Monster Mods

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Monster Mods Whats that coming over the hill....

#1 Jarv

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Bike:Warrior XV1700
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Posted 06 October 2010 - 03:45 PM

Quote: "I woke up the other morning and there was a baby monster in my garage!" - Kelpie.

Funny enough - so did I!
The only thing was . . I knew it was there 'cos I'd been over to the UK to buy it the day before!

I've never been one to leave any bike as standard - so this was going to be no exception.

I thought I would share some of the mods I have done / or am going to do.

So here goes. Purchased as a bog standard 2004 Monster 620ie.

Attached File(s)

photo(2) (Custom).jpg (61.95K)
Number of downloads: 10
IMAG0198 (Custom).jpg (95.57K)
Number of downloads: 10
IMAG0202 (Custom).jpg (45.86K)
Number of downloads: 8

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#2 Jarv

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Posted 06 October 2010 - 04:14 PM

First mod - TAIL CHOP. PART ONE.

In my opinion, the rear "tea tray" on the monster is an eyesore, so I removed it.

I had done this mod to my other monster in 2002 - see first pic.
I removed all the existing mularky, marked the frame in the correct position and cut the rear section off.
I plugged the end of the frame rails with a Givi carrier mounting parts and stainless bolts.
I remember last time I did it, I bought a carrier rack -
and realised that the place where the rack bolted to, was in the scrap bin... whoops!
So - these plugs are threaded and allow a mounting point for a rack -which I intend to make at a later date.
I made a light mounting box from 2.5mm aluminium, slotted to fit around the rear crossmember.
I wanted to use the standard indicators this time - they are not too bad looking - I reckon.
I painted and fitted the box, then made a number plate mount that bolts to it behind the light.
Unfortunately, I realised once I tried to fit the indicators that with the rear seat cover fitted,
they were a bit too close and just about touched when riding over bad bumps.
The answer was to make some spacers out of a piece of 8mm aluminium
That extra bit allowed decent clearance.
The seat lock cable and the wiring needed tidying up.... and all done!

Monster TAIL CHOP - Part TWO

Attached File(s)

2) cut down (Custom).jpg (37.89K)
Number of downloads: 2
My first Monster 2002 (Custom).jpg (27.41K)
Number of downloads: 4
1) standard rear frame (Custom).jpg (38.41K)
Number of downloads: 6
3) threaded frame plugs (Custom).jpg (36.36K)
Number of downloads: 1
4) Aluminium light mount (Custom).jpg (18.8K)
Number of downloads: 0
5) rear indicator mountings (Custom).jpg (17.58K)
Number of downloads: 0
6) cut out for rear light connectors (Custom).jpg (24.61K)
Number of downloads: 0
7) cut out for seat lock cable (Custom).jpg (20.63K)
Number of downloads: 0
8) painted black and slotted over frame crossbrace place (Custom).jpg (34.45K)
Number of downloads: 0
9) this picture shows holes for rear light and smaller holes for number plate bracket (Custom).jpg (40.15K)
Number of downloads: 0
10) number plate bracket (Custom).jpg (32.71K)
Number of downloads: 1
11) 8mm spacers for indicators (Custom).jpg (36.48K)
Number of downloads: 1
12) wires connected (Custom).jpg (45.36K)
Number of downloads: 1
13) finished job (Custom).jpg (24.04K)
Number of downloads: 4
14) a cleaner look to rear end (Custom).jpg (23.45K)
Number of downloads: 4

#3 pawh

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Posted 06 October 2010 - 04:33 PM

interesting , keep the pics coming :rolleyes:

#4 Jarv

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Posted 06 October 2010 - 04:45 PM

EXHAUST MOD

The standard exhausts are usually replaced - mainly to achieve that "Ducati sound".
Only problem with this.... is the price!
This mod was free!
I removed the standard silencer. Measured - the outer sleeve is 500mm long.
I marked the length I wanted - 420mm.
The mounting bracket bolts hold the outer sleeve in position.
Remove the bolts and then slide the sleeve back.
It is VERY tight and needs a fair bit of "persuasion"!
Once the outer has been pushed back - it will only go a few inches - the inner, actual silencer, is revealed.
I ground the welds off that hold the end cap on and removed it - again....loads of bashing!
The actual "exit" tube where the gases come out, is a tight fit in the centre.
It could have been cut through with one of those tube type tank cutters,
but it would obviously make the hole in the end cap bigger - and I wanted it to look standard.
Once the end cap was off, I cut through the outer aluminium sleeve to the correct length,
then the stainless silencer casing and exit tube.
The pic below shows the seperate parts.
I cut the final section of the tube off and spot welded it back into the end cap - so it lookes "normal".
I then fitted the end cap back over the stainless can and welded it.
The outer sleeve edge was cleaned up withb a file and the inner edge champhered slightly for a good fit.
I added some silicon sealer to the edge of the cap and then the Outer sleeve was pressed back over the welded end cap.
The mounting bracket was refitted and the silencer put back on the bike.
New length 420mm.
I have made a drawing of the way the exhaust works.
The reason the sound is improved - is not so much because it is shorter, but because the mod changes
the way the gasses flow through the silencer.
The gasses enter the can - chamber 1. Then go through a tube into the end chamber 3...
then back through a short tube into chamber 2, then into the exit tube... straight through, avoiding chamber 3, and then out of the end cap.
By making the cut at the end of the can, the gasses go from chamber 1, through the tube into chamber 3,
and then straight out of the end cap - missing out chamber 2 completely.
This helps the flow through slightly, but importantly creates the desired sound.
I cut the silencers down by 80mm so that a fairly standard look is kept, but could easily have removed another 80mm!
The shorter look of the bike with the silencer and rear mudguard chop makes for a more "cafe racer" look.

