Trouble Starting - Ducati Monster Fuel Pump Wiring Fix - CA Cycleworks Fuel Flange Swap How To v1472

First of all - this is less of a "how to" and more of my experience vlog as I replaced this part on my bike. So as many of you may know, my bike started acting weird. Sometimes it would start, sometimes it would just crank and crank. It would ALWAYS end up starting after sitting for 10-15 minutes but I knew that one of these days I won't be so lucky and it will leave me stranded. Fuel Flange harness is a known weak spot on these bikes with the epoxy falling apart after many years of being submerged in gas and exposed to the elements on the other side - and instead of rewiring/soldering and re-epoxying the old harness I bought a whole new one from CA Cycleworks - see the link below. I do plan on repairing the old one to have as a spare. Hopefully this video helps someone with this issue and feel free to ask any questions. Thank you all for your time, for the comments, and all that. Ride safe, be happy, and if you read this far let me hear you say "flung flange"
Get your Fuel Flange Wires here - ca-cycleworks.com/fwires.html
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Intro Directed by Gianluca Miotto
/ myotto

[@foxtrotbravo]

thank you for making this video avaliable to all us ducatistas worldwide! =)

[@ducatinyc]

You are most welcome. I hope it helps someone one day. I'm sure I'm not showing the most important parts :)

[@Tarabass]

I love your reaction man! You did it. Awesome feeling, congrats!!

[@ducatinyc]

best feeling ever when the bike starts up. woot woot.

[@paullazarro4295]

Here's a virtual pat on the back. Good job!

[@ducatinyc]

Thank you much! :)

[@alexrich9389]

Thanks for making these types of videos

[@ducatinyc]

You are most welcome.

[@puravida1340]

Very good job Bro! I've learned some important spot about Ducati Monster 620. Thanks a lot. Regards from Spain.

[@ducatinyc]

You are most welcome. Thank you for watching!

[@jamet77]

Literally doing this with my 2005 620ie now. Having to do the whole re-potting the the epoxy though as the pack you have from CA Works is unavailable till August. Saw the repair written out on a Ducati forum and it wasn’t until I googled it properly did your video show up! And I’m glad it did - excellent walkthrough: made sure I took it apart over a bucket to avoid flinging petrol all over my house 😂😂

[@ducatinyc]

Ha! My house stunk for days! I also suggest replacing fuel filter pump and fuel filter while you're in there. No idea why I didnt. Its such a pain to take all apart you might as well do the complete overhaul.

[@MattieXMoto]

It's alive!!!! Congrats!

[@ducatinyc]

Thank you!

[@McGinsrocks]

Hell yeah, intermittent starting is a nightmare. Nice job.

[@ducatinyc]

Yea man, I couldn't live with it.

[@mbhla]

Dude, you rock! So much I can do whatever swagger!

[@ducatinyc]

Hahahaha thank you! You're too kind

[@TomBMotoV]

Nice job mate! Like some self mechanical skills👍🏽

[@ducatinyc]

Thank you brother. Always feels good to fix something.

[@billkabb]

great work ... i had also problem starting my monster sometimes but in my case the issue was a wire under the headlight .. Thanks for sharing ..

[@ducatinyc]

I HATE starting issues - my least favorite. I hope you figure it out!

[@rigasvw]

Hey man. I have a problem starting my bike after messing with wiring under the headlight. Could you please tell me witch wires gave you problem's?

[@Starkiller1326]

It's alive! ALIVE!

[@ducatinyc]

YES SIR

[@biagiobrando1099]

This is the video I was referring to…. Thank you!

[@ducatinyc]

Oh. The link to the part is literally in the description...... but here it is again ca-cycleworks.com/fwires.html

[@losttogether4ever]

Damnit...after my Guzzi I swore off of Italian Bikes I thought not another, just because the Japanese are so so good and reliable but maybe boring cause they are so good. But now after following you for a while I'm getting pulled back into the Eye-Talion thingy...Looking at an Apliria Tuono as my next bike!!

[@ducatinyc]

There is something about them eye-tay-ley-yan machines that draws you towards them. Its obviously not the most logical of things.

[@MotoNoir]

Nice job broski. You did God's work. And...He's ALIVE!!!!

