Question about 2004 Ducati Monster 620 Capirossi
2002 Monster 620e I have no Fuel pressure to the injectors, and am in process of removing the top of the fuel tank so that I can get to the pump. I cant get it off. I have taken the 5 allen bolts off and removed the cap. I then removed the 5-6 small set screws that look like they hold this cap system on, but nothing, it wort come off. Any advice?
Pull real hard. Or you can use a small thin plastic prybar, with a rag between it and the tank and slowly work the assy out. Its in there real good.
Posted on Nov 20, 2008
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The fuel pump pressurizes the fuel rail/line to a high pressure in the neighborhood of approximately 58 psi. so to avoid an uncontrolled discharge or spray of gasoline, the pressure must always be bled off prior to fuel line removal and top plate removal. To do this remove the left side saddlebag and the left side cover and then remove the remove 15 amp fuel pump fuse. And then start the engine and allow the motorcycle to run until it stalls and then turn the engine over for about three seconds to remove any remaining fuel from the fuel supply line. THEN remove the maxi-fuse and reinstall the 15 amp fuel pump fuse. THEN remove the filler cap and drain fuel tank with a safe method of your choice and store the fuel or appropriately dispose of it. THEN remove the seat the console by releasing the socket screw to release front of console from the fuel tank weldment, the hex screw to release rear console bracket from the clip nut on the rear fuel tank bracket. NOW lay a clean shop towel or towels on the forward part of the rear fender and lay the console upside down on them. Then you will need to get a special tool for Cam ring removal and installation. HD have one as part number HD-48646) which tool you will place over the top plate, aligning the four notches at the bottom of the tool with the four tabs on the cam ring. THEN get a 1/2 inch drive ratchet, install it in the tool and rotate in a counterclockwise direction until the cam ring is loose. BE CAREFUL to properly align the tool and push down on it while rotating it to loosen the ring and to control the ring because if it slips off the ting during rotation and hold both the ratchet and tool carefully so it cannot slip and slide across the fuel tank doing substantial paint damage. WHEN it is loose remove the retaining ring, insert a small plain screwdriver between the latch and top plate, depress either side of the latch, gently tug on the harness and remove the top plate up by lifting it up. THEN locate the ground wire spade terminal in the slot of the top plate, insert the tip of a small flat blade screwdriver through the window to depress the tang, and then pull the terminal from the slot. THEN depress the collars and remove the tubes from the fittings on the fuel filter shell. Move the top plate to a bench area and remove the filter (which would also be necessary it the top plate replacement is necessary).
If installing a new top plate, first install the fuel filter shell pursuant to the fuel filter replacement instructions I have set out below.
Carefully inspect the seal ring at the bottom of the top plate for cuts, tears or other signs of deterioration and if necessary, install a new seal ring with the nubs contacting the ring groove walls. THEN move the top plate back to the motorcycle and connect the two different sized tubes to the proper sized fittings on the fuel filter shell. The tube with the smaller diameter fitting runs from the fuel pump to the fuel filter housing and the tube with the larger diameter fitting runs from the fuel pressure regulator housing to the fuel supply valve. THEN install the connector at the bottom of the top plate and route the ground wire from top plate connector along the inboard side of the vapor valve and install the spade terminal into the slot in the top plate and gently tug on the wire to verify that the terminal is locked in place and if it is not locked in properly bend the tang upward slightly away from the terminal body with a thin flat blade, like that on a hobby knife, to enable it to lock in place. THEN install the fuel tank top plate by inserting the index tab on the outer diameter in the slot at the front of the fuel tank collar and install the cam ring over the fuel tank top plate with the "TOP" stamp facing up. If there is a filler cap present on fairing equipped models, remove it. NOW get the CAM RING REMOVER/INSTALLER tool and one half inch ratchet assembly and place it/them in over top plate carefully aligning the four notches at the bottom with the four index tabs on the cam ring and then carefully pushing down on the tool with both hands, rotate it in a clockwise direction until each of the four index tabs begin to engage slots in fuel tank collar. And continue rotation until the index tabs are all the way seated into the slots. You should use the same care when aligning and pushing down onto both the ratchet and the tool and rotating the tool as was done when removing the ring to avoid unnecessary damage to the fuel tank paint etc. When this done reinstall the console. Being careful to avoid pinching any of the wire harness and vent tube while reinstalling the console back onto the fuel tank and then start the socket screw to fasten the front of the console to the fuel tank weldment and then start the hex screw to fasten the rear console bracket to the clip nut on the rear of the fuel tank bracket and alternately tighten the socket/hex screws to 36-60 in lbs (4.1-6.8 Nm). THEN install the seat, maxi-fuse, left side cover and left side saddlebag. THEN put fuel in the fuel tank, carefully inspect for leaks, start the engine inspect for leaks again.
Fuel Filter replacement instructions:
After you have removed the fuel tank top plate and find the ground wire spade terminal in the slot of the fuel filter shell. Then insert the tip of a small flat blade screwdriver through the window to depress a tang, and then pull the terminal from the slot and then gently raise the locking arm and pull the U-clip from the holes in the fuel filter shell and remove the fuel filter shell from the end cap and then also remove the o-ring and filter from the fuel filter shell. To reinstall a new filter in the fuel filter shell seat a new o-ring on the counterbore at the top of the filter and then install the fuel filter shell over the end cap, so that the slot in the fuel filter shell engages the index pin on the end cap and then. Holding the parts together, slide the U-clip through the holes on the locking arm side of the fuel filter shell and push the U-clip until its ends exit the holes on the opposite side and then retract U-clip until contact is made with the step in the locking arm. When that is done route the ground wire from top plate TORX screw around the index pin side of the end cap and install the spade terminal into the slot in the fuel filter shell and gently tug on the ground wire to verify that the terminal is locked in place. If the ground terminal does not lock in place properly use a thin flat blade,(like that on a hobby knife), to bend the tang outward slightly away from the terminal body. Then reinstall the top plate.
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