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Old 10-23-2014, 05:11 PM   #1
Grant2k OP
Joined: Feb 2013
Location: NJ
Oddometer: 10
My Multistrada 800- The bike Ducati should have built

I hope this is worthy of this forum since it really just amounts to an engine swap. I put a Monster 800 engine into my Multistrada 620. It wasn't a straight bolt in though, and I was pretty proud when it started, so here goes. I've lurked around this site for years but never really thought I had anything worth posting. Now that this is coming together I thought some people might enjoy it. I am not the first person to do this swap. My real inspiration came from Dan (Dukerdr) here [url][/url. He also gave me some good advice to help along the way. There is also a very old thread on that site by someone who did this way back when a 620 was a new bike. Overall I would say it's not a beginner project, but not all that complicated if you're adept at turning wrenches. Other than the machine work the rest was just removing and replacing the engine plus some other stuff I did, and there will be more to come. I started it for the first time the other night and took it around the block. It was cold and dark (and deer season (and the registration was expired)) so I didn't tempt fate and try to ride it too much, but it felt good to take it out again after riding my Sportster all summer. It certainly felt stronger than the 620 but I won't be able to really say how much more so until I get some real time on it. I am not good at documenting stuff like this but here's my attempt at a build thread anyway. I still need to do the important stuff like sync the throttle bodies and then get it on a dyno and get the fueling figured out. Right now there's a big cough right around 4500 rpm. I can't seem to load an 800 map into my 620 Power Commander so for now it's running on a 620 map but it still starts up and runs strong. The idle is low so I have to use the choke lever to keep it up. Revs great though.

I got a new phone so I don't have any recent pictures of the bike before I took it apart. It was really dirty. It ran OK but had a bent shift fork and sometimes fell out of gear or grinded going into gear. It ran strong but it also ran really hot. I have no explanation besides potentially being really lean due to the exhaust. When I put it together this time I used Permatex Ultra Copper gasket maker on the exhaust joints so it should be pretty tight. Besides that it was just a 620. Here is a picture that shows my home made exhaust (built from a Two Brothers for an R1) and a rack I made for a BMW top case. The picture is old so the bike looks significantly cleaner than it did when I took it apart. The only thing not in this picture is the Multistrada 1000 Showa forks.

The difference between a Multistrada engine and a Monster is the width of the case where the swingarm mounts. On a Monster the swingarm just mounts to the engine, therefore the part of the case that the swingarm bolts through it very wide. On a Multi or Hypermotard the swingarm goes around the engine cases and then inside the frame so it is significantly narrower where the swingarm attaches. But it does make for a stronger pivot point for the swingarm. To make the engine fit I had to machine the cases down. I did this by mounting the engine on it's side to a 1" aluminum fixture plate and bolting the whole thing to a mill, then flip it over and do the other side. The hardest part was finding something to measure off of to do the first side.

Here's it is ready to go back in.

All bolted up. With a bike jack and good adjustable straps it wasn't overly difficult to get back in by myself. Moving it around is a pain in the ass though. I'm not the biggest dude around. There are some intricacies to getting it in place that you just kind of figure out as you do it.

I had the PCIII on the bike before I did this swap, but I never liked how it was mounted. I have to use one for a Monster 620 so the ground wire on it is really short because on a Monster it would mount right on the battery, which it can't do on a Multistrada. I had to mount the unit strapped to the outside of the bike. It was never a problem but I never liked it there, so I found a way to move it. I also may go naked someday so took this opportunity to get some pod filters from Ca-Cycleworks. Chris is great and their customer service is the best. I cut up the airbox to keep the coils mounted in their stock location and give me a place to mount the PCIII. Someday I may fabricate something to make this prettier and mount the battery and electronics and stuff.

It gives a lot more room to work this way also, not having the big ugly airbox in the way.

Here's the breather for the crankcase.

I also took this opportunity to install the Multistrada 1000 Showa rear shock I've had on the shelf for like 2 years. I had to make a mount for the preload adjuster since a 620 doesn't have one. I used my favorite medium, 1/2" square tube from Home Depot and a piece of the original bracket. I am no expert welder, that's for sure.

My junkyard engine didn't come with an oil cooler, so I found one on ebay for $60 from a 750. The older bikes used different oil line threads so I got some -6AN to 14mm adapters from Jeg's. I bent up some mounts from aluminum bar just to get the bike together. These will be replaced. It's pretty crooked right now.

