Question about 2004 Ducati Monster 620 Capirossi

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Fuel Tank Filler Removal 2002 Monster 620

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?

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  • Anonymous Mar 15, 2014

    I have a t595. cant find out where the fuel injection pump bolts onto the motor

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  • Master
  • 2,712 Answers

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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Replacing Fuel Filter on 2007 FLHTC Harley Davidson


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 and the hex screw to release rear console bracket from the clip nut on the rear fuel tank bracket. THEN lay a clean towel or towels on the forward part of the rear fender and lay the consoleupside 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 by lifting it up. After you have removed the fuel tank top plate and found the ground wire spade terminal in the slot of the fuel filter shell 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 endsexit 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 bladed tool to bend the tang outward slightly away from the terminal body. Then reinstall the top plate.)



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 and if top plate replacement is necessary, remove the fuel filter shell.

If installing a new top plate, first install the fuel filter shell. THEN inspect the seal ring at the bottom of the top plate for cuts, tears or signs of deterioration and if and as necessary, install a new seal ring with the nubs properly contacting the ring groove walls. THEN move the top plate to the motorcycle and connect the tubes to the fittings on the fuel filter shell noting that the fittings are of different sizes to prevent improper assembly such that the tube with the smaller diameter fitting runs from the fuel pump to the fuel filter housing, while 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, route the ground wire from the top plate connector along the inboard side of the vapor valve and install the spade terminal into its slot in the top plate and lightly tug on the wire to verify that the terminal is locked in place and if it does not lock in place use a thin flat bladed tool to bend the tang outward slightly away from the terminal body so that it will lock in place. THEN install the fuel tank top plate engaging the index tab on the outer diameter in the slot at the front of the fuel tank collar, install the cam ring over the fuel tank top plate with the TOP stamp facing UP.THEN if so equipped remove the filler cap from the top plate on fairing equipped models and get an appropriate CAM RING REMOVER/INSTALLER tool and put it in place over the top plate while aligning the four notches at the bottom with the four index tabs on the cam ring and then while all the time pushing down on the tool with both hands rotate it in a clockwise direction until all four of the index tabs begins to engage with the slots in the fuel tank collar at which time insert a 1/2 inch drive ratchet into the tool and rotate the tool until the cam ring is fully installed. THEN re-install the console next by:
FLHR/C: Use caution to avoid pinching the wire harness and the vent tube. FLHX, FLHT/C/U, FLTR: Use caution to avoid pinching the wire harness, the vent tube and the overflow tube and then re-install the fuel filler cap. THEN start to thread in the socket screw to fasten the front of the console to the fuel tank weldment, start the hex screw to fasten the rear console bracket to the clip nut on the rear fuel tank bracket and alternately tighten the socket/hex screws to 36-60 inlbs (4.1-6.8 Nm). THEN re-install the seat, re-install the maxi-fuse re-install the left side cover, re-install the left side saddlebag, refill the fuel tank check to be sure there are no fuel leaks, start the engine and again inspect for any fuel leaks.

Oct 09, 2014 | 2007 Harley Davidson FLHTC Electra Glide...

1 Answer

How to remove fuel injectors from a 2005 road glide


Release fuel pressure and then disconnect the fuel fuel line from the quick disconnect. You will possibly have to raise the fuel tank a few inches. If you move the fuel tank crossover tube behind the coil you can lift the tank about another 3 inches and then move it straight rearward. You can disconnect the fuel line from the fuel rail by undoing the one fastener that secures the fuel tube/line to the fuel rail by a clamp. Two T20 Torx screws hold the fuel raill to the induction module. Remove them. Pull the fuel rail away from the injectors. Disconnect the fuel injector wiring connectors. Twist and turn and pull the injectors from the intake module.

