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XT660X to XT700X conversion
Well, tonight the motor came out & there is good & bad news.
The good news I will be able to make the Raptor barrel fit. The bad news it is not a straight fit on kit. 1> XT casings are 2mm smaller then the Raptor barrel, I will machine out the casing 2mm. 2> The outer 6mm hole on the raptor barrel on the cam chain side is 4.5mm out to the casing, I will mill out the holes on the Raptor barrel to line up the 6mm bolts on the crank case. 3> The raptor barrel will need a semi-circle cut into the sleave on clutch side, it is for the crank case breather. 4> The back edge of the raptor barrel will need a 1mm chamfer cut into the sleave to clear the balancer shaft. 5> The outer edges of the XT head will need to be blended to the edge of the raptor barrel, by 1mm. 6>The raptor stage 1 cam is not a straight bolt on cam, the only thing that fits from the XT cam to the Raptor cam is the pin that pushes on the rocker roller. Otherwise you need the decompressioner, decompressioner pin & raptor sprocket, luckily freez gave me a heads up & I ordered these extra parts from the States before stripping. Good news, the piston is the correct height & will need no adjustment. I will full you in as I work my way through this mod, over the next few days. http://i201.photobucket.com/albums/a...x/DSCF2400.jpg http://i201.photobucket.com/albums/a...evxtx/1-13.jpg http://i201.photobucket.com/albums/a...evxtx/2-10.jpg http://i201.photobucket.com/albums/aa202/kevxtx/3-7.jpg http://i201.photobucket.com/albums/aa202/kevxtx/4-8.jpg http://i201.photobucket.com/albums/a...x/DSCF2414.jpg http://i201.photobucket.com/albums/a...tx/cutaway.jpg http://i201.photobucket.com/albums/a...x/DSCF2421.jpg http://i201.photobucket.com/albums/a...x/DSCF2424.jpg http://i201.photobucket.com/albums/a...x/DSCF2427.jpg http://i201.photobucket.com/albums/a...stonheight.jpg http://i201.photobucket.com/albums/a...rockerrods.jpg |
hmm very nice kev hope it all works out for you, sounds like that is quite a bit to change over.
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Good work Kev, I am sure glad you are attempting this rather than me. I hope you get a good torque gain as you want because this looks like a mod to far for me and most others I would of thought.
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Sure is a big mod. I have wanted to do it for a while now & have finaly got around to it.
I will be up at 6AM tomorrow & off to the machine shop to meet (KLR Kev2) & we will machine all the nessary parts. I will post some more photos soon. |
KIN HELL LOOK WHAT YOU DID TO THAT NEW BIKE!!
Im going out to give mine a cuddle!! I hope it all works Kev !! GOOD LUCK I cant look again toooo meny twidly tecanicle fiddly bits !! |
Well that's something only Kev can attempt to do, he sure knows his ways around motors.
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Damn, I was hoping this mod would involve a lot less work, but like you say, it is not so easy.
Good luck with all the mods and I hope the upgrade is well worth the effort. Are you going to port the head while you are at it? There is a few extra ponies in that head and while it is off, it is not much more to get it ported. If you do this right and you get the gains I see possible on the 700R raptors, then you are looking at bumping your Xt's 52 odd HP to around 60 to 64HP mark easy. Imagine that.... your XT would be wicked. |
Todays machining took 4 hours taking it very slowly. We had to machine 0.90mm out of the casing so the barrel could fit into the crank cases with the correct air gap. The material used for the casings on these motor is very poor quality.
To make sure all was well after machining the casings, I pulled off the clutch cover to check the wall thickness between the clutch side & the crank case 4.35mm left after machining. I did a fluid test on the clutch casing to see if any fluid leaked into the crank case, I did this because of the poor material used by Yamaha & was worried about oil pressure on the clutch side. http://i201.photobucket.com/albums/a...x/Workshop.jpg http://i201.photobucket.com/albums/a...chineholes.jpg http://i201.photobucket.com/albums/a...lloutholes.jpg http://i201.photobucket.com/albums/a...eatherhole.jpg http://i201.photobucket.com/albums/a...nupcutaway.jpg http://i201.photobucket.com/albums/a...stfinished.jpg http://i201.photobucket.com/albums/a...xtx/before.jpg http://i201.photobucket.com/albums/a...erupcasing.jpg http://i201.photobucket.com/albums/a...hinecasing.jpg http://i201.photobucket.com/albums/a...ngmachined.jpg http://i201.photobucket.com/albums/a...machining4.jpg |
Well done Kev... You are a brave man to take this on. But I guess that's what sets people like you above those of us with more limited knowledge, and no urge to give ourselves this kind of agro..
