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Performance Modifications & Enhancements Engine, Fuelling & Throttle performance mods

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Old 12-08-06, 13:12
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Kev Kev is offline
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Lightbulb XT660.com Modifications Index - PLEASE LOOK HERE FIRST BEFORE ASKING QUESTIONS.

XTX & XTR. Mod Section.


BUY YOUR MODS FROM OUR ONLINE SHOP
http://www.xt660.com/site/node/129


Mods affecting warranty.
Just to clear up things, any addition to the wiring or any mod to a motorcycle will void warranty of the replacement part, if the mod can be proven to be the fault or cause of the failure of the component.


Engine & performance mods


What HP do I get from that mod
http://www.xt660.com/showthread.php?t=4509

1/ Dyno results.
http://www.xt660.com/showthread.php?t=3215

2/ Removal of the air filter snorkel. Air Box explained
http://www.xt660.com/showthread.php?t=12547

Fit a K&N, stage 1 & 2 DNA, Piper cross or BMCmain filter.

Difference between a DNA & K&N filter
http://www.xt660.com/showthread.php?t=9848

Stage 1 filter DNA.
http://www.dnafilters.com/filterdeta...p?filterid=143

Stage 2 filterDNA.
http://www.dnafilters.com/filterdeta...p?filterid=258
http://www.xt660.com/showthread.php?t=165
http://www.bikehps.com/acatalog/Pipe...or_Yamaha.html
http://www.xt660.com/showthread.php?t=6406

DNA Stage 3 Air Box
http://www.xt660.com/site/node/311
http://www.xt660.com/site/node/310
http://www.xt660.com/showthread.php?t=11801&page=3

4/ Reroute the engine breather, cleaner air to motor.
http://www.xt660.com/showthread.php?...light=breather
http://www.xt660.com/showthread.php?...ngine+breather

5/ AIS removal stop your bike popping.
http://www.xt660.com/showthread.php?t=5544

6/ Making your clutch lighter
http://www.xt660.com/showthread.php?t=8611

7/ Fit a DNA stage 2 filter.
Stage 2 filter
http://www.xt660.com/showthread.php?t=165
http://www.xt660.com/showthread.php?t=474
http://www.xt660.com/showthread.php?...=Co+adjustment
http://www.knfilters.com/search/prod...x?Prod=YA-6604

8/ Kev's Air box Mod, drilling of 5 holes in the air box.
http://www.xt660.com/showthread.php?t=321

9/ XT700 conversion.
http://www.xt660.com/showpost.php?p=51632&postcount=59
http://www.xt660.com/showthread.php?t=5895
http://www.xt660.com/showthread.php?t=6689
http://www.xt660.com/showpost.php?p=58076&postcount=13
http://www.xt660.com/showthread.php?...ighlight=xt700
785cc XT
http://www.xt660.com/showthread.php?t=14819

10/ Cylinder head porting.
http://www.xt660.com/showpost.php?p=59612&postcount=93
http://www.xt660.com/showpost.php?p=97770&postcount=123

11/ Fitting a Stage 1 Hot Cam
http://www.xt660.com/showthread.php?t=6635
http://www.xt660.com/showthread.php?t=6958

Stage 2 Hot Cam
http://www.xt660.com/showthread.php?t=14736

12/ Fitting a axillary water cooler
http://www.xt660.com/showpost.php?p=58076&postcount=13

13/ +2mm bigger throttle body.
http://www.xt660.com/showthread.php?t=7571
http://www.bluetraxx.com/reviews/kds_throttlebody.htm
http://www.kdsracing.com/
http://www.xt660.com/showthread.php?t=9621

14/ Stroker crank.
http://www.xt660.com/showthread.php?p=82827#post82827
https://www.xt660.com/showthread.php?t=18704

