Options for a dead/dying Monster

[SterbenSoup]

Hey guys! I have a 2005 Monster 620, and she is's now fairly close to death.  I've been looking into all the options as far as engine swaps, bore kits, etc., but so far the info I found is pretty minimal. 

Let me clarify the "Close to death" comment.

She jumped timing and from what the local Duc shop said, "bent a valve", then started causing a bunch of havoc.  After they offered to fix it for a whopping 2K, I brought her home in pieces.

So, looking at the valves, piston, and cylinder, they look fine, no bent valve, no scarring or pitting on the piston, and the cylinder looks good too!  This being the case, I still only get about 40  PSI in the rear.

I'm re-doing the valves this weekend, so we'll see what comes of that and fixing the timing.

Now that the back story is out, I haven't been able to find much reliable info on many swaps, though from what I understand a 900 swap is pretty common, again, haven't been able to find that documented, or how much its going to cost me.

So what I need from all you gurus out there, is how cost effective would it be for my to buy a 900 engine off eBay, what else would I need to complete the swap, or should I just keep tinkering with mine and maybe bore it out when I get it running?

[Langanobob]

Sorry you haven't received any replies yet.  I haven't done this engine swap but I think there are several members who have.  Maybe everyone is out riding taking advantage of the spring weather. You could also try a forum search.

It only takes a relatively slight contact with a piston to bend a valve enough to lose compression and the bend isn't always easily visible.  Can you talk to the tech at the dealership who diagnosed the problem and see exactly what he found?

Just wondering how the timing jumped?  Pretty rare I think.  How many miles/km on the engine and since the last belt change or tension adjustment?

Hope this will bump your thread and get some of the engine swap guys involved.

Bob

[Howie]

The engine swap itself is easy.  The hard part is getting the fuel injection right, not so hard if they both use the same generation of fuel injection. 

[SterbenSoup]

Apparently the timing jumped due to a bolt that just "happened" to come loose.  How that happened I have no idea, though the tech actually suggested it looked like someone might have been tampering with it.  I keep my bike in a locked garage when I'm not riding, so that seemed unlikely.

Anyways, the bike has about 24000 miles on it, I'm the second owner bought it last October.  I honestly have no idea how long its been since the bike was serviced, but judging by the state of the change and the oil when I changed it, it may have been easily 10k miles, possibly since the bike was purchased originally.

Maybe I should just go with some new valves and see what happens?  I'd rather do one thing at a time instead of drop 1600+ for something that could be fixed considerably cheaper.

[He Man]

same thing happened to me.


now i have a 1100 EVO motor in my bike.

http://kuixihe.com/S2R1100

[thorn14]

620-800 FI is a direct swap, just reflash the ecu and you may need a different tps sensor with tps reset. 900 and above require different headers as well, and possibly wiring harness.

That's a condensed checklist, there are small hiccups here and there depending on donor engine and host bike.