Engine swap 620 to 800

mr.freezer · March 07, 2014, 01:37:59 PM

Hi guys.. I have read lot of topics about engine swapping.. The easiest way is to swap 620 to 800... som guys say you need to swap harness, ECU, dash and imobilizer too.. the friend of mine have swapped 800cc engine from S2R to multistrada 620 without any other changes... He even have not swapped ECU... and its working.. What do you guys think about that... I have 40 000 KMs on my 620 and I can buy S2R engine with just 16000 KMs...

thorn14 · March 07, 2014, 01:58:31 PM

I did the swap of a Monster 620 to the engine from an 800ss. All that was needed for me was ECU reflash (a used 620 ecu reflashed with an 800 DP map and removed the immobilizer) and the swap to a linear TPS (the one that isn't adjusted manually but only reset via software.) After this my bike ran fine.

Before I changed the nonlinear TPS from the 2002 620 (The multistrada may have the correct one, doublecheck) it ran like shit. I would double check what you have on your bike currently.

Also, why waste money upgrading to a larger engine, and not get at least the ecu mapping to be correct?

Lastly, 40,000 km is not a lot. That engine will easily double that being extremely conservative, and likely triple or more with proper maintenance. If you are going to swap, you may as well go for the 1000cc, more work and money, but a lot more worth it compared to the 10hp or so bump in power.

P.S. I get confused on linear vs nonlinear TPS and may have it backwards.

mr.freezer · March 07, 2014, 11:30:44 PM

Hi... my monster has non linear TPS... and as I know.. S2R has non linear too... I want to swap, because I need to change clutch on my engine and just plates cost 200â,¬ and I can buy S2R engine for 400â,¬... So I need to find somebody, who can reflash my ECU... thanks a lot

thorn14 · March 08, 2014, 01:07:55 AM

Ok thats a killer deal then if it's all in working order compared to prices that I was finding when I was swapping.

brad black · March 08, 2014, 06:48:28 PM

all 800 are linear.

bassjavi · May 20, 2014, 04:39:50 PM

Quote from: thorn14 on March 07, 2014, 01:58:31 PM
I did the swap of a Monster 620 to the engine from an 800ss. All that was needed for me was ECU reflash (a used 620 ecu reflashed with an 800 DP map and removed the immobilizer) and the swap to a linear TPS (the one that isn't adjusted manually but only reset via software.) After this my bike ran fine.

Hi, thorn14! I did the same swap in my monster and want to reflash my stock ECU to an s2r800 DP map. Do you think it will work with my stock 620 wiring harness?

thorn14 · May 20, 2014, 05:20:04 PM

What year 620?

bassjavi · May 21, 2014, 01:23:39 AM

It's a 2004 620ie, don't know the year of the engine, it's from an 800ss

I got the harness from the 800 too, but didn't change it because my mecanic said it's too much work!

In the spare parts catalogue both harness (620 and S2R800) look identical...

thorn14 · May 21, 2014, 07:25:47 AM

Ok, it should be a straight up swap then. (My 620 was missing the clutch switch but yours will have it.)

Just swap the engine, get the ECU reflashed, and change this to this TPS type with the screw hole that isn't adjustable.http://www.ebay.com/itm/Throttle-Position-Sensor-Magnetti-TPS-PF1C-Ducati-Monster-SS-MTS1000-SC1000-/191185800441?pt=Motorcycles_Parts_Accessories&hash=item2c838fccf9&vxp=mtr

Then get the TPS reset and might as well get the throttle bodies and c/o trim adjusted. It should run beautifully after that.

bassjavi · May 21, 2014, 08:17:29 AM

Thanks!
I've been running this engine with the stock ECU and a PCIII for a year, but I want to start doing things right

I'll let you know how it works!

thorn14 · May 21, 2014, 08:46:14 AM

How's it run? Mine wouldn't with the wrong tps but I assume you haven't reflashed yet and are still running the 620 map?

bassjavi · May 21, 2014, 09:47:42 AM

Yes, I only swapped the engine; ECU and everything else is 620.
My mechanic put the PCIII and tuned it (without dyno) until it ran "right", but it has two little power holes I've learned to live with.

Mmmh... Will I be able to ride to the garage to change TPS when I put the reflashed ECU, or it won't start at all??

thorn14 · May 21, 2014, 10:02:01 AM

It'll likely run decent without the TPS being reset but you WILL need to swap the new one in. That's how I figured out I needed to change it

You just need to unplug and unscrew two screws (no need to worry about what position it was in), then the reverse to install the new one and ride to the garage.

brad black · May 22, 2014, 04:02:27 PM

Quote from: bassjavi on May 21, 2014, 09:47:42 AM
Yes, I only swapped the engine; ECU and everything else is 620.
My mechanic put the PCIII and tuned it (without dyno) until it ran "right", but it has two little power holes I've learned to live with.

Mmmh... Will I be able to ride to the garage to change TPS when I put the reflashed ECU, or it won't start at all??

i'd spend the money getting the pc3 mapped properly. the spark maps are much the same, so it's as good a solution as any i would say.

bassjavi · May 23, 2014, 10:28:28 AM

Thanks for the answers, Brad Black!

The PC3 was starting to give problems, so I think a reflash is the best option in case I decide to sell the bike. Here in Spain people is not so "open minded" to engine-swaps and other experiments, I want to keep it as simple as possible.

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Engine swap 620 to 800