15/ RPM increase
http://www.xt660.com/showthread.php?t=801

16/ Removing your XT660 motor.
http://www.xt660.com/showthread.php?t=6338

17/ Installing a Stage 1 Hot Cam
http://www.xt660.com/showthread.php?t=6635

18/ Engine paint.
http://www.xt660.com/showthread.php?t=10708

19/ Different RON Fuels
http://www.xt660.com/showthread.php?t=14216

20/ Temperature Gauge
http://www.xt660.com/showpost.php?p=144994&postcount=3

21/ Radiator cap
http://www.xt660.com/showpost.php?p=143923&postcount=4

22/ Removing the 33HP restrictor
http://www.xt660.com/showthread.php?t=23128

23/ Build your own stage 3 air box.
http://www.xt660.com/showthread.php?p=209801#post209801
http://www.xt660.com/showthread.php?t=23122&page=7


Fueling mods

Kev's Fuel mod can be bought from this link. http://www.xt660.com/site/node/136

WB's DNA Stage 2 filter covers can be bought from this link. http://www.xt660.com/site/node/194


1/ Adjust the CO, up.
http://www.xt660.com/showthread.php?...=Co+adjustment

2/ Fitments of Kev's fuel adjuster mod with Air box Mod.
http://www.xt660.com/site/node/53
http://www.xt660.com/site/node/136
http://www.xt660.com/showthread.php?t=525

3/ Fit a power commander.
http://www.xt660.com/showthread.php?t=13756
http://www.powercommander.com/

4/ Throttle Sensor Adjustment
http://www.xt660.com/showthread.php?t=56

5/ Fuel devices.

1/ Power Comander PCIII & PCV
http://www.off-the-road.de/Other-bikes/Engine-Tuning/Dynojet-Power-Commander-Yamaha-XT-660.html?listtype=search&searchparam=power%20comma nder

2/ Rapid Bike
http://www.rapidbikeusa.com/cgi-bin/shopper.cgi?search=action&category=1287&keywords=a ll

3/ Ignijet
http://www.ignitech.cz/english/ignijet/ignijet.htm

4/ Memjet
http://www.memjetmodule.com/products-page/yamaha/

5 SFI
http://www.staintune.com.au/sfi_yamaha_xtx660.htm

6/ The Kev Fuel Mod.
http://www.xt660.com/site/node/136

6/ Power Commander fuel maps for XT660X/R can be found in the ASK Kev section.
http://www.xt660.com/showthread.php?t=2887

7/ Drill fuel tank to get an extra 15kms before the fuel light comes on.
http://www.xt660.com/showpost.php?p=82572&postcount=9

8/Kev's 2010 New O2 Mod for XTX & XTR's
http://www.xt660.com/showthread.php?t=14746

9/ DNA Air filter clean.
http://www.knfilters.com/cleaning.htm10/ Fuels
http://www.xt660.com/showthread.php?t=14216

11/ Removing the restrictor for full power
http://www.xt660.com/showpost.php?p=141082&postcount=2

12/ Which Power Commander fits which XT660?
http://www.xt660.com/showpost.php?p=144104&postcount=8

13/ Twitchy Throttle, good mod to do.
http://www.xt660.com/showthread.php?p=154983#post154983


Exhaust mods


1/ Fit a set of cans.
http://www.xt660.com/showthread.php?t=103

2/ Stopping the popping back from your exhausts. AIS Mod.
http://www.xt660.com/showthread.php?...ghlight=ais%2A
http://www.xt660.com/showthread.php?...ghlight=ais%2A

3/ 2-in-1 exhaust
http://www.xt660.com/showthread.php?...ed=1#post81267
http://www.xt660.com/showthread.php?p=92518#post92518

4/ Recoating that rusted exhaust
http://www.xt660.com/showthread.php?...d=1#post112607

5/ Servicing after market exhaust.
http://www.xt660.com/showthread.php?t=8360

6/ Modifing your exhaust baffle
http://www.xt660.com/showthread.php?p=126290#post126290

A lot of the links & mods are discussed in the ASK KEV section, if the link does not work it may be because you are not a paid up supporter & will not have access to those links.
__________________
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


Last edited by Kev; 26-07-18 at 10:46.
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  #2  
Old 11-08-07, 01:19
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Kev Kev is offline
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Join Date: May 2006
Location: Brisbane, Australia
Posts: 6,063
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XTX & XTR Mods PART 2

Suspension mods

Rear links can be bought from this link http://www.xt660.com/showthread.php?t=8939

Fork spacers can be bought from this link. http://www.xt660.com/site/node/135


1/ Front Suspension springs & Fork Spacer Mod.
http://www.xt660.com/site/node/135
http://www.xt660.com/showthread.php?t=947
http://www.xt660.com/showthread.php?t=8826
http://www.xt660.com/showpost.php?p=124421&postcount=46

2/ Fitting a XTX front wheel to a XTR
http://www.xt660.com/showthread.php?...d=1#post105255
See the PDF at the bottom of this post.