Attached File(s)

a) standard cans 500mm sleeve (Custom).jpg (20.73K)
Number of downloads: 3
b) mark required length (420mm) (Custom).jpg (31.66K)
Number of downloads: 3
c) exit tube (Custom).jpg (32.75K)
Number of downloads: 1
d) slide sleeve to show inner can welding (Custom).jpg (24.48K)
Number of downloads: 2
e) 80mm cut and inner sections (Custom).jpg (31.18K)
Number of downloads: 3
f) re-assembled 420mm (Custom).jpg (41.07K)
Number of downloads: 2
exhaust can (Custom).jpg (9.1K)
Number of downloads: 0

This post has been edited by Jarv: 06 October 2010 - 04:52 PM

#5 Kelpie

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Posted 06 October 2010 - 04:50 PM

Deadly!

I can see a trip to Leitrim in order... with my van full of bits for you to modify!

Looking forward to this thread.. it's good to ~~steal~~ share ideas.

Wear well dude!

This post has been edited by Kelpie: 06 October 2010 - 04:51 PM

"All that is necessary for the triumph of evil is that good men do nothing" Edmund Burke.

#6 Jarv

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Posted 06 October 2010 - 05:00 PM

BAR END MIRRORS mod.

This ones a little bit easier!

I always fancied these bar end mirrors - just for the look.
I thought about putting a pair on the warrior - but the bars are (more than) wide enough already!

Not sure if they are any good - but will find out tomorrow when I ride to Sligo to pay the VRT - Boooo! :vomit:

Whatever happens - the original ones won't be going back on!

These were on ebay - from Hong Kong. Cost £22.00 plus about £10.00 postage.
I used to sell the Motrax version @ about £50.00 so these are a good price - and are prob the same ones!

Attached File(s)

ebay bar end mirrors (Custom).jpg (36.93K)
Number of downloads: 1

This post has been edited by Jarv: 06 October 2010 - 05:00 PM

#7 Jarv

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Posted 06 October 2010 - 05:14 PM

Slightly off topic I suppose....but -

Heres a picture from 2006 of me on an S4 in the Italian dolomite mountains.
Paulo, a friend that I had met a few years earlier, through Dainese, had set up a biking holiday company in Vicenza and asked a couple of us to come over and test some of the routes with one of his guides.
It was a difficult descision - but...

He started off with 6 Air cooled M1000 monsters and 2 of the S4's

Anyway - this S4 was a beauty - so powerful - a great bike on the mountain roads.
His idea was to take guests on rides all over northern Italy, or to Moto GP races, Superbikes,
the Ferrari or Ducati factory... wherever.

It looked like a great idea.
He already owned a beautiful resteraunt, a guest house... and with a little help from Ducati...it could work!

The company started later that year - and has grown into this....

http://www.jpbari.com/

It's not cheap - but I suppose this kind of thing never is!

Attached File(s)

After a hard days riding in the Dolomites (Custom).JPG (22.61K)
Number of downloads: 13
S4R at Paulo\'s resteraunt.JPG (24.25K)
Number of downloads: 9

This post has been edited by Jarv: 06 October 2010 - 05:25 PM

#8 klu

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Posted 06 October 2010 - 05:26 PM

Lovely work man!

#9 pugwash

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Posted 09 October 2010 - 02:20 PM

Nice work...fair play to ya :thumbsup:

#10 The Mex

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Posted 09 October 2010 - 02:35 PM

Glad you posted up this thread!!

Keep it going....

Great bit of work.

