Home

Go Back   .: XT660.com - The #1 XT660 Resource :. > XT660X & XT660R > XT660X & XT660R General Discussions
FAQ Calendar Search Today's Posts Mark Forums Read Main site

Google

XT660X & XT660R General Discussions General discussion related to XTX & XTR Only

Reply
 
Thread Tools Display Modes
  # 1  
Old 23-08-10, 12:40
richardsracingmad richardsracingmad is offline
XT-Moto SuperStar
 
Join Date: Jul 2010
Location: the South
Posts: 875
richardsracingmad is on a distinguished road
Big Bore and Gas Flowed Head Project

Ok, after my Stage 3 DNA Airbox mod (with a Power Commander and cans), I am looking at doing further modifications now to compliment the DNA Airbox.

What is so good about the DNA Airbox, you don't lose any power or torque anywhere, and the improvements are in a very wide area of revs, right from just above tickover to the rev limiter. This makes it a cracking mod in my books.

(With some mods, you lose power at one end, and gain on the other end; normally the top end of revs).

So, I am looking at a Big Bore, which should give me gains through the rev range, and a Gas Flowed Head.

This should give me a nice and smooth power boost, and I am hoping for a total gain, with my existing mods, of around 10-12hp over a Standard bike.

I have just started this project, it will probably grow and change a bit, and have sourced a second hand barrel, but I am looking for a spare cylinder head. If anyone has one, please pm me, thanks.

Last edited by richardsracingmad; 01-10-10 at 09:48.
  # 2  
Old 23-08-10, 13:11
Kev's Avatar
Kev Kev is offline
Administrator
 
Join Date: May 2006
Location: Brisbane, Australia
Posts: 6,063
Kev is on a distinguished road
You will need these.

http://cgi.ebay.co.uk/GENUINE-YAMAHA-CYLINDER-BASE-GASKET-XT660X-XT660R-/380239567677?pt=UK_Motorcycle_Parts

http://cgi.ebay.com/ebaymotors/Yamaha-Raptor-Grizzly-700-EST-Top-End-Gasket-Set-103mm-_W0QQcmdZViewItemQQitemZ220636955493QQptZMotorsQ5f ATVQ5fPartsQ5fAccessories

http://cgi.ebay.com/ebaymotors/COMETIC-EST-TOP-END-KIT-103MM-YAMAHA-RAPTOR-700R-06-_W0QQcmdZViewItemQQitemZ380260180414QQptZMotorcycl esQ5fPartsQ5fAccessories

I would use this piston if I did it again. The difference between a 102mm 11.5:1 & a 103mm 11:1 piston would be less than 1 HP difference.

http://www.tqsatv.com/proddetail.php?prod=RAPTOR-700-TECH-PISTON
__________________
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; 23-08-10 at 13:22.
  # 3  
Old 23-08-10, 13:48
richardsracingmad richardsracingmad is offline
XT-Moto SuperStar
 
Join Date: Jul 2010
Location: the South
Posts: 875
richardsracingmad is on a distinguished road
Kev...thank you for those links!! Top Geezer!! I was wondering.........

Firstly....I didn't realise the bore needed plating, however I have found someone who does Nikasil ...so no problem with that. Would the bore wear out quickly without it? Is it an alloy bore, coated as standard?

Secondly,

...on the Carillo site , the CR pistons are either 11:1, 12:1 or 12.5:1?? Not 11.5:1 ?????
Is the CR piston forged, and the others not? Is that why its dearer/better?

I have found a JE 103mm piston kit 11:1 (item no. 360083541989 on ebay.com) , he will send it carriage free to the UK at $171.99, and a top end gasket set for $68, about �155........I'm think I'm going to go for that..........

Thirdly, do you think a gain of 10-12 hp is on with this, over Standard, with my mods?

Last edited by richardsracingmad; 23-08-10 at 18:20.
  # 4  
Old 23-08-10, 13:49
A7 UFO A7 UFO is offline
Expert XT-Moto
 
Join Date: Apr 2010
Location: Basingstoke
Posts: 105
A7 UFO is on a distinguished road
being just up the road from you, I'd be interested to see the results of your conversion
__________________
  # 5  
Old 23-08-10, 23:20
Kev's Avatar
Kev Kev is offline
Administrator
 
Join Date: May 2006
Location: Brisbane, Australia
Posts: 6,063
Kev is on a distinguished road
You will need head work & a +2mm throttle body to get that HP with a standard cam.

All the research has been done on these conversion have a read on what HP you get from what mod in the mod section.