XTX Front wheel spacer size.
http://www.xt660.com/showthread.php?p=70349#post70349

3/ Lowering your XTX

Use the XTR rear shock link plates. Then lower the forks through the fork bridges.

http://www.xt660.com/showpost.php?p=132647&postcount=3

4/ Raising your XTR
Use the XTX rear links & Kev's fork spacers
http://www.xt660.com/showpost.php?p=80055&postcount=20
http://www.xt660.com/showthread.php?t=8939
http://www.xt660.com/showpost.php?p=132647&postcount=3

5/ Correct speedo reading after sprocket ratio change. Speedo Healer

http://www.xt660.com/showthread.php?t=3266
http://www.xt660.com/showpost.php?p=77956&postcount=23
http://www.speedohealer.com/your_pic...4/tutorial.htm

6/ Upside-down forks
http://www.xt660.com/showthread.php?t=8397&page=2
http://www.xt660.com/showpost.php?p=142600&postcount=1

7/ Fitting rim locks XTR
http://www.xt660.com/showpost.php?p=97754&postcount=1

8/ Free play in sprocket holder mod.
http://www.xt660.com/showpost.php?p=99604&postcount=9
http://www.xt660.com/showpost.php?p=113529&postcount=1
http://www.wemoto.com/bikes/Yamaha/X..._Rubber_-_Set/
http://www.xt660.com/showthread.php?t=21410

9/ Rear pad change.
http://www.xt660.com/showthread.php?t=368
http://www.xt660.com/showpost.php?p=125789&postcount=4

10/ Rear brake pedal adjustment.
http://www.xt660.com/showpost.php?p=126196&postcount=7

11/ Fitting rear suspention links.
http://www.xt660.com/showpost.php?p=46533&postcount=50

12/ Servicing your steering head bearings
http://www.xt660.com/showthread.php?p=114085#post114085

13/ Build your own bike stand.
http://www.xt660.com/showthread.php?t=9105

14/ Rear Wheel bearing sizes
http://www.xt660.com/showpost.php?p=114797&postcount=12

15/ Adjusting your front brake light switch.
http://www.xt660.com/showthread.php?t=7612

16/ Want to rebuild your shocks to your spec, these guys can do it.
http://www.motocd.com/

17/ Mag Wheels
http://www.xt660.com/showthread.php?...Brother+wheels

Body

WB's DNA Stage 2 filter covers can be bought from here http://www.xt660.com/site/node/194

WB tail tidy send him a PM to order one
http://www.xt660.com/showthread.php?...d=1#post104366

1/ Fitting metal foot pegs
http://www.xt660.com/showpost.php?p=46622&postcount=1

2/ Rear light Conversion. Tail tidy
http://www.xt660.com/showthread.php?t=20723
http://www.xt660.com/showthread.php?...d=1#post104366
http://www.xt660.com/showthread.php?t=320
http://www.xt660.com/showthread.php?t=5752&page=4
http://www.xt660.com/showthread.php?t=7020
http://www.xt660.com/showthread.php?t=14247

3/ Modified seat
http://www.xt660.com/showpost.php?p=81454&postcount=3

4/ Helmet Lock
http://www.xt660.com/showthread.php?t=9481

5/ New Front fender for XTR.
http://www.xt660.com/showthread.php?t=10007

6/ Recovering your seat.
http://www.xt660.com/showthread.php?p=99525#post99525

7/ Vibration damper in the bars
http://www.xt660.com/showthread.php?t=12164

8/ Screen 08 XTX onwards.
http://www.shopmania.co.za/moto-acce...-04-06-1323308
http://www.vespaspares.co.uk/spares/...X%202010&uID=0


9/ XTX & XTR Handguard Fitting Instructions
http://www.xt660.com/showthread.php?...d=1#post140052

