have done with other bikes in the past.

1) I'll need to do a cursory clean. I've heard diesel fuel and swish it around to rinse, drain, repeat. Is diesel necessary or can I just use gasoline?

2) Also, should I try to scrub the interior with a plastic bristle brush to get the stuff off that wants to come off?

3) Thanks for the NAPA part number! Hope those fuel lines come off easier than the fuel lines on the bottom exterior of the tank which didn't. Had to cut those, but only 3/4 of an inch.

4) Anything else I need to know about the TANK?  (not getting into anything else just yet)

[ducpainter]

I'd change the filter and call it good unless you want to coat the tank. All the other machinations are fruitless IMO.

The amount of rust in that tank is minimal IMO, and I've seen a 'couple'.

[Howie]

I'd change the filter and call it good unless you want to coat the tank. All the other machinations are fruitless IMO.

The amount of rust in that tank is minimal IMO, and I've seen a 'couple'.

Double on what ducpainter said.  You want to replace that filter because you don't need the stale fuel in it run through the injectors.  Make sure you use gasoline hose that meets SAE 30R10 specifications.

[joshuajcrouch]

I would recommend getting the hinge brazed while you have the tank off.  But I guess that totally depends on if you plan to keep the bike or sell it.  If weren't keeping the bike, its probably not worth the hassle to get it brazed and do some POR15 treatment.

I will be following your thread for sure, since this is almost the same thing I did a year ago.  Here is one of my threads if it would help.  Mine was a carbie with 900 miles, so not all things are the same:

http://www.ducatimonsterforum.org/index.php?topic=61934.0

[Mr.Maim]

Just to round off this thread. I've done the following to the bike:

- Removed tank, scrubbed the interior as well as I could reach with various nylon brushes and got 97% of the rust out
- Put tank back, replaced a couple of the fuel lines.
- Added see-through inline fuel filter
- Replaced dead battery with new Yuasa battery
- Drained motor oil. Not surprisingly it was clean.
- Cleaned off drain plug magnet.
- Removed and replaced OEM oil filter
- Replaced oil with Mobil 1 as recommended by motorcycle shop
- Suctioned out master brake cylinders on handlebar and side of bike. Flushed through new brake fluid with the help of a hydraulic bleed pump until all old fluids had been replaced. Bled air from lines, rear caliper, both front calipers.
- Suctioned out master cylinder on handlebar for clutch. Flushed through new hydraulic fluid with a bleeder pump. Bled air from lines.
- Replaced choke lever which had broken
- Removed spark plugs. Spray lubricant into cylinders in the event of frozen rings. Move pistons with tansmission in 4th gear turning rear wheel. Turns without issue. Verify with depth guage that the pistons are moving.
- Replace spark plugs with new NGK plugs
- Pressure check tires
- Insert key, fuel filter primes, guages check, warning lights test!

Will not start. Continued here: http://www.ducatimonsterforum.org/index.php?topic=67817.0

[koko64]

The in line filter, what type? Remember that this EFI motor runs with fuel pressure at around 45 PSI. A new in tank filter will be fine. I would be careful to use EFI rated hose clamps and the correct in tank lines as Howie mentioned.

[Mr.Maim]

The in line filter, what type? Remember that this EFI motor runs with fuel pressure at around 45 PSI. A new in tank filter will be fine. I would be careful to use EFI rated hose clamps and the correct in tank lines as Howie mentioned.

koko64: It's a $3 inline clear filter I got from the local Ride Now, all the guys there are  sport bike riders but I feel that your post is well warranted. I will check to make sure that the filter is up to par. 45 PSI? Jeez! I'll double-check to be sure the filter is up to par. I like having an inline filter as a troubleshooting tool to determine if I have fuel flow, I have put one on every motorcycle I have owned since they started making them.

Need to replace the in-tank filter which is OEM. I will run through a tank of gas first because I am sure there is still sediment that will be shaken up with the first few rides.

Good advice! THANKS!

[Mr.Maim]

To Do List:

Top off oil (changed oil and filter last week)
Remove LH exhaust and thoroughly clean chain, lubricate with Dupont Chain Lube.
Check for proper chain tension
Reinstall LH exhaust
Reinstall rear tire fender
Wash bike
Fill up with Premium unleaded
Get some mirrors installed
Slap on license plates, check insurance coverage, get GF into a rider's class!   

[Howie]

Fill it up with 87.  I'm guessing the filter you added is external and after the pump?  Get rid of it and replace that fuel hose with SAE 30R9 hose, 30R10 for any in tank hoses.  Do chenge te in tank filter before starting.

[Mr.Maim]

Fill it up with 87.  I'm guessing the filter you added is external and after the pump?  Get rid of it and replace that fuel hose with SAE 30R9 hose, 30R10 for any in tank hoses.  Do chenge te in tank filter before starting.

Why 87?