Well done Kev, and good luck. |
Got the motor together.
Raptor barrel & piston in. Measured both the XT & Stage 1 camshaft, piston to valve clearances, checked the spring coil gaps. http://i201.photobucket.com/albums/aa202/kevxtx/a-2.jpg http://i201.photobucket.com/albums/aa202/kevxtx/b-3.jpg http://i201.photobucket.com/albums/aa202/kevxtx/c-1.jpg http://i201.photobucket.com/albums/aa202/kevxtx/e-1.jpg http://i201.photobucket.com/albums/aa202/kevxtx/f-1.jpg http://i201.photobucket.com/albums/aa202/kevxtx/g-1.jpg http://i201.photobucket.com/albums/aa202/kevxtx/h-1.jpg http://i201.photobucket.com/albums/aa202/kevxtx/i-1.jpg http://i201.photobucket.com/albums/aa202/kevxtx/j.jpg |
dribbling on keyboard here Kev, stop teasing or I'll get done for perving!! :support:
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Speechless with admiration.
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Will it be a Kev mod on Ebay? lol :toothy12:
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Brings my (lack of) capabilities to reality :090: |
I take my hat off to you Kev, its looking good and I certainly hope it runs well and gives you what you were looking for in terms of performance etc.
I would say you are in a small club of people with this mod LOL. |
Nice work
looking good but how the hell did you open up the crankcase to recieve the barrel shoulder on a universal mill without removing the conrod and using a boring head? No rotary table either? please share this technique, cos im very impressed.
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kev , dyno are waiting for you :toothy10:
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wow simply amazing. League of your own man!
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Motors back in this morning, filled up the motor in the tank & crank case with the correct amount of oil.
Dam I have to go out in ten min's time, the wife is chasing me & will have to wait until tomorrow before I start her. http://i201.photobucket.com/albums/aa202/kevxtx/1a.jpg http://i201.photobucket.com/albums/aa202/kevxtx/3a.jpg http://i201.photobucket.com/albums/aa202/kevxtx/4a.jpg http://i201.photobucket.com/albums/aa202/kevxtx/5a.jpg http://i201.photobucket.com/albums/aa202/kevxtx/6a.jpg |
Got back early from my mate house. Can't wait till tomorrow to start the XT Raptor conversion.
I pulled the spark plug out, disconnected the injector & cranked the bike over for 20 seconds to get the oil pressure up & oil all over the motor. Fitted everything back, hold your breath, heart rate up, right thumb a bit twitchy. Pushed the starter, 2 turns of the motor & off she went. Checked for oil pressure on the oil filter housing, all ok. Switch off & checked for water & oil leaks, looking good so far. Grabbed my helmet & went on a 20 min ride, the tappets got a little noisy as I rode, I expected this & was warned on the Hot Cam print out, I will have to reset them tomorrow morning from cold, I did set them on the big side of the spec. Got back, out with the lead light & checked for water & oil leaks none so far. I had to make my own clutch cover gasket as Yamaha was closed & more then likely would not have one in stock. I will order the correct clutch cover gasket & fit it later. First impressions, alot smoother low down in the rev range, I did not take it much over 3000RPM. I will know more about the performance as the kms get up & the bike has run in. I will book a Dyno run for the 1st or 2nd April & should have it run in by then. I will make a list on what I did & which parts I used. http://i201.photobucket.com/albums/a...evxtx/aa-1.jpg http://i201.photobucket.com/albums/aa202/kevxtx/aaa.jpg http://i201.photobucket.com/albums/a...evxtx/aaaa.jpg |
Kev,
Congratulations on a job very well done! Look forward to see the results after the run-in. Not sure what the situation is in Os, but I can imagine the conversation with my insurance company here after informing them of that 'little' mod!!! Nick. |
