I also want to thank you all for the prompt support

Thanks, don't mention it, that's what we're here for.

Thats amazing Capt Moto diagnosing a bike without seeing it.How do you know that there is no problem with clutch adjustment.These things can be marginal and are always best eliminated as it only takes 2 mins to check.If the knurled adjuster on the clutch lever vibrates loose then the adjustment can change and the clutch may not fully disengage contributing to cutting out or stalling when the gears are disengaged or selected.Also XT's have this adjuster underneath a rubber cover so it is not something that you would see unless you specifically looked for it.All views welcome.

I detect a hint of sarcasm. Look pal, of course I can't give you a definite cause of the problem without seeing the bike, I am not a magician but you know what funny man, we've been dealing with these bikes and their common issues almost since time began.

As for Kev what he doesn't know about the XT's its not worth knowing, personally I don't have ANY mechanical expertice or knowledge, as I am more of a bike abuser than a mechanic but, having owned the same bike for long enough to know what is likely to go wrong and also having run this forum shoulder to shoulder with someone with the knowledge and experience of Kev, I can confidently say that working by eliminations and suggesting to check the most common faults first, would help myself and Kev to figure out what is the cause and then suggest a solution, bear in mind that the OP has stated that his mechanics couldn't see anything wrong, if they are only half good they would have spotted an insufficient clutch "bite" and let me also remind you these clutches have self adjusting plates that even with the slightest of "play" in their action will eventually do what is designed for them to do and that ultimately in our experience, problems with clutches on these particular bikes have been as rare than hen's teeth.

:064:

Another vote for the side stand switch !!! Check it is making proper contact with a multimeter or if you can't just cut the wires and join together then insulate with tape.

Sorry your upset I don't think it's very fair to just dismiss my suggestion as it is not impossible for this to be the case.If you think it is unlikley then fair enough,according to Kev everyone's view is welcome pal.

No worries mate I was not upset. And yes all views are welcome, so keep them coming. :hippy2:

FINNALLY somone having the same problem, the dealers pretty much tell you your making it up when you tell them but now i can show them this thread and tell them to sort the ****er out!

Don't get suprised. The same thing happened to me at the official service store here in Athens (Greece). When I asked about it they affirmed that this kind of problem hasn't been reported. The forums reveal another truth.

We have seen this problem since 2004 on all XT variants, bike cuts out as you blip the throttle on the down change, 90% of the time lifting the idle speed to 1500 rpm fixes the problem, 5% is from riders adjusting their Co to rich which can also cause the bike to cut out & the other 5% is unexplained.

So far I have not seen one problem rising from a failed or incorrectly adjusted clutch switch. The clutch switch is there to let the ECU know that the clutch has been pulled in when trying to start the bike in gear, the clutch switch also supposed to tell the ECU when the RPM is below 2000rpm to adjust the ignition timing to assist the idle speed which does not seem to work on the XT660's. On other bikes the clutch switch can be used to lift base idle speed by dampening the falling idle speed before base idle via a stepper motor.

Set your idle sped to 1500RPM when the bike is at operating temperature & let us know how you get on.