10/ Rear stone guard
http://www.xt660.com/showthread.php?...d=1#post199566



Electrical


1/ Audible Indicators
http://www.xt660.com/showthread.php?t=532

2/ Oil temp gauge
http://www.xt660.com/showpost.php?p=62068&postcount=14

3/ Head light conversion
http://www.xt660.com/showpost.php?p=50341&postcount=24

4/ Throttle Sensor Adjustment
http://www.xt660.com/showthread.php?t=56

5/ Fitting Zenon Lights
http://www.xt660.com/showpost.php?p=61818&postcount=11

6/ Getting rid of the O2 sensor
http://www.xt660.com/showthread.php?t=8478

7/ ECU swop 07 to 05
http://www.xt660.com/showthread.php?t=8478

8/ Rev counter in dash display.
http://www.xt660.com/showpost.php?p=4194&postcount=4

9/ After market Rev Counter Tacho
http://www.xt660.com/showthread.php?t=23714
http://www.xt660.com/showthread.php?...rev%2A+counter
http://www.xt660.com/showthread.php?t=11616
http://www.xt660.com/showthread.php?t=12793

10/ Batteries
http://www.xt660.com/showthread.php?t=551
http://www.xt660.com/showthread.php?...ed=1#post98409
http://www.xt660.com/showpost.php?p=167520&postcount=8

11/ Rev counter in dash display
http://www.xt660.com/showpost.php?p=4194&postcount=4

12/ XTZ setting speedo from KMS to MPH
http://www.xt660.com/showpost.php?p=59079&postcount=6

13/ ECU info
http://www.xt660.com/showthread.php?t=8546

14/ Electrical connectors
http://www.easternbeaver.com/Main/El...-MT/sm-mt.html

15/ After market tail light.
http://www.riffgmbh.com/shop/YAMAHA/...-10::2008.html

Easy reference

1/ Diagnostic Codes. http://www.xt660.com/showthread.php?t=53

2/ Parts manual.>
http://www.yamaha-motor.com.mx/Manua...On-Off/XT660R/
http://www.yamaha-motor.com.mx/Manua...On-Off/XT660X/

Online Parts Manual
http://www.apriliascooterspares.co.u...9000&pageID=11
http://oemmotorparts.com/oem2.asp?M=Yamaha
http://oemmotorparts.com/oem5.asp?M=...YA-XT-R-660_aj
http://www.cmsnl.com/searchparts_other.php?make=YA

1/ All workshop manuals for XT660.com forum supporters.
http://www.xt660.com/showthread.php?t=84

2/ Upload picutres to the forum.
http://www.xt660.com/showthread.php?t=10380

3/ After market parts.
http://shop.wemoto.com/index.dyn?oid=5834319

6/ Seat covers
http://www.dualsport-fx.com/shop/ind...50&language=en

5/ Graphics
http://www.xt-660.de/forum/viewtopic.php?f=9&t=8181

All discounts to forum members
http://www.xt660.com/showthread.php?t=1945

OILS explained.
http://www.ferrarichat.com/forum/faq...=haas_articles

A lot of the links & mods are discussed in the ASK KEV section, if the link does not work it may be because you are not a paid up supporter & will not have access to those links.
Attached Files
File Type: pdf XtX Wheels on XtR.pdf (1.17 MB, 283 views)
__________________
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


Last edited by Kev; 18-08-15 at 23:18. Reason: moving things around
  #3  
Old 29-09-07, 11:06
Kev's Avatar
Kev Kev is offline
Administrator
 
Join Date: May 2006
Location: Brisbane, Australia
Posts: 6,063
Kev is on a distinguished road
Xt660z

XTZ mod section


BUY YOUR MODS FROM OUR ONLINE SHOP
http://www.xt660.com/site/node/129


Engine Mods

What HP do we get from the DNA filters
http://www.xt660.com/showthread.php?p=118359&posted=1#post118359

What stage DNA filter is what: http://www.xt660.com/showthread.php?t=22985

1/DNA stage 2 filter & top cover mod.

http://www.xt660.com/showpost.php?p=89929&postcount=21
http://www.xt660.com/showthread.php?t=9636
http://www.xt660.com/showthread.php?...ed=1#post98634