[@ducatinyc]

Thanks man. Sure glad got this issue out of the way.

[@jonhewitt3]

Make sure the fuel filter is in the right direction! I remember my first bike, just gravity and qauze mesh

[@ducatinyc]

Yep! I made sure to triple check the direction before i removed it :)

[@xdural6269]

You're most handy. Make starting for a long time!

[@ducatinyc]

I try my best :)

[@luddite6239]

Well done for posting this how-to guide - it's definitely going to be a boon to a lot of owners of older Monsters. Good decision to change the filter while you were in there too. By the way, how long did your apartment smell of petrol after that?! 🤧

[@ducatinyc]

Oh for just a day or two, that was most unexpected. And yes, I know this is not a perfect how to but it might help someone :)

[@henrifischer1119]

yes you are. well done!

[@ducatinyc]

Working the magic.

[@mechainhearts6044]

Love from india 💕💕💕💕

[@ducatinyc]

Sending love back!

[@Tarabass]

Before you put the pins into the connector first unlock it. They should go in easily, click, lock the connector and voilà. Also use some oil on the rubber ring/seal before assembling it. And search for the nm in the technical reference before tiden the bolts. And fill up the filter with gasoline before putting it back. Lol!

[@ducatinyc]

Good tips on the connector tip! Had no idea! All good things to know! Thank you

[@Tarabass]

@@ducatinyc been there done that. Good job though. Many people don't dare to do it. That feeling afterwards, hell yeah!

[@billkabb]

yes some oil on the rubber ring is important .. also there is a small hole underneath the tank cap , is a drain path to prevent rain water enter the tank , mine it gets some serious salt inside so it is a good idea to pour some vinegar with a syringe and unblock it ...

[@Rgh71fish]

Hey, great video. Have you ever had to clean/replace injectors? I discovered a lean running condition after inspecting my spark plugs and am lead to believe its fuel related. My '05 620 recently started having the odd stumble during warm up, and once warm backfires and pops on deceleration more than normal.

[@ducatinyc]

I have never had to clean the injectors but I have come close. Seems all my issues like that had to do with coils/plugs and that wiring. And then gas pump wiring. Never injectors.

[@Rgh71fish]

@@ducatinyc thanks for your reply, friend. We have "at least" 10% ethanol in our fuel here in Canada, and it creates problems, thats why it was my first suspicion.

[@serarang772]

cool video! may I ask you to test our cool LED headlights for the car!

[@ducatinyc]

Thank you!

[@rustamka2]

Do you have any issues or did you do anything to prevent tank swelling? I m thinking of replacing 2004 metal tank with 2006 plastic one like you have and tank expansion from ethanol/water seems to be a concern.

[@ducatinyc]

Yes, my gas tank is swollen but it’s not a concern to me really, doesn’t affect the bike at all

[@ftby59mikeD]

"Flung Flange" You mentioned you found the culprit on the old unit, any chance you can repair it? I've seen another KZbinr solder the break in the wire & reuse it. Pays to have a spare brah!👍ride safe.

[@ducatinyc]

Yep, that is exactly the plan - i mention that in the video description :)

[@PauloBriggs1]

Hi Mike, did you by any chance fix yours? I just bought seal all and plan on fixing (re soldering) mine this weekend

[@ftby59mikeD]

@@PauloBriggs1 I ended up replacing my entire unit, the pump itself failed. Here's the link to the video for repairing your existing one.kzbin.info/www/bejne/aJDIZ2SqidCcqc0 & Follow up kzbin.info/www/bejne/rGTVnX6Brrh3j68

[@maitai1598]

Good job, can we watch more mechanic skills videos? :D

[@ducatinyc]

Always! As more tasks come up.

[@CorGP]

Not sure if you’ll see this but I’m having issues with my 620 that I think this video will help fix. The fuel light flickers and the bike turns off sometimes while I’m riding. I can start it back up and get going but it’s an annoying and dangerous issue. Any insight to this problem I’m having?