Sep 01, 2014 | 2005 Harley Davidson FLTRI Road Glide

2 Answers

How to remove gas tank on 2003 ultra classic electric glide


1. Drain fuel tank as follows:
Obtain a short section of hose with a 5/16 inch (7.9 mm) I.D.
Insert bolt in one end of hose and install hose clamp to
ensure that end is securely plugged. Using a side cutters, cut
clamp from one end of crossover hose beneath fuel tank.
Quickly replace crossover hose on fuel tank fitting with open
end of short hose while directing flow of gasoline from free
end of crossover hose into suitable container.
2. Remove seat.
3. Purge the fuel supply line of high pressure gas. Proceed
as follows:
a. Remove the 15 amp fuel pump fuse.
b. Start the engine and allow the vehicle to run.
c. When the engine stalls, operate starter for 3 seconds
to remove remaining fuel from fuel lines.
4. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
5. Carefully cut anchored cable strap securing main harness
bundles, console pod conduit, fuel level sender/fuel pump conduit, and fuel vapor vent tube to left side of frame backbone.
6. Open fuel door on console. Remove two Allen head
screws inboard of rubber bumpers. These screws
secure console to clip nuts on the canopy bracket.
7. Remove Allen head screw to detach flange at rear of
console from clip nut on fuel tank weldment.
8. Lay a clean shop towel on forward part of rear fender.
9. Remove filler cap from neck of fuel tank. Remove console
and lay upside down on shop towel. Reinstall filler cap.
10. At top of canopy, depress button on socket side of 3-
place Mini-Deutsch connector to release fuel tank harness.
11. Gently pry fuel vapor vent tube from fitting on filler neck
of fuel tank. Exercise caution to avoid pulling fitting from
filler neck.
12. Locate quick-connect fitting on left side of fuel tank. Pull
up on chrome sleeve and pull down on fuel supply line
fitting to disconnect.
13. Remove two fuel tank front mounting bolts (with flat
washers) from left and right side of frame. Remove bolt
(with flat washer) to free rear of fuel tank from frame
backbone.
14. Remove fuel tank from vehicle.

Jun 29, 2014 | 2003 Harley Davidson FLHTCUI Electra Glide...

1 Answer

How to remove gas tank from Ducati Monster 2012 1100 evo


Hi, Anonymous sorry you can't find the first and best tool you ever bought for your Ducati despair not for a mere $10 you can download another one. For more information about your issue and valuable free downloads that you will need please visit the websites below. Good luck and have a nice day.
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May 24, 2014 | 2012 Ducati Monster 1100 EVO

1 Answer

Ducati monster turning off when warmed up and is not the temp.sensor.


Hi, Anonymous the following applies to carbureted also fuel injected models and the usual suspects are:
1. Severely discharged or damaged battery, 9 volts or lower.
2. Failed alternator/generator and or voltage regulator.
3. Loose or corroded battery terminals and or cables especially the "NEGATIVE" cable, look for loose, corroded, or broken connectors inside the cable harness at "BOTH" ends.
4. Failed main circuit breaker or ignition switch, check for loose connections and continuity.
5. Failed system and or ignition relay, check for continuity.
6. Failed ignition coil, ignition/electronic module.
7. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor, corroded, loose or broken wire connector pins/sockets.
8. Throttle cables and or idle speed improperly adjusted hot idle speed should be 950 RPM to 1000 RPM.
9. Air/fuel mixture screw improperly adjusted.
10. Water or dirt in the fuel system, carburetor or filter.
11. Restricted, blocked or kinked fuel line.
12. Fuel tank empty.
13. Gas cap is not venting properly or fuel tank venting system blocked.
14. A failed fuel pump, pressure regulator and or fuel injectors.
15. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
16. Needle and seat stuck closed in the float bowl.
For more information about your issue and valuable free downloads that you need please visit the websites below. Good luck and have a nice day.
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Jul 16, 2012 | 2003 Ducati Monster 620 i.e.