Have a look at my dyno runs with just the big bore with a 11:1 102mm piston it got an extra 2.5 HP gain so I would expect the 103mm to have around 3 to 3.5HP gain. You would have less vibration from the motor with a 102mm piston unless you get the motor balanced.

CP do make a 11.5:1 is has been around for a while now, I have seen good results with this piston with dyno runs. The link I gave you is a valid.
__________________
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; 23-08-10 at 23:28.
  # 6  
Old 24-08-10, 08:50
richardsracingmad richardsracingmad is offline
XT-Moto SuperStar
 
Join Date: Jul 2010
Location: the South
Posts: 875
richardsracingmad is on a distinguished road
Thank you Schoemrich for the barrel ! I collected it last night....you have a nice bike project XT there mate, I am looking forward to seeing that coming together in the New Year!!

CP have returned my email and confirmed a 686cc 102mm 11.5:1 CR piston.
Kev is pointing me towards this, thank you for your input mate, but I would like a 700cc conversion...

So, I'm going to go with the JE piston kit, a 700cc 103mm 11:1 CR piston. (a Standard bike has 10:1 CR, so this is still a good compression boost.)

I have now ordered it today, and will wait for it to arrive from the USA, so that I can take the new piston and the barrel to the machine shop to get a match.

I am hoping to see gains on my bike of around 10hp..this is my estimate..

My Standard Bike with PC111 44.50HP
With DNA St.3 airbox and CCC 50.00HP (49.01 so far -not been fine tuned)
With JE 700cc Piston 11:1 53.00HP
With a gas-flowed Head 55.00HP

I am hoping that the standard throttle body can chuck in enough air/fuel to make it work properly.

Torque wise, I am looking a similar gain of a total 10ft/lbs.
Torque gains in the low to mid range - is the really important part of the Project for me...

Money-wise for just the 700cc conversion, my estimate,
Spare barrel �60
Machine/ plating �130
Piston kit �115
Top end gasket �37
Bottom gasket �10
Oil sundries �20

Total �372


Now, I am turning my attention to the cylinder head. I am thinking of keeping the standard valves, in order to keep the torque gains to the maximum, at lower revs. I am keeping the Standard Camshaft. Or would bigger valves still give as much gain in low revs?
So, I am looking for a cylinder head.....anyone??

Last edited by richardsracingmad; 26-08-10 at 08:01.
  # 7  
Old 24-08-10, 17:47
dazmatic dazmatic is offline
XT-Moto SuperStar
 
Join Date: Jul 2009
Location: leiston
Posts: 358
dazmatic is on a distinguished road
would a raptor head Fit?
__________________
09 XT660X:

CCC Stainless Rounds, Stage 1 DNA, Stage 2 DNA, PCV With Custom Autotune Map, PCV AutoTune, Home made O2 eliminator, Self machined Fork Spacers, DIY Autotune Switch.
  # 8  
Old 24-08-10, 17:51
richardsracingmad richardsracingmad is offline
XT-Moto SuperStar
 
Join Date: Jul 2010
Location: the South
Posts: 875
richardsracingmad is on a distinguished road
apparantly the Raptor head wont fit.....I am ringing round Breakers, but they will only sell a whole lump. And I don't want a whole lump, well not another to go with my tuned ZZR x2, ford X-FLOW x3.........I'll be stubbing my toes on it.

By the way..i've had 192bhp out of a ford x-flow (Mk1/11 Escort)...i couldn't keep it in a straight line even with a LSD .....
  # 9  
Old 24-08-10, 17:54
dazmatic dazmatic is offline
XT-Moto SuperStar
 
Join Date: Jul 2009
Location: leiston
Posts: 358
dazmatic is on a distinguished road
Doesn't the Capt have some spare bits?
__________________
09 XT660X:

CCC Stainless Rounds, Stage 1 DNA, Stage 2 DNA, PCV With Custom Autotune Map, PCV AutoTune, Home made O2 eliminator, Self machined Fork Spacers, DIY Autotune Switch.
  # 10  
Old 24-08-10, 19:30
richardsracingmad richardsracingmad is offline
XT-Moto SuperStar
 
Join Date: Jul 2010
Location: the South
Posts: 875
richardsracingmad is on a distinguished road
No, not any more.....Someone must have a cylinder head.....

I'm looking at possibly adding a +2mm Throttle Body...but I need to understand how it will help my Conversion...I'm not convinced at the moment, as it has been only used on the "big power/ hot cam" conversions.
Has anyone tried one with a standard camshaft?
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT +1. The time now is 16:02.
Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.

  XT660         Archive   Main site


Footer
vBSkinworks Top