2/ DNA stage 3 filter
http://www.xt660.com/site/node/324

3/Air box drain pipe mod.
http://www.xt660.com/showpost.php?p=97949&postcount=47
http://www.xt660.com/showpost.php?p=98276&postcount=58

4/AIS Mod
http://www.xt660.com/showthread.php?...d=1#post101266

5/Protect the DNA stage 3 filter form your boots.
http://www.xt660.com/showthread.php?t=13512

6/ A Cheap PRE-FILTER mod for your Tenere
http://www.xt660.com/showthread.php?t=13520

7/ Piper Cross filter
http://www.demonbikes.com/more/on/details/10299

Fuel Mods

Kev's Fuel mod can be bought from this link. http://www.xt660.com/site/node/136

1/ Quick full tank mod.
http://www.xt660.com/showthread.php?t=9051

2/ Different fuel mods
http://www.xt660.com/showpost.php?p=121245&postcount=9
http://www.xt660.com/site/node/53

3/ fitting a power Commander.
http://www.xt660.com/showthread.php?t=13756

4/ Clean fuel, inline filter
http://www.xt660.com/showthread.php?t=13003

5/ Yamaha Diag tool
http://www.xt660.com/showpost.php?p=206754&postcount=14
Exhaust Mods

1/Exhausts
http://www.xt660.com/showpost.php?p=61950&postcount=6
http://www.xt660.com/showpost.php?p=62752&postcount=1
http://www.xt660.com/showpost.php?p=67946&postcount=1
http://www.xt660.com/showpost.php?p=63131&postcount=1
http://www.xt660.com/showthread.php?t=10953

2/ De-cating your standard exhaust
http://www.xt660.com/showthread.php?t=13652

Suspension Mods

1/ Correcting the speedo after changing sprockets.
http://www.xt660.com/showthread.php?t=3266
http://www.xt660.com/showpost.php?p=77956&postcount=23
http://www.speedohealer.com/your_pic...4/tutorial.htm


2/ Brakeline kit xtz tenere 08
http://www.xt660.com/showthread.php?t=7666

3/ Chain Pre-oiler
http://www.xt660.com/showthread.php?t=9053

4/ Lowering the Z
http://www.xt660.com/showpost.php?p=132647&postcount=3
http://www.xt660.com/showthread.php?t=7371

5/ Free play in sprocket holder mod.
http://www.xt660.com/showpost.php?p=99604&postcount=9

6/ Suspension upgrade.
http://www.xt660.com/showthread.php?t=11030
http://www.xt660.com/showthread.php?t=12517

7/ Cheap Cush Drive Mod
http://www.xt660.com/showpost.php?p=99604&postcount=9
http://www.xt660.com/showthread.php?t=21410
http://www.wemoto.com/bikes/Yamaha/X..._Rubber_-_Set/

8/ 140 rear tyre.
http://www.xt660.com/showpost.php?p=126931&postcount=7

9/ Wheel bearing sizes.
http://www.xt660.com/showpost.php?p=84189&postcount=12
http://www.xt660.com/showpost.php?p=153838&postcount=5

10/ Steering dampener
http://www.xt660.com/showthread.php?...d=1#post149984

11/ Chain Guide Mod
http://www.xt660.com/showthread.php?t=17951

12/ Yz450 front forks
http://www.xt660.com/showthread.php?...d=1#post181773

Body Mods

1/ New seat for XTZ
http://www.xt660.com/showpost.php?p=62227&postcount=1

2/SW-Motech gear.

http://www.xt660.com/showpost.php?p=70384&postcount=3
http://www.xt660.com/showpost.php?p=70385&postcount=1

4/ Short front fender.
http://www.xt660.com/showpost.php?p=67741&postcount=3
http://www.xt660.com/showthread.php?p=107303#post107303

5/Chopping the tail...
http://www.xt660.com/showthread.php?t=7558
http://www.xt660.com/showpost.php?p=...&postcount=640

6/Racks for the Z
http://www.xt660.com/showthread.php?t=7380
http://www.xt660.com/showthread.php?t=12440

7/Turbulance Stopper.
http://www.xt660.com/showthread.php?t=9180
http://www.xt660.com/showthread.php?t=13650

8/ New fance levers.
http://www.xt660.com/showthread.php?t=9943

9/ Bar risers.
http://www.xt660.com/showthread.php?t=10699

10/ Fitting engine protection bars.
http://www.xt660.com/showthread.php?t=10902

11/ Tenere Storage Mod
http://www.xt660.com/showthread.php?...d=1#post115392

12 ARD cases.
http://www.xt660.com/showthread.php?t=12787

13/ Fitting Pannier Rails & Panniers
http://www.xt660.com/showthread.php?t=14319

Brake mods.