1 Answer

How do I replace the 2003 road king fuel level sender


Use the following as a template fro how to get at the fuel sender:

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.
DIAGNOSE as follows:


Feb 24, 2012 | 2003 Harley Davidson FLHR Road king

1 Answer

I can not get my Ducati to run it has just been sitting


Hi, Mnskaterdude if your bike has been sitting idle for months or years and you did not do any pre-storage maintenance I feel your pain it will probably have a dead battery and not want to start or if it starts it will idle and run poorly, here are the following steps necessary to complete in order to get your bike back to an acceptable running condition.
1. If your battery was 3 years or older when you last had the bike running you should replace it.
2. If you believe your battery might still be serviceable remove it from the bike and put it on a 1 or 2 amp trickle charger for 24 hours. If it is the old lead acid type with visible cells and acid levels fill each cell to the top line with distilled water and replace the caps, run the vent tube into a plastic or styrofoam cup, any cells that are cloudy/milky replace the battery.
3. After charging remove the leads and let the battery sit for a couple of hours then check the battery voltage with a volt meter, you should have 12.5 volts or better, any readings in the 11 volt range you need to do a proper load test on the battery and replace as necessary, any readings in the 10 volt range you have a dead cell and replace the battery.
4. Drain and flush fuel tank, google " how to clean a motorcycle gas tank" find a couple forums to view the different options available.
5. Remove your air cleaner and clean and re-oil per Mfg. specifications.
6. Remove the carburetor, disassemble and decontaminate with a carb dip or if you have EFI remove injectors and clean with carb spray and compressed air
7. Remove fuel valve and filter disassemble and clean as necessary, remove fuel lines and replace with new ones.
8. Replace spark plug with a new one and check for spark.
For more information about your issue and valuable free downloads that you will need please visit the websites below.com. Good luck and have a nice day.
http://www.ducatimonster.org/forums/general-monster-forum/291129-2001-m600-repair-custom-paint-job.html
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Sep 04, 2011 | 1999 Ducati Monster 600 - Dark - City -...

1 Answer

Hi I have a Daytona 600 2004 and i have removed the fuel tank I need to know where the evaporative fuel system line attaches too could you please help.


The two evaporative fuel system lines are located on the underside of the tank, one is the drain hose for the filler cap, the other is the fuel tank breather (or eveaporative connector hose) Best to have marked them before removal.

Please see diagram below for fitting:
chozbert_2.gif
Hope this helps.

Feb 12, 2011 | 2004 Triumph Daytona 600

1 Answer

How do i access the battery


It appears the battery is under the left side of the gas tank.
First get a 3 mm hex key and remove all the side panel screws and remove the screws that hold the cover around the gas filler cap, and remove the two plastic side panels. After the screws are out the side panels the panels slide forward and will come out. There are two hex screws (size ?) that have to be removed to release the fuel tank. One is under the tank and is accessed from the rear with about a 1 foot extension for the hex bit. The other is on the front rt side and is quite obvious. There is enough fuel hose on the tank that you can simply prop-up the front of the tank with a piece or wood or anything convenient and get access to the battery. I put battery tender leads on my 696. Hardest part is removing all the small screws that hold the side panels and cover for the fuel tank.

Oct 21, 2009 | 2008 Ducati Monster 696

1 Answer

How to reach the battery on 696 monster ducati, and install charger.


Under gas tank cover

First get a 3 mm hex key and remove all the side panel screws and remove the screws that hold the cover around the gas filler cap, and remove the two plastic side panels. After the screws are out the side panels the panels slide forward and will come out. There are two hex screws (size ?) that have to be removed to release the fuel tank. One is under the tank and is accessed from the rear with about a 1 foot extension for the hex bit. The other is on the front rt side and is quite obvious. There is enough fuel hose on the tank that you can simply prop-up the front of the tank with a piece or wood or anything convenient and get access to the battery. I put battery tender leads on my 696. Hardest part is removing all the small screws that hold the side panels and cover for the fuel tank.

Oct 20, 2009 | 2008 Ducati Monster 696

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