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

[DarkMonster620]

  I bow to your awesomeness! Thank you. My Google-fu is not doingwell today. Looks like I'm going to have ample opportunity to use my Snap-On Digital Techwrench torque wrenches.

Now to order up some belts. Any suggestions on a source? I want to be sure I'm getting NEW Stock, not New Old Stock. I understand that the new belts are kevlar reinforced, is that correct?

do you want a copy of the manual? send me your email via pm to send it

[Mr.Maim]

Removed the timing belt covers and checked condition, they look good but will get replaced. Tension is a little more lose than spec on the front-facing piston. All tensioner rollers are rolling fine.

Still the whining sound persists. If the bike is not moving, then I can rule out the transmission, correct?

[DarkMonster620]

Removed the timing belt covers and checked condition, they look good but will get replaced. Tension is a little more lose than spec on the front-facing piston. All tensioner rollers are rolling fine.

Still the whining sound persists. If the bike is not moving, then I can rule out the transmission, correct?

mine has had that whne noise since new, all pulleys replaced, and the noise is still there . . . now, I tell people is supercharged . . .

[Mr.Maim]

mine has had that whne noise since new, all pulleys replaced, and the noise is still there . . . now, I tell people is supercharged . . .

You serious? If so that puts me a bit more at ease.

[DarkMonster620]

You serious? If so that puts me a bit more at ease.

had the noise when new they replaced rhe tebsiomers and idlers still the noise . . . I have since replaced the belts 3 times . .  Still there

[SpikeC]

 Do they not have straight cut primary gears? Those whine.

[DarkMonster620]

then it would be when running, the whining is just engine on[idle] and while accelerating . . .

[Mr.Maim]

Back at it after a long business trip. Got new ExactFit belts from California Cycleworks (great price, fast shipping) that will get installed this weekend if the garage isn't too hot (110-F today!).

[seevtsaab]

Good Luck - I see you had a link to a tutorial, the most important advise I have there is to lock the cam pulleys in place.
My motor had short screws in the cam belt cover (to seal the holes I recon) , I took one to the hardware store and bought longer ones
that jamb the pulleys in place when the belt comes off (just 2 for the cam pulleys).

[Mr.Maim]

Good Luck - I see you had a link to a tutorial, the most important advise I have there is to lock the cam pulleys in place.
My motor had short screws in the cam belt cover (to seal the holes I recon) , I took one to the hardware store and bought longer ones
that jamb the pulleys in place when the belt comes off (just 2 for the cam pulleys).

Lock the pulleys so they don't rotate, or the gears?

[seevtsaab]

Outboard single pulleys, you'll see a small screw installed in each cover, possibly aligned with the a TDC mark, I think
both align with pulley markings when Horizontal Cylinder is TDC (not doing you any favors working from a faulty memory).

Obviously you can return the pulleys to the correct position but there's some spring tension at TDC iirc making that somewhat difficult.

It's all pretty simple and easy to get familiar with, good to make some notes.
I marked Vertical pulley location for TDC on the belt housing,
if you ever get hosed up you can always get each cylider to TDC and realign your pulleys.

[Mr.Maim]

Outboard single pulleys, you'll see a small screw installed in each cover, possibly aligned with the a TDC mark, I think
both align with pulley markings when Horizontal Cylinder is TDC (not doing you any favors working from a faulty memory).

Obviously you can return the pulleys to the correct position but there's some spring tension at TDC iirc making that somewhat difficult.

It's all pretty simple and easy to get familiar with, good to make some notes.
I marked Vertical pulley location for TDC on the belt housing,
if you ever get hosed up you can always get each cylider to TDC and realign your pulleys.

Okay, when you say "pulleys" you are talking about the cam gears and the crankshaft gear. I understood your use of "pulley" to mean the tensioner pulleys. Got it. I took the covers off a few weeks ago to make sure that this bike had the marks on the gears, it does, but I am going to use a white paint marker to make them more obvious.

Your advice about locking them up so they don't move while replacing the belts... that is EXCELLENT advice! THANK YOU!

[seevtsaab]

Ah sorry about that. Since they have belts going around them "pulleys".
And FWIW the 5mm - 6mm allen wrench thingy for belt tension (under the fixed pulley) is a breeze.
Just clicked over 55K miles yesterday and the little 620 just hums along.

[Rudemouthsky]

Removed the timing belt covers and checked condition, they look good but will get replaced. Tension is a little more lose than spec on the front-facing piston. All tensioner rollers are rolling fine.

Still the whining sound persists. If the bike is not moving, then I can rule out the transmission, correct?

Ahem..I'm one of the least mechanically inclined folks here so with that disclosed; I have to wonder since this is a part I just replaced; isn't a "whining" or "whirring" sound a common symptom with bearings that are on the way out? Those "rollers" are actually 2 stacked 6201 sealed bearings...about $5 each. Idle time is not the friend of a bearing so would it really be a bad idea to replace them? Mine had dried out on an 11,000 mile motor simply from sitting.

[Mr.Maim]

Ahem..I'm one of the least mechanically inclined folks here so with that disclosed; I have to wonder since this is a part I just replaced; isn't a "whining" or "whirring" sound a common symptom with bearings that are on the way out? Those "rollers" are actually 2 stacked 6201 sealed bearings...about $5 each. Idle time is not the friend of a bearing so would it really be a bad idea to replace them? Mine had dried out on an 11,000 mile motor simply from sitting.

Where did you buy your bearings?