1/ Rear brake lever mod
http://www.xt660.com/showthread.php?t=10470

2/ Rear pad thickness
http://www.xt660.com/showpost.php?p=125789&postcount=4

Electrical

1/GSP Power supply.
http://www.xt660.com/showthread.php?t=7624

2/ Dash lights to bright.
http://www.xt660.com/showpost.php?p=60013&postcount=4

3/ Extra Lights / Axillary lights
http://www.xt660.com/showthread.php?t=10995

8/ XTZ setting speedo from KMS to MPH
http://www.xt660.com/showpost.php?p=59079&postcount=6

9/Fitting A Speedo Healer
http://www.xt660.com/showthread.php?...ghlight=Healer

10/ Extra fuse box
http://www.xt660.com/showpost.php?p=109058&postcount=1

11/ HID Lights
http://www.xt660.com/showthread.php?t=12605

12/ Turn signal LED conversion
http://www.xt660.com/showthread.php?t=13944

13/ Upgrade your battery to a Lithium iron battery.
http://www.xt660.com/showpost.php?p=167520&postcount=8

XTZ service related

1/ Service + setting tappets.
http://www.xt660.com/showthread.php?t=17573

XT1200Z Super Tenere

1/Adjusting the CO
http://www.youtube.com/watch?v=ZwTfu...eature=channel

2/ Fitting side boxes
http://www.xt660.com/showpost.php?p=132339&postcount=27

Known Faults & fixes for XT660Z

1/ Injector loom shorting out on frame.
http://www.xt660.com/showthread.php?p=136754&posted=1#post136754

2/ Hole in Radiator.
http://www.xt660.com/showpost.php?p=141475&postcount=1

3/ Drive nut comes loose
http://www.xt660.com/showthread.php?t=23951



XT660Z After Market Suppliers
Off the Road http://www.off-the-road.de/xt660_tenere_ersatzteile_parts.html?&L=1

Touratech http://www.touratech.com/shops/008/index.php?cPath=8_72&osCsid=92ab690d6a462e0ccb140d 366068de22

Metal Mule http://www.metalmule.com/yamaha/xt-660-z-tenere/

Adventure Spec (our newest sponsors) http://www.adventure-spec.com/

http://www.ruggedroads.com/shop/page/1?shop_param

http://www.kedo.com/


A lot of the links & mods are discussed in the ASK KEV section, if the link does not work it may be because you are not a paid up supporter & will not have access to those links.
__________________
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


Last edited by Kev; 30-08-15 at 06:14. Reason: Moving things
  #4  
Old 18-02-09, 10:16
Kev's Avatar
Kev Kev is offline
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Join Date: May 2006
Location: Brisbane, Australia
Posts: 6,063
Kev is on a distinguished road
Common Problems XTX & XTR


Cutting out/ Stalling.


This is my research having tested every XT660 ECU from 2004 to 2010 models.

The main problem is Yamaha built a over run fuel shut off system in the fuel injection mapping on the 00 & 01 ECU's 2004 to 2006, so when the throttle is closed & the revs are dropping the ECU shuts off the fuel injecting with the A/F ratio higher than 18:1 until 1750rpm for the 00 ECU & 2000rpm for the 01 ECU then it starts injecting again so the bike can get ready for the idle speed, with the fuel been shut off then start to inject again the motor sometimes battles to keep running & cuts out.

Adding more fuel in the zero zone from 1750 to 2250rpm range using a Power Commander does not fix the cutting out on the 00 & 01 ECU's, adjusting the TPS to 16 & setting the idle to 1500 rpm works better.

