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

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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

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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.

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.

You're right there Tony, that is some serious mod you are undertaking there Kev, but if anyone can do it, you can.:notworthy:

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.

It's not that new, only 2 & half months old with 3500kms on the clock.

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

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http://i201.photobucket.com/albums/a...nupcutaway.jpg

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http://i201.photobucket.com/albums/a...xtx/before.jpg

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http://i201.photobucket.com/albums/a...machining4.jpg