I have a 2007 Monster 695. I don't ride it much since I got a couple other bikes, so it only has 4300 miles.
A few months ago, my bike started cutting out here and there, and had trouble starting.
Eventually it was fully diagnosed that my fuel pump was going out. And the part alone was $900.
Not wanting to pay the crazy money they were asking, I investigated the fuel pump issue myself.
Using resources from here I determined that one RED wire was causing my fuel pump not to work.
For those of you who don't know how to fix it, feel free to contact me regarding how to fix it, its extremely easy but a little time consuming because of wait time. Entire work time is approx. 1-2 hours but wait time is 24 hours.
I am extremely disappointed in Ducati with how they designed this wire issue. The wires go through some epoxy and because of the short length of wire, will eventually break or fray if you lift your tank up.
Strangely enough, I have only lifted my tank up twice, once to replace the battery and once to replace the ECU with the termi unit.
I think that too many customers are having or had this issue. Please reply back and state year and make of the bike and how you fixed the fuel pump issue.
I am trying to get a head count for possible litigation or to lodge a complaint with the NHTSA.
I am having this problem on my 2006 Monster 620. Took me well over a month to diagnose the problem after being stranded on the bike numerous times. It is definitely the wire that feeds through the epoxy to the pump. I am attempting a fix this weekend based on all the research I have conducted on these forums. I was going to use JBWELD Wet to seal the wires after I am finished. Have you heard of this epoxy well to the ethanol? Also if you have detailed instructions, feel free to post; there are tons of people out there still trying to diagnose this problem. Seems to be specific to the plastic fuel tanks and the wire design. Thanks for the help on this!
My o7 695 died a few months ago. I took it to NPR Ducati in Watkinsville ,Ga. They found a wire that had come loose on the fuel bump. They soldered the connection and covered the connection with epoxy. That saved me a bunch of $.
wow I can't believe you found a garage that would do that for you! Most mechanics won't touch it. I just fixed mine this morning. It was a tedious process, but not too hard. Hopefully the solder made a good connection; we will see in 24 hours I guess.
For future DIYers make sure you have I believe half a dozen #6 internal teeth washers and I believe a half dozen #8 or #10, they're cheap so order both haha! Also you will need a snap ring removal tool.
Besides that some solder, some extra wire, some shrink tubing, JB weld, allan wrenchs, and basic tools should be everything you need.
Had the same problem on my 2008 S2R 1000.
Both black wires became loose on the tank side of the epoxy plug.
I believe the epoxy within the plug is not formulated for use
with ethanol containing gasoline.
The dealer quoted me $1200 to replace the fuel pump assembly.
That is the same material many people use for coating the inside of the plastic
tanks to prevent expantion and deformity. The info sheet specifically
mentions that it can be used in combination with ethanol and gasoline.
Regular epoxy will gradually soften and starts crumbling when exposed to
the current gas containing ethanol.
I am not saying that JB Weld won't work, just do
not know enough about it...
This is an awfully small number of people for a problem that seems like it should be very common. Does this impact only 6xx monsters? Or do the larger models also feel this?
It's Multisrada as well. I'm working on a fix and was talking to my dealer about what bikes are affected. They had one in the shop. Too bad. The only option that they could give that poor soul was replacing the whole assembly.
The dealer said that they've tried fixing them but they fail pretty shortly afterward.
I am experiencing the same problem. Ducati dealer just quoted me $1100 to repair. Seeing as this problem is indirectly caused by the tank expansion, Ducati should pay for the repair.
Another common fuel pump issue are the hoses becoming detached from the pumps. This happened to me and I spent many, many days chasing it down. I was told that the ethanol in the fuel was breaking down the hoses and that the clamps were crap.
Hi kpxturbo - I think I'm having the same problem. I am also being asked for close to 1k to install new fuel pump. I consider myself pretty handy but don't have experience with bikes. Do you think this is something I could do myself? If so, can you provide some details on how to do, e.g. (parts and tools I would need)? Thanks.
Wow, I bet I have the same problem (broken or loose wires leading to fuel pump). All of my symptoms are the same as described in the original post. When I'm having my problem I'm not hearing the fuel pump prime. I just removed my fuel pump flange casting and I will start testing continuity tomorrow morning. I hope JB weld works because that's what I have on hand and I hope to finish this job tomorrow.
I feel like I have complete success with my fuel pump wiring harness rebuild. I disassembled everything and tested continuity of old wires. Yes, I had a break or high resistance connection for the red wire (power for pump) and white wire (goes to low fuel warning sensor). Continuity changed as I manipulated the wires. By the way, my low fuel warning light was not working. It was really shocking that the wires looked great and there was no visible problem. It must have been a break internal to the wire insulation. I pulled all the old wires and replaced them with equal or larger gauge new wire. Other than the need to be careful about taking everything apart (take photos as you go), the majority of the effort involved removing the epoxy-material that houses the wires where they go from the wet to dry side. You will need to 'gut' that material, run new wires through and reseal with something. I used JB weld (2-part epoxy) and I assume it will hold. It's only been one day but everything is working great! Some of these pics are before new wires and some are after new wires.
I feel like I have complete success with my fuel pump wiring harness rebuild. I disassembled everything and tested continuity of old wires. Yes, I had a break or high resistance connection for the red wire (power for pump) and white wire (goes to low fuel warning sensor). Continuity changed as I manipulated the wires. By the way, my low fuel warning light was not working. It was really shocking that the wires looked great and there was no visible problem. It must have been a break internal to the wire insulation. I pulled all the old wires and replaced them with equal or larger gauge new wire. Other than the need to be careful about taking everything apart (take photos as you go), the majority of the effort involved removing the epoxy-material that houses the wires where they go from the wet to dry side. You will need to 'gut' that material, run new wires through and reseal with something. I used JB weld (2-part epoxy) and I assume it will hold. It's only been one day but everything is working great! Some of these pics are before new wires and some are after new wires.
How did this turn out Paul? Looks like your bike and my bike went down around the same time. I pulled mine apart same as you but I'm machining a whole new assembly to get rid of the epoxy problem. When I pulled the epoxy out of that bung the wires just fell apart in my hands (the epoxy was holding the connections) because the solder had failed. I'll post pics of my final product. I'm really bad at keeping up to date pics of projects that I do.
I had posted earlier that I had a wire problem fixed by NPR. Later the fuel pump died. With the tank removed and the pump hooked up it would not prime. I replaced the pump with a $50.00 ebay pump and it has worked flawlessly.
I have this problem with my 08 695. If someone would take a minute to PM me and explain some steps they took to fix this problem, it would be much appreciated!
I finished the build tonight. I started from scratch and built a whole new bulkhead. I didn't use any of the original parts so it won't be prone to the same failures. Also no experimental adhesives, epoxies, sealants, or substrates, only elements with confirmed resistance to Ethanol. It's tougher than it sounds. I think I've laid the groundwork for a permanent fix. Pretty sweet. Only time will tell. I've been sharing peeks of my build with my local dealer and they're pretty interested in seeing it work. It's a good thing that I put it in tonight. A short test ride and I'm confident. I think that this weekend I will swing by the dealer. Maybe I can trade my work for a Panigale.
I have the same issue. First the wires now an epoxy issue. I replaced the bad wires with the CA Cycleworks wiring harness, but now the epoxy is leaking... I feel like i can't win with this one. How are everyone's repairs holding up?
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