If you're reading this you're just as mad as about your Ducati 916 style bike as every other owner.
As awesome as these bikes are, the engines have certainly aged and all the cool kids now swap in the testastretta evoluzione engines (848, 1098, 1198 and others) into these frames.
This piece is intended to highlight all tasks and details to complete in order to end up with a successfully swapped hybrid Ducati 916.
Table of Contents (Use "CTRL"+"F" to search guide)
I. Engine Specs
II. Bill of Materials
III. Swap Challenges
IV. Engine Installation
V. Throttle Body
VI. Cooling System
___________________________________
I. Engine Specs
Below will be a spec sheet comparing the 916 style desmoquattro engines to the 1098 testastretta evoluzione engines
Horsepower (HP) - 114
Torque (lb-ft) - 66.3
Horsepower (HP) - 114
Torque (lb-ft) - 68.6
Horsepower (HP) - 98
Torque (lb-ft) - 55.3
Horsepower (HP) - 134
Torque (lb-ft) - 70.8
Horsepower (HP) - 160
Torque (lb-ft) - 90.4
Horsepower (HP) - 170
Torque (lb-ft) - 97
____________________________
II. Bill of Materials
This will greatly vary according to your build.
Some people (as myself) utilize all 1098 electronics. Others still use some variant of the 916 ECUs and have a custom EPROM cut for the 1098 engine. One individual has utilized the complete electrical system from a Panigale with his 1098 swap. The possibilities are endless...
Regardless. I will list what parts can work for this swap. If there if any modification required it will be mentioned.
Version 1 - All 1098 components used
Electrical
1098 Wiring Harness (Complete with sensors)
1098 Ignition Coils
1098 Dash
1098 Ignition Barrel & Key (Must match with Dash or be re-programmed for it)
1098 ECU
1098 Left Hand Switch gear
Cooling
1098 Radiator
1098 Cooling Fan (2)
1098 Coolant Hoses
1098 Thermostat
Engine
848/1098/1198 of your choice
1098 Oil Cooler
1098 Oil Cooler Lines (2)
1098 Throttle Bodies
1098 Streetfighter Throttle Cables
1098 Injectors (2)
1098 Exhaust Manifolds
1098 Exhaust
Custom (Required)
Airbox to mate with throttle bodies
Mount for 1098 shower injectors (goes inside airbox)
Bracket to hold 1098 dash
Exhaust fabrication required where muffler piping mates to exhaust manifolds (vertical pipes by the right handside rearset)
Chin fairing must be modified to mate with new cylinder head design
Version 2 - Some 916 Components used
Electrical
916 1.6M ECU &
916 1.6M Wiring Harness
996 5M ECU &
996 5M Wiring Harness
916 Dash
916 Re-flashed EPROM Chip (Required if using either variant of OEM ECU)
916 Ignition Coils
916 Ignition Barrel & Key
916 Switch Gears
Cooling
916 Radiator
916 Thermostat
916 Coolant Hoses &
1098 Coolant Hoses
Engine
848/1098/1198 of your choice
916 Oil Cooler
916 Oil Cooler Lines (2)
1098 Throttle Bodies
1098 Streetfighter Throttle Cables
1098 Injectors (2)
1098 Exhaust Manifolds
916 Exhaust (50mm+ required)
Custom (Required)
Airbox to mate with throttle bodies
Mount for 1098 shower injectors (goes inside airbox)
Exhaust fabrication required where muffler piping mates to exhaust manifolds (vertical pipes by the right handside rearset)
916 Chin fairing must be modified to mate with new cylinder head design
____________________________
III. Swap Challenges
There are a few notable challenges that come with this swap. There is and has been a solution for each item listed below but there isn't only one means to address each of them.
1. Air box
The most significant obstacle in the swap. The 1098 throttle bodies are of a different shape and in a different position with respect to those of the 916. As a result, one has to cut out the floor of the OEM air box (if being used) and re-mold the floor using fiberglass or other means to encapsulate the 1098 Throttle Bodies.
In addition, there must be injector mounts within the air box since the 1098 utilizes a shower style fuel injection system. There are individuals and vendors that can make and/or sell you drop in air boxes with mounts to remedy these issues. See chapter XX of this guide for contact information
2. Throttle Bodies
In the kyalami frame, there is a cross member that interferes with how the 1098 throttle bodies would normally sit within their respective intake manifolds. As a result the throttle linkage must be flipped 180 degrees to clear the cross member.
The Streetfighter 1098 throttle cables are long enough for the job.
3. Exhaust
The 1098 exhaust manifolds route just fine with the 916 frame. However, in many cases fabrication has been required where the mufflers mate to the manifolds. This is the vertical section of piping behind the right hand side rear set. Some individuals have reported using the complete 1098 exhaust system with success having no interference issues.
This will all depend on what exhaust you plan on using as well.
That all being covered, let's jump into completing the swap step by step.
__________________________________
IV. Engine Installation
A. Preparation
The engine mount bolt patterns are the same between the 916 desmo and 1098 testa engine. HOWEVER, the 916 frame holes are 10mm in diameter whereas the 1098 engine accepts 12mm mounting bolts. I used a 31/64" drill bit.
So the 916 engine mount holes must be drilled out to 12mm in order for the 1098 mounting bolts to slip through.
The engine will be mounted to the frame via the swingarm bolt and the two aforementioned frame bolts.
It is easiest to install the swingarm first, then install the engine.
Remove the vertical intake boot as well, otherwise it will bump into the crossmember.
Use a titanium drill bit to accomplish this task. If you are in the great old United States of America, consider purchasing this drill bit kit from Harbor Freight. Comes with the size you need and more.
Mounting Locations: Green - Swingarm Bolt. Yellow - Frame bolts, need to be drilled to 12mm.
Factory hole diameter
1098 Bolt Diameter
I used a 31/64" drill bit
B. Actual Installation
It's easier to have the swingarm installed before putting in the engine.
If you decide to install the swingarm afterwards, then you will have to physically expand the frame to squeeze it in. Kind of a pain to deal with...speaking from experience.
Remember, remove the vertical cylinder intake boot for ease.
________________________________
V. Throttle Bodies & Cables
In stock form the 1098 throttle body linkage interferes with the cross-brace on the 748/916/996 frame. To remedy this issue, the linkage must be rotated 180 degrees. Pictures and videos of how to do so are below.
Steps:
Front Linkage "Pulley"
Undo 10mm nut
Pull pulley off the shaft
Rotate pulley 180 degrees and refit onto shaft
Secure pulley with 10mm nut
Rear Linkage "Pulley"
Remove safety clip on the end of the shaft (other side of the throttle body)
Remove two T20 security screws holding the butterfly plate into the shaft
Remove butterfly shaft
Rotate pulley and shaft 180 degree and refit into throttle body
Refit the safety clip onto the shaft end
Reinsert the butterfly plate. Facing up should be the side with "56" etched into it.
Resecure the T20 security screws with loctite. Peen the screws.
Note the Streetfighter 1098 throttle cables are longer than those of the 1098 sportbike. So they will provide more slack and adjustment - I recommend getting those.
The 2001 - 2010 Yamaha R1 throttle tube is also compatible with the throttle cable assembly. It also requires 15% less travel to wide open throttle.
In OEM form. Linkage needs
Final result
Front Linkage Pulley
Result. (10mm nut not pictured)
Need to remove the two T20 security screws
Remove the clip on the end of the shaft as well
Safety clip
Removed with pick
Butterfly plate removed
Final Result
Front pulley
Rear pulley
Installed on motorcycle
Any video? If you need help let me know