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He worked miracles for me this Easter weekend, did all the machining on his days off. The same man that makes the spacer & link kits for us at his cost price. He is a top machinist, he machines up equipment for scientist that spit atoms & laser experiments, you need to see the stuff he makes, he is brilliant. The machining was a bit heart stopping, the only problem was if the rags got caught in the cutter it would have smashed the motor to bits. Kev2 first levelled the motor using a sprit level both ways north south east west. He then clocked the top face, then clocked the inner surface. Calculated all the measurements including clearance around the conrod & over the crank webs. I just stood there & vacuumed the swarf out. He then wrote up a program on his PC & transferred/posted it to the machine. The cut was done in two cuts & worked perfectly total cut 0.90mm. The cutting was done dry. I took off the last 2mm at the base with a die grinder. Removed all the rages & pored 4L of engine oil through the motor. then washed it out with petrol & pored some more oil through the motor. I did not know that the casing needed to be bored out, I did try for six month to find out as much as I could & was told the barrel fitted straight on with only needed the 6mm holes machining. I now question if anyone has actually fitted a Raptor barrel before, I know Off The Road bore & plate the standard cylinder. Here are a few more photos. http://i201.photobucket.com/albums/a...tx/machine.jpg http://i201.photobucket.com/albums/a...inebracing.jpg IMG]http://i201.photobucket.com/albums/aa202/kevxtx/mil.jpg[/IMG] http://i201.photobucket.com/albums/a...vxtx/mill1.jpg http://i201.photobucket.com/albums/a...vxtx/mill2.jpg http://i201.photobucket.com/albums/a...tx/milling.jpg |
Legondary work Kev, and top quality report and pictures. I sure hope it makes you the gains you are hoping for. It's an awful lot of work, just hope its all worth it.
Top work Kev. |
Kev if off the road do a conversion why bother with this? I do appreciate your mechanical prowess & guru status, is it something to do with costs or am I missing a point?
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Let me explain Tony
Off The Road doesn't use a raptor barrell and do not go up to 700cc, but, you need to send them your bits and they will bore them out and send it back to you with a new piston and conrod. You will be then using your same top end and valves etc etc, so you can appreciate that it is more of a bodged job than a full on conversion like Kev has just done. Don't you think Kev would have spared himself the trouble otherwise when money is not the issue he could have easily gone and ordered a OTR conversion. That is why! :) |
Off The Road will supply you a 102mm piston kit, their own special cut piston. I have now proven that a JE 102mm 11:1 piston will fit straight in & no need to pay more then double the price for the Off The Road piston.
I would have needed to send my barrel half way around the world to be bored & plated & then sent back to me, turn around time 2 months. The cost of posting, plating & posting back was around the AUD$600, to buy a Raptor 102mm barrel from the USA cost AUD$400.00 & I could build the motor up in one weekend. As I have said I did not know that the casing need to be bored & was told that it did not need to be bored. After doing this conversion I would do things a little different on my next XT. I would machine the outer sleave on the Raptor barrel. The total time spent including machining was around 11 hours of work lots of measuring parts in this time, the total cost in AUD$ was ZERO for machining & labour. Now knowing what has to be done I recon I could do the mod in 7 hours. I surpose someone had to do it & document for all to see, others have said we have done it, but will not disclose how they have done it & if you want to know how it is been done pay up front first. I have taken the risk to do this mod & have learned a lot more about the motor. I am a mechanic so doing this sort of job is easy for me, I have all the equipment to carry out 99% of all the repairs & mods. I don't need to justify my actions on doing this mod to anyone, but would like to share my findings. It would be up to others by reading my postings about this mod to determine if they would go this far. I can now tick this mod off my list & move onto the next one. I am wanting to source a a second XT660 cylinder head & get it flow bench ported & re-valved with a bigger inlet valve & will fit it at a later stage. I did not do it this time as I did not want to put anymore money into the raptor conversion until I knew that it would fit. It has been proven on the Raptor forums that there is a few more HP to be had from the head & a +2mm throttle body. This mod I have done is a mild mod & I can put my bike back to standard at any stage. |
Cheers Kev, its nice to know the reasons behind the way you choose to go so it offers others who are considering a big bore kit an alternative option and from your excellent postings an informed oppinion can be formed accordingly.
