Swap engine on a 620. Anyone done it?

[ab]

Looking for an engine to swap on my 620m.  Has anyone done it?  What are things to consider ?  Would s2r or s4r fit the frame?

[thorn14]

I think anything up to a 1000 fits air cooled (1100 may also fit as I think he-man used one.) not sure about 4v bikes.

800 is the largest you can go and keep the same headers.

Most will require an ecu or remapping. Otherwise the variables are wire harness exhaust and swingarm.

If I had to redo it, I'd go with a 900 or larger. Love my 800, but no dry clutch and limited options for increasing the power compared to my 620.

Why do you want to swap the engine?

[ab]

My 2004 dm, She is dying slowly at 53k and figured rebuild would cost just as much or more.  I don't really know what rebuild entails and cost

[DarkMonster620]

My 2004 dm, She is dying slowly at 53k and figured rebuild would cost just as much or more.  I don't really know what rebuild entails and cost

Why don't do the rebuild plus this http://www.ferracci.com/fast-by-ferracci-parts/engine-parts/piston-kit/piston-kit-88mm-11-1-750.html

[ab]

That kit was done on her long time ago around 10k miles . She is huffing and puffing now. Not running smooth at all.  Lost horse power (afew) in last dyno.  When has, there is a lag and popping in the engine like its breathing out (not same as the back firing). She is burning lots of oil and going thru it fast.  Not sure what I should do.  Valves, belt etc are checked on schedule and was serviced this past winter.  My mechanic wants to take her out and shoot her.
I am trying to find out what exactly rebuilding an engine means?  What gets rebuilt?  What are the parts I need?  Trying to figure it out and tally the numbers.

[thorn14]

I know nothing.

With that said, I'd assume all you need is head/cylinder work for a refresh. Likely check valves/guides and piston/rings. No idea on price.

My 800 engine cost $800  . I reflashed my ecu with an 800 map, bought a different tps, and all was golden. Most engines you find will be more than $800 and closer to $1200 if you want more power, unless you find a good deal, preferably without shipping.

[Howie]

Rebuilt means replace all wearing parts.  Particulars will vary from shop to shop.  In your case, overhaul is probably better, replace what is necessary.

Once your engine is apart you get to inspect and measure parts.  If you get to reuse the crank, cylinders and pistons not  so bad.  If there are no knocks or other reasons to suspect you might have a crankshaft or bearing problem you could avoid splitting the cases, big labor savings.  In your case I would perform a cylinder leakage test.  If the rings are sealing I would think of doing valve guides and calling it a day.  The bottom ends are pretty rugged.  Worn valve guides will cause excessive oil consumption and, if bad enough, poor performance.  Blue smoke on deceleration and when accelerating after prolonged idle, like after waiting at a traffic light is probably guides. 

Your engine repaired is a known quantity.  A used engine is...well...a used engine, maybe no better than what you have.

[JamesBill]

I know nothing.

With that said, I'd assume all you need is head/cylinder work for a refresh. Likely check valves/guides and piston/rings. No idea on price.

My 800 engine cost $800  . I reflashed my ecu with an 800 map, bought a different tps, and all was golden. Most engines you find will be more than $800 and closer to $1200 if you want more power, unless you find a good deal, preferably without shipping.

Where can you get an ECU flashed and why do you need a different TPS?  I have a 5 speed 620 and want a 6th gear. More power would be a great secondary prize as I do a good bit of freeway riding and would like the higher gearing a 800 can spin.

Did you add an oil cooler?

[thorn14]

It was necessary for my particular swap and is detailed in a thread I started, it just depends on what combo you use. It came with an oil cooler, haven't noticed too much of a difference.

Refresh if you don't split the cases, new engine if you split the cases and go for the bigger engine and transmission.

[Rudemouthsky]

Ab, the 620 is one of 2 bikes you own, right? I think I recall you saying you had a late model Speed Triple?

Since that's the case I'd say this is a perfect excuse to really have some fun with the 620. I dunno if I'd put much $ into heads that are mated to a 50,000 mile motor. Maybe confirm if your harness and ecu will work with a 1000ds motor and go from there. You'd have your 6th gear...

[DarkMonster620]

ab, I might not be the best person here to say if rebuild or get used . . .

My POV:

Rebuild: you put in it what you want to get upgraded,
           6th gear kit, Ducati had one, just have to do some searching
           since you already had the FF750 kit, can you get the rings and piston pins from FF as replacement?
           +2 on howie's suggestion of checking HEADS first and maybe improve on them

Used: might last a while and then, rebuild?
        if 6s, then swap FF kit and keep bottom end

Dunno, just my HO 

[ab]

This is great info.  I wish I knew how to do this but alas.  I will talk to my mechanic but it looks like he is getting out if wrenching :-(. I need to start saving $. I really want to keep her as long as possible.  Love my 2006 speed triple triumph but not as much as my DM

[JamesBill]

It was necessary for my particular swap and is detailed in a thread I started, it just depends on what combo you use. It came with an oil cooler, haven't noticed too much of a difference.

Could you link that thread. The search feature isn't doing me any favors.