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2004 to 2006 ECU's have twin spark ignition systems for emission control, the ignition fires every 360 crank shaft degrees to burn off the hydrocarbons left over from the power stroke. This second ignition sparks when the exhaust valve is open & will light up the unburnt fuel this is where your popping comes from, by blocking off the AIS you are stopping fresh air from entering the exhaust header this helps reducing the popping but won't stop it completely. Make sure you Co is not adjusted over 20 this will help with reducing the popping back.
From 2007 to present the ECU is a single spark ignition where the ignition fires every 720 degrees, it only fires on the power stroke. When you block the AIS there is no fresh entering the exhaust header * there is no spark to light up any unburnt fuel, 2007> onwards the popping is reduced by 99% by blocking the AIS pipe.
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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 /
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My 07 XTX
Raptor 700 cylinder 102mm
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Modified Crank Case to take a 105mm Raptor Cylinder
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11:1 102mm JE Raptor piston
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Stage 1 Raptor Hot Cam
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Ported head
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Colder Spark Plug
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+2mm Throttle body
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DNA stage 1 & 2 filters
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Modified Air Box
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Snorkel removed
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Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts
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Recovered seat in Black
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O2 Eliminator
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My 09 XTX
59HP
at the rear wheel
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Stage 2 Raptor Hot Cam
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DNA stage 3 Air Box
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Carbon Can Exhausts
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Modified Exhaust Link Pipes
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PCIII With Custom Fuel Map
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Wideband Commander O2 Data logger
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LCD100 Dyno Jet display & fuel adjuster
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2500 OHM HT lead instead of a 10K OHM XT lead
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Extra Coolant Cooler
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Protaper Fat Bars
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Tail Tidy With LED Tail Light
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OKE Protection Knobs
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LED indicators
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AIS blocked
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Modified rear sprocket rubbers
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Rear Foot Pegs removed
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09 ECU With 02 Sensor Changed To A 06 ECU
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Complete wiring harnes Changed from 09 to 04
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Home made LED resistor flasher
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Hole drilled in the fuel tank filler neck to allow quicker filling
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Modified Bar End Weights
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Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer
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Changed front & rear guards from blue to black
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47T rear sprocket
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Speedo Healer V4.0
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Kev throttle cam mod
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Throttle grip mod
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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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