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I have to congratulate Kev for the work he put in.
Now I need to see those dyno reports to see what difference this mod made. I also agree with you, if I have to do this mod, I would take a raptor sleeve and have the sleeve cut to match the XT's crank case. At that sleeve height, there is no compression, so I don't think it will be that risky to run 1mm thinner sleeve at the lower end. I also don't like to bore the sleeve bigger to a 102mm and install a bigger piston. I hate to run a thinner sleeve with higher compression, but it will most likely not be a problem in the long run. My biggest question will be to how much more torque and HP that extra capacity gives you. It only added about 26cc's, but the extra compression and cam will do wonders. Just an example of cost here by me in South Africa. It will work out cheaper for me to bore the XT sleeve and have it coated than getting a new one. That cost will be around 120 Euro for bore and plating, then piston, either from JE or Wiseco, will be another R120 to 150 Euro, cam another 100Euro, with the extras for the cam and gasket, say about 50 Euro and you have yourself a 686cc, 11:1 piston with stage 1 cams for around the same price as a new barrel from Yamaha. |
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Cylinder $389.00 JE piston kit $147.00 Stage 1 hot cam $ 138.00 Gasket set $70.00 Extra camshaft bits $66.00 Total USD$810.00 All the parts came from the States as they we almost half the price then in Australia. Boring & plating a cylinder in Australia cost USD$350, that's why I went for a brand new Yamaha cylinder for ony a few more $. If I get an extra 5HP & a bit more torque I would be happy. The stage 1 cam has approx 0.6mm of more lift on the inlet valve, going by the piston to valve clearance between the standard XT & stage 1 cam. The stage one cam also has more duration on the inlet valve. I need this bike to be ridden in traffic as well in the mountains, I do not want hard starting & cutting out at low engine speeds that normaly comes with high lift camshafts, which might have happened with a stage 2 cam. Who knows I might buy a stage 2 cam & try it. So far done 120kms & it has not missed a beat. The stage one cam is noisy when warm, I have reset the tappet clearance from cold again. |
Personly I think it is a TOP CLASS job and I wish I had the balls and the
know how to take on such a job well done Kev I hope you get a long and trouble free service from the bike!! :Worship_9TRHEA: |
Exellent job mate, congratulations.So to fit hotcam stage 1 in our bikes, we need to by also these parts from the raptor?
REF NO. PART NO. DESCRIPITION 9 1S3-12176-00 Sprocket, Cam Chain 4 1S3-12290-00 Lever, Descompression spring 5 1S3-12280-00 Descompression assy 7 5VK-1111F-00 Plate I�ve took this part numbers, from the parts catalogue of raptor 700r.Please correct me if I�ve made a mistake.:100::100::100: |
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I am trying to sort out a Standard piston conversion with JE pistons a 11:1 100mm bore.
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Luv ya work Kev :notworthy[1]:
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Kev, you are the man:clap::clap::clap:
Excellent work |
Thanks Kev, very very good,seems that my bike will have some extra power with this mod.Excellent thead this one...:038::038::038:
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One more question Kev.If we buy the hotcam stg1, and all the necessary parts from the raptor 700 to install the cam as you said, it will be an straight bolt on mod.Correct?We only have to do the correct valve clearances before changing the cam for the baby to run OK.What should be the correct valve clearances for the hotcam stg 1?Do you think we can gain 2 horsepower with the stg1 raptor cam?It is a reliable mod?
Sorry to make too much questions:hae18::hae18: |
Dear Brunobarcia and everyone else. As from today Kev is taking some time off and will not be available for answering questions.
We can help answer some of these provided they are within our limited knowledge otherwise please be patient until Kev will return. Could be a week, or more, I am not sure. |
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