Question about 2004 Ducati Monster 620 Capirossi
I'm putting on a new gas tank and need help on how to remove the fuel pump and insert it in the new tank???
If you have a Front and/or Rear stand, put the bike up on it. Make sure you are working in a well-ventilated place that is not sensitive to fuel vapors and spills. Although fuel spill should be very minimal (around 2 ounces), there will be a strong smell of fuel.
--- Siphon out of as much gas from the Fuel Tank as you can, collect it in a gasoline container... place in safe place. (You do not need siphon fuel out if you are not removing the fuel pump, which is located inside the tank. You only need to make sure that you have no more than 1/2 tank of fuel in there, and keep the tank propped-up - you should have little or no problems with fuel spilling then)
--- Remove the 3 allen bolts under the seat section on each side of the bike.
At the very tip of the tail fairing, you will need to gently "pop" off the tab (underneath) that connects it to the sub frame. There is no bolt to unscrew, just a tab you need to pop-away with slow, progressive pressure until come off. (this is for monoposto, may be slightly different for biposto)
--- The TAIL FAIRING, the SEAT and the FUEL TANK are all connected into one whole assembly. You will first need to separate the fuel tank. To do that, lift UP on the whole assembly and prop it up.
After you have propped-up the TAIL-SEAT-TANK assembly, remove the 17mm Bolt underneath the seat, in order to separate the TAIL-SEAT from the TANK.
Put the TAIL-SEAT Assembly in a safe place where it will not be damaged or scratched.
--- Now you can work exclusively on the Tank. The first thing you need to do is get an old towel or good size rag to place underneath. There will be a minimal amount of fuel spill, so put that on to protect your engine from getting fuel spilled on it.
--- There are 3 couplings underneath the tank that you need to remove. Two of them are fuel lines, the other one is a power line.
Disconnecting the fuel lines are a bit tricky. You need to just squeeze them and they will come off. If you have large fingers, call your S/O and make her do it ... or for lonely guys, you might have some luck with needle-nose pliers.
--- As you handle the tank from this point forward, keep the tank propped-up, to avoid any further spilling.
--- Next, disconnect the 2 breather hoses in front of the tank. You will need to squeeze the connector with pliersso that it comes loose. Do not use hard pressure, only slow progressive pressure. Nothing will spill out of these hoses.
Once you have disconnected all lines and hoses from the Tank, you are ready to remove the tank. The front of the tank is connected through two guide pins - all you need to do is just slide the tank towards the back end of the bike and it will come off. Have a ready area to put it down where it will not get scratched... make sure that the Fuel Pump is at the top end, so as to avoid any spilling.
To remove the Fuel Pump:
--- remove the 3 bolts that attach the Pump to the tank. Once removed, slowly pry-off the pump assembly away from the Tank with the help of progressive pressure on a flat head screwdriver. Try to do it evenly a little bit at a time, on each of the 3 sides... that makes it easier to remove.
--- You will need to slowly move the fuel pump assembly around to get the whole thing to come off the opening in the tank. There is an O-Ring there that is most likely damaged due to dis-assembly, so you will need to replace that. This is very important ... if not, it will most likely lead to a huge Fuel Spill (guess how I know that).
When putting the fuel pump back,, with NEW O-Ring, apply a liberal amount of grease, vaseline or some lubricant... if you do not apply enough lubricant, you will run a very high risk of: (1) HAVING A VERY DIFFICULT TIME REINSTALLING THE FUEL PUMP; (2) STRIPPING THE 3 CONNECTION SCREWS due to uneven flange and/or (3) DAMAGING THE O-RING.
When reinstalling the fuel pump assembly, make sure that you try to pop it in with progressive hand-force, and as evenly as possibly through out the 3 connection points. If you put enough lube, things should slide in with relatively little effort, and all you will need to do is just bolt the 3 screws back.
So that's it... to reinstall, just do everything Backwards!
Hope this helps
Posted on Mar 07, 2016
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Posted on Jan 02, 2017
That is not the fuel pump you hear, the pump is vacuum and the noise you hear is the ignition coming to life. Don't use any additives in your fuel, bad news, and just use the choke only, twisting the throttle does nothing till the engine starts. The choke is a slow speed jet. There is no way to check the air filter without pulling the seat and lifting the tank. But I have never found mine dirty, and I live on a dirt road. I call it the multistrada. 02 ,S4. Are you burning high test? 92 octane? How about keeping it warm or under cover? I think the fuel problem might be the dampness, humidity, etc, How about them spark plugs? Check them lately? I switched to autolites, they work a lot better than the champions. Hope this helps.
Posted on Apr 18, 2010
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