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  #1  
Old 16-09-08, 20:35
marjani marjani is offline
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XT660 to 700ccm conversion

Hello guys,

Shortly I'm doing a 660 to 700cc conversion. Here's so far what I've done.

1. bought a used XT660 head + cylinder + cam (oem)
2. bored and coated (nicasil+?) the cylinder to 700 ccm; done by http://www.powerseal.nl; they use a special process. See pics IMG_0869.jpg IMG_0870.jpg IMG_0874.jpg
IMG_0875.jpg
3. bought a suitable 103mm JE piston (thanks Kev for the advice!); See pics IMG_0876.jpg IMG_0877.jpg IMG_0878.jpg IMG_0880.jpg IMG_0881.jpg
4. tuned the cylinderhead + paint job (done by http://www.off-the-road.de; see pics before (head already sand blasted) - (IMG_0940.jpg IMG_0944.jpg IMG_0945.jpg IMG_0946.jpg IMG_0947.jpg IMG_0948.jpg IMG_0949.jpg) and after head tune job and coating job (IMG_1198.jpg IMG_1199.jpg IMG_1201.jpg IMG_1202.jpg IMG_1203.jpg).

Next steps:
- coating the cylinder to black
- still waiting for the OTR cam; will arrive shortly.
- remove the engine

Will keep you informed!

Greetings from Holland,

Marcel (marjani)
Attached Images
File Type: jpg IMG_0869.jpg (60.8 KB, 176 views)
File Type: jpg IMG_0870.jpg (43.9 KB, 108 views)
File Type: jpg IMG_0874.jpg (60.2 KB, 97 views)
File Type: jpg IMG_0875.jpg (50.6 KB, 80 views)
File Type: jpg IMG_0876.jpg (87.9 KB, 125 views)
File Type: jpg IMG_0877.jpg (83.6 KB, 92 views)
File Type: jpg IMG_0878.jpg (81.3 KB, 99 views)
File Type: jpg IMG_0880.jpg (87.5 KB, 95 views)
File Type: jpg IMG_0881.jpg (66.8 KB, 110 views)
File Type: jpg IMG_0940.jpg (75.8 KB, 113 views)
File Type: jpg IMG_0944.jpg (55.3 KB, 86 views)
File Type: jpg IMG_0945.jpg (57.1 KB, 89 views)
File Type: jpg IMG_0946.jpg (65.6 KB, 83 views)
File Type: jpg IMG_0947.jpg (55.0 KB, 103 views)
File Type: jpg IMG_0948.jpg (61.0 KB, 99 views)
File Type: jpg IMG_0949.jpg (52.2 KB, 93 views)
File Type: jpg IMG_1198.jpg (46.1 KB, 170 views)
File Type: jpg IMG_1199.jpg (68.9 KB, 132 views)
File Type: jpg IMG_1201.jpg (81.2 KB, 146 views)
File Type: jpg IMG_1202.jpg (54.6 KB, 129 views)
File Type: jpg IMG_1203.jpg (79.8 KB, 139 views)

Last edited by marjani; 03-01-09 at 11:51.
  #2  
Old 16-09-08, 20:51
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CaptMoto CaptMoto is offline
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another Fran-kenstein motor, well done, I feel like an organ donor

Hello Ladieeeeeeesssss There's more organs where that came from!!

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  #3  
Old 16-09-08, 21:06
marjani marjani is offline
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oeps, forgot to mention CaptMoto for the used head+cylinder+cam.
Thank you Fran!
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bike is sold:
103mm Big Bore|Nicasil cylinder (PowerSeal)|JE piston|CR 11,3:1|ported head (OTR)|Modified cam (OTR)|Powder coated head+cylinder (black)|PCIII|+2 TB l Modded 2-in-1 exhausts (Trinity+Akrapovic)|DNA stage 1 & 2 Filters|Tail Mod|XTX Wheels|XTX chain cover|XTX rear shock connecting arms|Metal footpegs|Acerbis handguards|Hyperpro springs|15W fork oil|Snorkel removed|AIS blocked|NGK CR9EK|SpeedoHealer|Reroute engine breather hose|HRC brake reservoir l Magura Hymec hydraulic clutch
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  #4  
Old 16-09-08, 21:23
desert desert is offline
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what Hp will u get after that?
  #5  
Old 16-09-08, 21:33
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Well done that man, glad it's finally coming to the install.

I have my fingers crossed for you, +60HP for sure. Can't wait to see the dyno results, as we have a few other 700 conversions going on behind the scenes so there will be a few compassions to compare.
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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 2018 MT09SP ABS + TCS

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

  #6  
Old 18-09-08, 21:09
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skorzeny skorzeny is offline
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Marjani , how much are the costs so far?
Want to do the same...
  #7  
Old 18-09-08, 22:22
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Quote:
Originally Posted by skorzeny View Post
Marjani , how much are the costs so far?
Want to do the same...
Remember Skorzeny if you are interested I have a spare engine minus the thorttle body (but you can use yours)
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  #8  
Old 19-09-08, 15:16
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skorzeny skorzeny is offline
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Thanks Capt,

Since my engine is somewhat older than most bikes (one of first of 2004) i am thinking of modifying it and in case of a brakedown use newer replacement parts. But don´t want to go as far as having a whole spare engine.
Or isnt that what you mean and am i not getting the point?
  #9  
Old 26-09-08, 23:28
marjani marjani is offline
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Yesterday I recieved the OTR cam. Nothing more to tell about this part, looks just the same as the oem cam.
I also started the Engine Removal; removed the exhaust pipes, drained the oil and coolant, side panels. Wanted to remove the fuel tank, but have to drain it first. Guess there still about 7 liters of fuel in there, so have to be carefull not to spill it around the garage (my wife will kill me, haha!). Lucky I don't smoke
Today I took the cylinder for a powder coating job. It's now 'paint it black'

I'm very frustrating at the moment, because the weather forecast will be good the whole weekend and I can't drive my damn blue steel horse! But I have still got my good ole' Vespa and a baby Honda dominator to drive....no wheelies for me for the moment

Guess I need some mental coaching here, because this is a hell of a job! Wish Kev was my neighbour...


Skorzeny: I will give you a full review of the prices asap.

Greetings from a sunny Holland,

Marcel
Attached Images
File Type: jpg IMG_1220.jpg (72.4 KB, 126 views)
File Type: jpg IMG_1221.jpg (63.9 KB, 109 views)
File Type: jpg IMG_1222.jpg (57.2 KB, 87 views)
File Type: jpg IMG_1223.jpg (79.0 KB, 157 views)
File Type: jpg IMG_1224.jpg (88.3 KB, 169 views)
__________________
bike is sold:
103mm Big Bore|Nicasil cylinder (PowerSeal)|JE piston|CR 11,3:1|ported head (OTR)|Modified cam (OTR)|Powder coated head+cylinder (black)|PCIII|+2 TB l Modded 2-in-1 exhausts (Trinity+Akrapovic)|DNA stage 1 & 2 Filters|Tail Mod|XTX Wheels|XTX chain cover|XTX rear shock connecting arms|Metal footpegs|Acerbis handguards|Hyperpro springs|15W fork oil|Snorkel removed|AIS blocked|NGK CR9EK|SpeedoHealer|Reroute engine breather hose|HRC brake reservoir l Magura Hymec hydraulic clutch

Last edited by marjani; 18-01-09 at 13:29.
  #10  
Old 27-09-08, 06:35
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Kev Kev is offline
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Looking forward to the results.

If you get stuck you know where to find me, I am always willing to help.
__________________
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 2018 MT09SP ABS + TCS

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

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