With 10 & 11 ECU's 2007 to 2010 models the over run cut off was no longer used & these ECU's only lean the A/F ratio out to 14:1 when the throttle is closed all the way to idle, this almost fixed the cutting out on the 10 & 11 ECU's. The solution for the 10 & 11 ECU s to add fuel in the zero to 2% zones from 1750rpm to 2250 rpm by 5%, this stops the 10 & 11 ECU's from stalling & set your idle speed to 1500 rpm.

Also make sure you TPS is not in the faulty range.

Make sure idle speed is set correct. I would recommending 1500RPM for all years.
http://www.xt660.com/showpost.php?p=22834&postcount=10


Set you CO1 up by at least 10 from your standard dash reading.
http://www.xt660.com/showpost.php?p=174&postcount=1

Make sure your TPS is reading correctly.
http://www.xt660.com/showpost.php?p=175&postcount=1

Recall, there was a recall for TPS on 2004 to 2005 models. Just make sure they fit the new A2 type not the same faulty A1 type.
http://xt660.com/showpost.php?p=15728&postcount=1
http://xt660.com/showthread.php?t=948

Surging
We have all had our share of surging when we first got our bikes. This can be greatly reduced.

Make sure your drive chain is adjusted correctly, not to loose.

Check your sprocket drive rubbers that you do not have any play in them. There should not be any free play when you move the rear sprocket back & forwards. Look in the mod section if you have ree play on the sprocket holder.

Adjust up your CO1.
http://www.xt660.com/showpost.php?p=174&postcount=1

2004 to 2005 models have old software with bad fuelling with a Engine ECU part number that ends with a 00, some riders have had luck in getting Yamaha to replace their Engine ECU's with a 01 ECU. This improves the slow riding conditions greatly & is well worth trying to get your hands on a 01 ECU. If you have a 00 ECU remove the ECU & check for a white paint dot on the back of it, if it has this white dot it means you have e remapped ECU & does not require an updated 01 ECU.

Have a look in the mod section for information on all ECU's

Make sure your TPS is set correctly
http://www.xt660.com/showpost.php?p=175&postcount=1

Below links will give you some ideas as to mods that can be done to smooth out your XT...

(1) Join XT660.com supporters to access the “Ask Kev” 1:1 technical help section -http://www.xt660.com/payments.php

(2) Check you haven’t got a dodgy TPS (which you’ve already done and got fixed) -http://www.xt660.com/showthread.php?t=948 Yamaha Recall

(3) Check you haven’t got a dodgy ECU - http://www.xt660.com/showthread.php?t=519 Yamaha Recall http://www.xt660.com/showthread.php?t=8546 (How to recognise the different ECUs)

(4) Twist-grip mod - http://www.xt660.com/showthread.php?p=154983

(5) Cush drive rubber mod - http://www.xt660.com/showthread.php?t=12422

(6) Adjust your CO - http://www.xt660.com/showthread.php?t=55

(7) Adjust your TPS - http://www.xt660.com/showthread.php?t=56

(8) Fit Kev’s fuel mod - http://www.xt660.com/showthread.php?t=194

(9) Kev's o2 controller http://www.ebay.com.au/sch/7416kevxt...p2047675.l2562



Fitting a fuelling device almost fixes most of the surging, there are a few options.

The best result for no surging is, up your CO1 by 15 to 20 & a Power commander with a custom made fuel map, TPS set to 16.

For the 07/09 models surging, as above & up your CO1 by 10, make sure your idle is set to 1500RPM. I now have a fix for 2007 to present XT660X & XT660R's with O2 sensor.

8/Kev's 2010 New O2 Mod for XTX & XTR's
http://www.xt660.com/showthread.php?t=14746
__________________
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


Last edited by Kev; 06-10-14 at 13:35.
  #5  
Old 06-05-11, 23:42
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Kev Kev is offline
Administrator
 
Join Date: May 2006
Location: Brisbane, Australia
Posts: 6,063
Kev is on a distinguished road
Updated
__________________
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

  #6  
Old 20-06-11, 13:28
Kev's Avatar
Kev Kev is offline
Administrator
 
Join Date: May 2006
Location: Brisbane, Australia
Posts: 6,063
Kev is on a distinguished road
Updated
__________________
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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