[@ducatinyc]

This is the exact issue I was having - and this is the part that I replaced, that I replaced in this video

[@oscarjmantilla144]

Hey I have a monster 696 2014 but I have a problem, some times don’t start or it’s difficult, when I drive slow run well, but when I put lots gas that not felling good

[@ducatinyc]

It sounds like it could be the same issue that i was having with intermittent starts and inconsistent power. Your fuel wiring inside the gas tank epoxy could be loose.

[@Love-Within]

At the end when it didn’t start right away did you have to let the choke out? What was that switch you were doing on the side to get it up haha?

[@Tarabass]

That was the choke hèhè

[@Love-Within]

@@Tarabass oh okay that’s what I though! Haha I was nervous when it didn’t start gave me nightmare flashbacks. My choke is down near the engine so I wasn’t sure.

[@ducatinyc]

Its actually throttle advance on these models, it just twists your throttle a bit - its a fuel injected bike so no choke.

[@Tarabass]

@@ducatinyc they call it a choke in the workshop manual ;-) But technically you are right!

[@Love-Within]

@@ducatinyc ohhh that’s actually cool! Lol lazy mans throttle for start

[@drasticthompson1995]

Do you know the product number of the clips for fuel filter? My lost his and we can’t put the fuel pump back in!

[@ducatinyc]

I do not but hopefully this can help issuu.com/ducatiomaha/docs/m620_usa_06_ed_01?e=1222863/10926783

[@drasticthompson1995]

@@ducatinyc Thank you

[@GianmarcoLatcovich]

I’ve issues when start my ‘03 1000s when cold. I’ve to try 6/8 times at least. Battery and spark plugs are new. This problem drives me crazy. After the first start, the bike starts without problem even if still cold. Can not figure what the problem is. Any idea?

[@ducatinyc]

I had the same issues for a long time - replacing this wiring really fixed it. Perhaps you're dealing with the same issue?

[@johnygsx-s7507]

Face reveal @ 4:16, great video as always

[@Hondadctrider]

Yeah I noticed that also.

[@ducatinyc]

It's true - before you know it I'll just start showing my face..... been thinking.... why not?

[@Hondadctrider]

@@ducatinyc Nah, keep the mystery going.

[@Bear5491]

So which gasket is giving you the air issues?

[@ducatinyc]

Not a gasket, it was those 2 hoses i plugged into the gastank in the end - one was not pushed in all the way.

[@spetersonmusic]

Get 'er done. flung flange

[@ducatinyc]

Had to do it to it. Happy 4th!

[@skizzo19761]

Hi, same problem where I can buy the part? Thanks

[@ducatinyc]

I'm haivng this issue again as well. DAMN. The link to where I bought it from is in the description, but you can also find it on ebay.

[@skizzo19761]

I do have a monster sr2 1000..It seem very common problems …due to extremely shitty design …sooner or later will fail ….did u figure it out what’s wrong ? Hopefully mine is the wires….Thanks mate!

[@ducatinyc]

@@skizzo19761 yea, it def is a very common problem yea the wiring inside the gastank gets loose and one of the wires that feeds the pump power lacks contact. I got a guy in UK who is fixing mine but it will take a few days for shipping back and forth.

[@skizzo19761]

@@ducatinyc I fix mine ….hopefully will last 🙏…..but definitely a crappy design…..hard to believe a suck of vitals connections ….. are faulty by poor and catastrophic design ! Good luck 👍

[@user-pn7br5jn7b]

Ты сам его ремонтируешь? Я думал в сервис сдаёшь. 😊

[@MrAlexanderUa]

Он же русский)

[@user-pn7br5jn7b]

@@MrAlexanderUa Я про это тоже подумал, но вроде как Америка, и там куча сервисов и разных высококлассных специалистов.😊

[@ducatinyc]

starayus kopeyechki sahranit i nauchitsya novim veshyam. vsegda veselo kapatsya s motikom

[@JasonJindaleeTreeService-ju4wi]

Turn key on let it run in checks turn off repeat repeat 3rd time halfway through hit start

[@ducatinyc]

That fixes a whole another issue - not in this case however.

[@plamendimitrov2224]

My time has come.. :(

[@ducatinyc]

Dang. I hope you fix it swiftly.

[@michaelrol4693]

Fuel pump? Weird

[@ducatinyc]

Yep. Always something :)