After a minor make-over, mostly superficial parts about 5 years ago, I have decided to tear down my wife's 620ie Monster which she has owned from new in 2003, for a complete rebuild. After 18,000 miles its started to show it's age, so now is a good a time as any to start. The only fly in the ointment is I need to have it ready by WDW 2016 in 14 weeks time. No pressure then. You can follow the project here: Ducati Monster 620ie Restoration Here's the initial result after 7 hours work. BTW Ignore the chaos, every part was documented as it came off and will be bagged and labelled by the weekend. The garage is just temporarily ugly.
It's just good lighting. Whilst I've seen a lot worse for the same year and model, even with all the TLC in the world, there no getting past the crap paint Ducati use on the engine that literally jumps off the crankcases., leaving behind a rather fetching furry coating. That and the multitude of cheap zinc plated corroded parts, all of which have been removed by the time this photo was taken, so as to cause less of an offence to the eyes.
Making some real progress. Frame already stripped of head race bearings and together with swingarm now at the powder coaters, plus the stripped wheels and a box of other parts. Much work done to the loom as well. More details and pics on the FB page.
Does anyone have an old U bracket for a Monster, that supports the headlight suitable for this model? I am actually after the two white plastic inserts that push into the top tubes. They are not available from Ducati and I pretty much destroyed them getting out of the part prepping it for powder coating. 21st March update: Managed to sort this one out now. A local engineering company are making me up some new ones in hard nylon.
Made some real progress over the last few days. Tank, front mudguard and seat cowl already at the paint shop. Frame, swing arm and other ancillary parts at the powder coaters and a bunch of other stuff awaiting zinc plating. Spent a fair bit of time finishing off the wiring loom. Needed to buy a few more specialist tools to complete the job. Looks like I will also need another alarm unit as the original has died after 13 years of use. Fortunately there is a company that supply a plug and play replacement unit, so no need to rip into the loom again. With respect to the engine, I am also having a special engine stand made up to support it once it has been painted and rebuilt. Engine is now at Carl Harrison Motorcycle Services being stripped down ready for media blasting prior to paint. Today the belly pan is off to a local CF repair specialist and got to collect the new LED indicators. Talking of LEDs, the headlight unit has been replaced with a new item and the number plate tail light is being switched over with an LED item, so the bike will be an all LED set-up Pictures can be found here: Ducati Monster 620ie Restoration
A few parts starting to come back in. Frame and swing arm have been powder primed then painted in titanium grey, as I'm not a lover of powder coated frames as the finish is too thick IMHO. Zinc plating all done. £20.00 for the lot. Bargain. Sadly not everything is that inexpensive. Engine is being stripped down to the cases for painting as well as barrels heads and side covers. A multitude of stainless steel fasteners have been delivered with more on the way. New LED indicators, and LED headlight. The list goes on....as does the cost...Gulp! Next stop, the soda blasters where the throttle bodies will get a thorough clean and the engine parts, forks and rear wheel hub. More details on the Facebook page.
Clock mods in the pipeline, assuming the kit I am after is still available. If not then I will just button this lot up and re-fit the cluster to the bike. Engine is now stripped down to the cases and already at the soda blasters. Should be ready on Monday. Then it's off to the painters. Hope to start re-assembling the engine by the end of next week. More photos can be found here: Ducati Monster 620ie Restoration
Frame now fitted with new steering head races and resplendent in it's new titanium grey colour, courtesy of Lustre Coatings Ltd. in Hethel. More info and updates here: Ducati Monster 620ie Restoration
Lots of progress being made, parts coming in and parts being rejuvenated. I've a few parts that are perfectly serviceable that have been removed and are now on the store, if anyone needs some bits and bobs for a monster: Ricambi Moto Engine should be complete tomorrow. Not bad for just six weeks in, which included a total strip down, soda blasting, etch priming, paint and re-assembly of all the major components. Lots of parts needed replacing as well as all the seals, gaskets etc, however mechanically the engine was sound internally after 18,000 miles and 13 years of use. All stainless bolts throughout and where not replaced, bright zinc plated. New billet parts, new alarm, brake and clutch lines, discs, specially coated calipers, tyres, the list goes on. I'm hopeful this bike will be better than new, when I bought it for my wife back in 2003. For a more comprehensive update, check out the FB page.
Getting ever closer to the finishing post. More pics and details on the FB Page. Hope to have the bike complete next week for initial engine runs and a shakedown and adjustment of any outstanding systems and final safety checks before it's MOT. Then it's all ready for WDW2016.
On the home stretch now. Just finished fitting the new "Cruscotto Forte" billet aluminium instrument housing to the bike (from Ducati Salzburg). Looks great IMHO. Bike has had it's first engine run since the rebuild and is having some last minute fettling done at Carl Harrison's in Harleston, in readiness for the MOT.
Can you please put all the pictures up here as not everyone is on Facebook including me Building my 900 this winter so like to see how every other Monster owner is doing there's
In total this ground-up rebuild took just 88 days from start to finish. Total strip-down to last nut and bolt, engine completely stripped down, media blasted, painted and rebuilt. More details on FB, but here are some pictures of the finished article.
