Ducati Monster Motorcycle Forum banner

1 - 20 of 46 Posts

·
Registered
Joined
·
29 Posts
Discussion Starter #1
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.

Thanks
 

·
Registered
Joined
·
2 Posts
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!
 

·
Premium Member
Joined
·
23 Posts
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 $.
 

·
Registered
Joined
·
2 Posts
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.
 

·
Registered
Joined
·
29 Posts
Discussion Starter #6
JB Weld seems to work great. I finished my install up and it doesn't leak or anything.

I am also surprised that a dealer fixed the problem. Multiple dealers told me the liability is to great for them to do it.
 

·
Registered
Joined
·
29 Posts
Discussion Starter #7
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.
 

·
Premium Member
Joined
·
29 Posts
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.

From the search I have done so far, I believe the best resin
to reseal the plug is a phenol novolac epoxy based tank liner called Caswell:
http://www.caswellplating.com/restoration-aids/epoxy-gas-tank-sealer.html

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...
 

·
Registered
Joined
·
7 Posts
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?
 

·
Registered
Joined
·
10 Posts
2005 s2r 800

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.
 

·
Registered
Joined
·
351 Posts
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.
 

·
Registered
Joined
·
1 Posts
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.
 

·
Registered
Joined
·
3 Posts
I think I have same problem

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.
 

·
Registered
Joined
·
3 Posts
Success

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.
 

Attachments

·
Registered
Joined
·
19 Posts
Hey Paul695 Just PM'ed you - Think I'm having the same issue and would appreciate any insight/help/advice you and provide.

Thanks,
 

·
Premium Member
Joined
·
23 Posts
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.
 
1 - 20 of 46 Posts
Top