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Performance Modifications & Enhancements Engine, Fuelling & Throttle performance mods

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  #1  
Old 23-06-07, 08:10
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Kev Kev is offline
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Dyno results

If any one has any dyno results please let me know & I will post them here.

http://www.xt660.com/showpost.php?p=10232&postcount=77

http://www.xt660.com/showpost.php?p=11400&postcount=79

http://www.xt660.com/showpost.php?p=11401&postcount=16

http://www.xt660.com/showpost.php?p=26624&postcount=1

http://www.xt660.com/showpost.php?p=25637&postcount=20

http://www.xt660.com/showpost.php?p=23036&postcount=1

http://www.xt660.com/showpost.php?p=21627&postcount=20

http://www.xt660.com/showpost.php?p=16389&postcount=1

http://www.xt660.com/showpost.php?p=11627&postcount=9

http://www.xt660.com/showpost.php?p=10297&postcount=8

http://www.dnafilters.com/newsdetails.asp?newsid=30

http://www.dot-e.dk/dot-e.dk/effektk...6-1cyl.pw/view

http://www.off-the-road.de/index.php...d257760907441d

http://www.1000ps.at/forum.asp?thema...606&id=2097606

2007 model dyno runs.

http://xt660.com/showpost.php?p=41822&postcount=1

XT700 conversion.

http://www.xt660.com/showpost.php?p=54997&postcount=86

http://www.xt660.com/showpost.php?p=54685&postcount=69

Stage 2 cam against stage 1 cam & big bore.

http://www.xt660.com/showthread.php?t=7158
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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a new 2012 KTM990SMR. 130.47 rear wheel HP, mod list below

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Last edited by Kev; 28-08-09 at 21:27.
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  #2  
Old 19-01-08, 10:30
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Kev Kev is offline
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kev's 07 Dyno run

This was yesterdays Dyno run. DNA stage 1 & 2 filters, power Commander & Carbon can slip ons, snorkel removed, AIS blocked, O2 Eliminator.

The map is not finished I spent 2 hours on the dyno, I just needed to know where the fueling was & I agree with Freez the new ECU's are very different to the 04 & 06 ECU's, it runs way to rich up top, even with the AIS blocked off.

The red line is the corrected power commander fuel map the blue is with a Zero map (Yamaha fuel map), I need to sort some problems I have with the low end & then get it back on the dyno & am sure I will get some better low end results.
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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a new 2012 KTM990SMR. 130.47 rear wheel HP, mod list below

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Last edited by Kev; 19-01-08 at 12:04.
  #3  
Old 25-01-08, 13:33
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Kev Kev is offline
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Dyno results

I was sent this Dyno result this week with a very nice power gain. A before & after run

kev Fuel mod
DNA stage 1 & 2 filters
Mivv Exhaust


__________________
CLICK HERE ----- For the full index of XT660 Mods


Click here to join the XT Supporter's scheme

Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a new 2012 KTM990SMR. 130.47 rear wheel HP, mod list below

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946
  #4  
Old 25-01-08, 13:43
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ManicMic ManicMic is offline
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Hi Kev. I'm a bit fick when it comes to reading dyno results but I am interested. Am I correct in saying that the red line is the before and the orange is the after? Also, what do the blue lines represent? Is that peak power showing 46 HP?
  #5  
Old 25-01-08, 21:59
Freez Freez is offline
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Red and Orange lines will be HP and the blue lines will be torque.

Good results there Kev.

Man, you must try and get the XT on a Dynojet dyno with the tuninglink software.

In the 2 hours you spend making a handmade map, you can make about 3 to 4 different maps with the tuninglink software, and try all of them to see which one works better and what A/F ratio is best.

At what A/F ratio are you running this bike at peak HP and towards max RPM. PM me if you want to keep it quite.
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  #6  
Old 25-01-08, 22:42
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Kev Kev is offline
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Quote:
Originally Posted by Freez View Post
Red and Orange lines will be HP and the blue lines will be torque.

Good results there Kev.

Man, you must try and get the XT on a Dynojet dyno with the tuninglink software.

In the 2 hours you spend making a handmade map, you can make about 3 to 4 different maps with the tuninglink software, and try all of them to see which one works better and what A/F ratio is best.

At what A/F ratio are you running this bike at peak HP and towards max RPM. PM me if you want to keep it quite.
I am now running my bike on a DynoJet dyno with link software, but having a problem with my low end fueling & can not get it right.

http://www.xt660.com/showpost.php?p=44180&postcount=5

I am going to the dealer in 1 hour to try & sort my bike out.