4 wheels transport the body....
....2 wheels transport the soul!!

memento mori

#11 Jarv

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Posted 30 October 2010 - 04:41 PM

BODYWORK mods

Some would say that carbon fibre parts are a waste of money....mmm probabley right...
Perhaps they were right - at one time.
The price of carbon bits has dropped drastically in the last couple of years.
Yes - I know there is a difference in quality between cheap and expensive carbon fibre products.
In many cases though - If it's only cosmetic stuff - as long as the quality is good "enough" it doesn't matter that much.
For example - I wanted a fibreglass belly pan for the monster.
Found one at a good supplier in Germany that offers a plain white fibreglass belly pan complete with fitting kit, for E99.00 plus E8.95 shipping. So add to that the price of paint... ?
OR - a supplier on ebay (co-incedentally in Germany) offering a carbon fibre version of the same item
for E119.00 plus E5.90 shipping. So the choice was carbon.
Once I had started, I couldn't resist a "gay" carbon ignition cover (seeing as there was no extra shipping cost) @ E25.00 !
I got some carbon heel guards on ebay for £25.00 - Looking like one of my christmas pressies!
Lets face it - carbon "jewelery" makes the world go round! :thumbsup:

Attached File(s)

Carbon jewelery.jpg (33.56K)
Number of downloads: 4
belly pan...jpg (52.98K)
Number of downloads: 4
carbon ign cover.jpg (72.45K)
Number of downloads: 4

This post has been edited by Jarv: 30 October 2010 - 04:42 PM

#12 Jarv

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Posted 30 October 2010 - 05:55 PM

COSMETICS - Adding a Corse stripe and fitting a Pyramid Plastics Fenda Extenda.

Tools needed: Drill, 4mm drill bit, 3 stainless pop rivets and gun, silicon sealant, tools to remove mudguard.
Time to complete: 30 mins.

I fitted a Fender extender before adding the stripes to the front mudguard.
This has to be one of the "best for the money" jobs you can do to your bike.
The Monster has a short front mudguard and the engine gets covered in sihte so the added protection
is worthwhile. It doesn't LOOK as good, but......
I removed the mudguard, cleaned it up and secured the extenda with double sided tape.
I then drilled 3 holes and pop rivetted it.
I thnk the rivets look a lot tidier than the self tapping screws supplied with the item
Tip: I always seal the inner edges underneath the mudguard around the extender with silicon sealant.
This stops the dirty water from running out of the gap between them and making the extender look crap.
Cost: E17.95.

Stripes;
Tools needed: Scalpal, masking tape, tape measure, rule, pencil/marker pens,
water/washing up liquid mix, clean dust free rags, meths, tools to remove bodywork.
Nerves of steel, patience of a saint.
Time to complete: approx 4 hours.. give or take a breakdown.

This was a very difficult job.
Ever done something that you wished you'd never started?
I thought that measuring and marking straight lines on curved surfaces was difficult....
But it was a doddle - compared to actually sticking the stripes on!
I carefully measured from every direction to find the centre of each part I was working on.
Marked the centre line with masking tape and then measured out from the line either side, to
find the line where the edge of the stripe would be. Then marked the guide line with a pencil.
The prep work is crucial to getting everything looking right.
The wide stripes had to be put on first, followed by the narrow outer stripes.
The area where the stripes were being fitted has to be spotlessly clean as even the smallest spec of dust
looks like a mountain under the tape and will ruin the finish as it can't be removed.
I washed it and then cleaned the area with meths to remove any polish that would stop the tape from sticking properly.
The instructions suggested spraying the area first with a mix of water and washing up liquid.
This is standard stuff and makes a big difference as you can slide the graphics around without it sticking instantly.
I found it really hard to get them lined up properly, but after a stressfull few hours - everything was done.
Cutting round the edges was tricky - especially as you are doing your best not to slice through your paintwork!!!
I took all the parts off the bike - except the petrol tank,
as I thought it would probably be easier to work on it while it was in a fixed position.
The finished job looks nice (in my opinion) but I wouldn't recommend doing it. It looks a lot easier than it actually is.
Cost to complete - inc a few Ducati stickers - was £24.00 - so a fair bit cheaper than getting it painted.
I originally got a graphics company in Carrick on Shannon to cut the stripes for me.
He was cheap enough - E10.00 for about 10 feet of stripes, quality was good but the vinyl was a little too thick
and wouldn't stretch / bend around the curves properly.
I tried the front mudguard as a test because it has the most drastic shape.
I was gutted at the time 'cos I waited 3 weeks for him to make them... then another week while I waited
for the other stripes to arrive from the UK.
I bet Rossi won't have this trouble next season!

Attached File(s)

fenda extender.jpg (39.25K)
Number of downloads: 5
front mudguard (Custom).jpg (38.58K)
Number of downloads: 6
tank.jpg (47.68K)
Number of downloads: 5
tail (Custom).jpg (23.01K)
Number of downloads: 7
Corse stripe.jpg (28.61K)
Number of downloads: 7

This post has been edited by Jarv: 30 October 2010 - 05:56 PM

#13 KeepinHerLit

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Posted 30 October 2010 - 06:08 PM

Loving the mods... Looks gorgeous..!! :thumbsup:

BOOM!!!

#14 Shinwacker

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Posted 30 October 2010 - 08:26 PM

Jarv would you ever get a job. Outstanding work on this bke mate, I love it and by the looks of it your having a blast. thanks for taking the time to post it up.

Shins

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