And finally, here it is all together. It basically just looks like a 620, but with my exhaust and rack. The oil cooler is the only thing to make it look different than a 620. I also Plasti-Dipped a few particularly ugly panels from a lowside. The whole bike will probably get that treatment to even things out. I need to move the forks down in the trees because it's a little high in the back now, but besides that it feels great and I hope to get some more miles on it this weekend.
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Old 10-23-2014, 07:36 PM   #2
aka Hugh Jarse
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Joined: Feb 2005
Location: Mudgee, Australia
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An interesting thing to note Grant is that once you've machined those cases, a KTM950 swingarm fits in there just nice....which allows you to fit up a 950 PDS shock, all you have to do is weld in a top mount for it
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Old 10-23-2014, 07:45 PM   #3
Grant2k OP
Joined: Feb 2013
Location: NJ
Oddometer: 10
Originally Posted by OldDog View Post
An interesting thing to note Grant is that once you've machined those cases, a KTM950 swingarm fits in there just nice....which allows you to fit up a 950 PDS shock, all you have to do is weld in a top mount for it
Hmmm, that is interesting to know. I do have ambitions for a more dirt-oriented setup one day and that could be helpful. I've already got a second set of wheels with knobbies so a little more travel would be cool. Also good for dirt tire and wheel options.
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Old 10-23-2014, 08:49 PM   #4
Dakar Dan
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Location: Bendigonia
Oddometer: 991
Great build. Looks like a high tech Terramostro.
Now comes with less dak and more arrgh!
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Old 10-24-2014, 07:47 PM   #5
Grant2k OP
Joined: Feb 2013
Location: NJ
Oddometer: 10
Muffler options

Thanks for the feedback. After riding to work today I've found that the fueling below about 5000 RPM is pretty awful. Above that it rips, but there are several spots in the lower revs where it coughs and sputters and it stalled on me several times.

The thing is, before I pay to put it on a dyno, I want to have the bike set up like I want it in any aspect that will affect tuning. One thing that's bothered me for a long time is that the exhaust I built is just too damn loud. I want to put serious miles on this bike and I think I would enjoy that a lot more if it was quieter. I love my Two Brothers cans because they look cool and they're really REALLY light. They also don't get hot, but again, way too loud. I have a Hypermotard muffler I've thought of fitting, but it's heavy, and might be TOO quiet. I do like a little growl. Does anybody have opinions of using a big single muffler, like from a KTM 500 or so? Would that be too restrictive? I also thought of a stock can from a late model 450 motocross bike, but I think they would be really loud also. Can anybody think of any muffler that would let my 800 breath, but not be TOO loud?
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Old 10-26-2014, 12:32 PM   #6
lizards,bugs and me
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Joined: Jan 2007
Location: Reading,Pa
Oddometer: 774

Hey ,

I think I have an ms4r box or chip, twin mufflers ,and air filter that were swapped for Ferraci or Termigoni items that I would dig out for and make you a smoking deal on if you want me to.

pennswoodsed screwed with this post 10-26-2014 at 12:54 PM Reason: found stuff
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Old 10-26-2014, 03:43 PM   #7
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Joined: Feb 2009
Location: Midwest, West Oz
Oddometer: 2,147
Originally Posted by Grant2k View Post
Can anybody think of any muffler that would let my 800 breath, but not be TOO loud?
GSXR1000, 2000-ish up, same as they use on the DR650 for a different muffler.
On a Gixxer, replacing just the can with anything won't gain any HP, the stocker is very good, but they are also fairly quiet (although louder on a big twin than an inline due to the pulses). The xx040 numbers are Ti and weigh under 2kg, the GSXR750/600 xx034/036 numbers versions are stainless and weigh in at just over 3kg, but are basically the same and 1/2 the price.

I have one in the shed that's also going on my VW Beetle hotrod (one day, eventually, when the bloody thing is running again!).
Who the hell would drag race a Ducati?!?!?!?!
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Old 11-09-2014, 07:40 PM   #8
I like everything.
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Location: SLC area, Utah
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I used a single Speed Triple can on my 1000 multi. Light titanium and just a bit of a growl.
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Old 11-10-2014, 10:50 PM   #9
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KT88,which triple muff is tit?
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Old 11-18-2014, 11:20 AM   #10
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Joined: Nov 2014
Location: Slovenija
Oddometer: 12
Akrapovič. with silencers isnt loud.
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