In the high end rev range I am running 13:1
__________________
CLICK HERE ----- For the full index of XT660 Mods


Click here to join the XT Supporter's scheme

Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a new 2012 KTM990SMR. 130.47 rear wheel HP, mod list below

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Last edited by Kev; 25-01-08 at 22:45.
  #7  
Old 26-01-08, 15:24
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Hyosung Hyosung is offline
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Question

Quote:
Originally Posted by Kev View Post
I was sent this Dyno result this week with a very nice power gain. A before & after run

kev Fuel mod
DNA stage 1 & 2 filters
Mivv Exhaust


That´s mine carbon limited edition xt , I´m so happy with the result, I have a question kev,I lost 1 km/h that can be because the humidity or temp of the bike?I have this settings:
Before:
Mivv exhaust
co:38
Without snorkle
Top speed:167 km/h
After:
Mivv exhaust
Dna stage 1&2 filters
Kev mod set on -8º
co:23
Without snorkle
Top speed:166 km/h

What dou you think about the "co" setting?
Thanks man,

Last edited by Kev; 26-01-08 at 23:15.
  #8  
Old 26-01-08, 23:11
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Kev Kev is offline
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Quote:
Originally Posted by Hyosung View Post
That´s mine carbon limited edition xt , I´m so happy with the result, I have a question kev,I lost 1 km/h that can be because the humidity or temp of the bike?I have this settings:
Before:
Mivv exhaust
co:38
Without snorkle
Top speed:167 km/h
After:
Mivv exhaust
Dna stage 1&2 filters
Kev mod set on -8º
co:23
Without snorkle
Top speed:166 km/h

What dou you think about the "co" setting?
Thanks man,

As your bike was run on the Dyno & the Air/fuel ratio was set leave the CO1 where it is. As the Dyno sheet shows more air & fuel = MORE POWER. Your torque curve is quite different with your Mivv exhaust compaired to the Carbon Company Cans, you seem to have better spread of torque at higher rpms & the CCC give more torque lower down.

I would put the 1kph loss to that ham burger you had eaten before the top speed test (only joking) It could be wind resistance & many other factors, don't worry about it. Your results are very good.
__________________
CLICK HERE ----- For the full index of XT660 Mods


Click here to join the XT Supporter's scheme

Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a new 2012 KTM990SMR. 130.47 rear wheel HP, mod list below

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Last edited by Kev; 26-01-08 at 23:26.
  #9  
Old 27-01-08, 07:49
Freez Freez is offline
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Kev, how is this guy mapping the bike?

Before you start, make 100% sure the PCIII's throttle position is set up correctly. I like to pull the throttle tight, not open, just tight, when I set 0% and then run the bike in say 3rd or 4th, and set 100% throttle with the throttle fully open. Set this with the tuninglink software, not the software that comes with the PCIII.

When you use the tuninglink software, use 4th gear for 60, 80 and 100% throttle. For 40% throttle use 3rd gear and 2nd for 20% throttle.
10% is mapped in 1st gear. This is with role on state on the dyno.

Then do 2, 5, 10 and 20% again in 1st gear, with steady state on the dyno software. Start with 2000 RPM if you can, but once you have one right, copy the 2000 RPM setting to 1750 RPM

Also, try running the following A/F ratio's

For less than 20% throttle run the bike around 13:1, then from 20 to 60, run it at 13.3: and form 80 to 100%, run it at around 13.5:1.

that will give you a nice boost in peak RPM power.

Let me know how this works out for you.

PS. If you can get me the settings the guy is using to control the load. I can't remember what you call it, but it is a value like 0.00250 or 0.0450 or something like that. You get 3 settings like that and they control the load on the dyno and how quickly it releases and starts.

Also, don't hook the spark plug RPM pickup over the HT lead, run it off the trigger wire to the coil. Might have to change the RPM setting on the software as it might reads double actual RPM when you run it off the trigger wire.
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  #10  
Old 27-01-08, 11:35
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Kev Kev is offline
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I will give your tunning advice a go & let you know the out come, now that I am using the link software those figures can be easily got. I will get the spec's you need from the set up, I know what you mean.

Basically Freez I was trying to get the fuelling right low down & spent alot of time playing around there, the dyno link software was leading us all over the place because of the ECU being faulty & in the end could not set the fuelling right between 2500 to 5000 RPM at 10 to 20% throttle.

I loaded one of your 07 fuel maps this morning with the new ECU & had both filters installed, snorkel removed with standard pipes & it worked just fine, it felt good all the way through with almost no surge 98% good, a fine tune on the dyno to my bike & it would be perfect.

When I tried the same map on the last ECU it was way to rich low down & ran worse, it felt much better using a Zero map & the dyno proved this when I had a dyno run a few days later.

Below is the Faulty ECU mapping, as you can see what I mean, being to rich low down as the link software wanted the fuel setting leaned out. The only thing the air/fuel ratio kept moving all over the place. The red ringed area should be the other way around in postive figures not negitive.

__________________
CLICK HERE ----- For the full index of XT660 Mods


Click here to join the XT Supporter's scheme

Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a new 2012 KTM990SMR. 130.47 rear wheel HP, mod list below

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Last edited by Kev; 27-01-08 at 11:50.
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