My considerably modified XT660R / Tenere part hybrid...!
 

Hi All,
Thought I would post a couple of pics of my XT660R which I have been riding and modifying (improving!) over the last couple of years. Thanks to this forum for a lot of inspiration and tips!

Also a before pic and a during pic...

Good job! , good looking bike! Steve

Thanks Steve! She doesn't look quite as smart as when I'd finished most of the work a year back, but these pics were taken today which is 8000 miles since then...

Very nice mate, it's nice to see some R's rather than ugly as z's

looks good.... love the XTRs....




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Thanks for your help with the shortcomings of a Gili tank Pete

Very nice bike you've made there , have been considering swapping the z for an r as struggle with the weight and height of the z in the mud and ruts around here , how does it fair off-road ?
All the best Mark

Thanks Mark, yes quite a weight saving over the Z. I live on a farm and use it quite a lot off road and am happy. I think it's about as good a compromise as I'll get for on and off road capability... This is with an Ohlins rear shock and KTM 690 front end by the way.

Had considered changing the front end on the z but it's still going to be top heavy and I've only got little legs ! You've made what looks like the ideal bike for me without going orange , if ever you want to sell it let me know will save me the hassle of making a copy ha ha .
Mark.

Nice work mate. Its always good to see some out the box thinking.

Hi, really like the Z headlight. Was it difficult to fit? Any info please...

Hi yep, was difficult to fit! I made a frame from scratch out of aluminium angle, and used some pipe clamps to fix this to the top of the forks, with a bracket at the base to the bottom yoke. It took me a couple of days in the workshop. I can take some closer pics if needed. I had to fit the R display into the frame too,

Drool

Another good thing with the XTR is..
put a high pipe on then lower it 50mm
& you still have 10mm more ground clearance
than it had with the standard low pipes...

good for short legs....




.

If you have the time, i`d be grateful to see the pics on how it all fits. Cheers.

Amazing

This is what I wanted when I had an xtr but didn't have the money to make it happen. Now I've a Z I'm hankering over a bike for two up and then a second bike for my one up and that xtr looks the stuff.

Better get the thinking hat on.......... how do I tell the missus I'm buying a house and it came with two bikes!!!!

Just an update to say how well my modified XTR performed on mainly off road trip in the Spanish mountains... and another pic of course!

Fantastic stuff !!!. I'd ask, is there anything you would have done differently to your build now you've put some miles in to it?

Thanks! I'm pretty happy with all the changes I made, but there was a lot of trial and error particularly with the forks/headlight/screen, but it all seems right now. The main downside is that having a large screen attached to the forks rather than the bike frame can cause the steering to weave at higher speeds, but this is an effective anti-speeding device! Also the Gillimoto tank was a bit of a pain to fit and in itself required a lot of work to seal properly, and fit to the bike (I feel their quality control is a bit lacking...) but having the extra range is really useful.

Regarding the engine, I had the throttle body bored out, and had fitted DNA stage 1 and 2 filters, and a power commander 5. I ended up removing the stage 2 filter as to me it gave the engine an unpleasant sound which aggravated my tinnitus! I don't feel it changed the performance noticeably and I think it's less vulnerable in very dusty or wet conditions. It has more than enough power for me particularly off road.

Great looking XTR. Lost quite a few KGs with the single pipe and new front end I reckon.

What kind of tripple clamp and fork combination are you using? Did you end up welding new steering stops to the frame?

I used clamps and forks from a KTM 690 Enduro. I don't think there was much weight difference compared to the original, but handling has improved dramatically!

No I didn't weld stops to frame, I made some longer stops out of aluminium blocks to bolt to the bottom yoke. I'll take a picture to show.

Okay sweet, hope you were lucky enough to find a used one! Have you crash tested those steering stops already? ;) Wouldn't it snap off once hit hard? A photo would be appreciated.

Yes I found used yokes and forks for a very good price! And yes the stops have been crash tested (well one side anyway) here

I hope they are strong enough...

Those add on for the lower yoke seems reasonably tough.

i may try that on my fork when i convert mine.

did you custom the header to run it to the right side??


Nice setup btw!!

Did them stem from the triple clamps off the tenere fit in the ktm triple clamps by any chance without modifications or was it a straight fit?

Well mine is an R not a Tenere - I'm not sure if the yokes are the same. But yes I pressed the R stem into the bottom yoke perfect fit, I had to machine a bushing for the top yoke though as this had a larger hole. Then of course you have to sort ignition barrel mounting which is not easy if you want to keep the steering lock. And lock stops too....

Also, I threaded the inside of the stem and used the bolt that held the KTM stem to the lower clamp, just to make sure it isn't going anywhere! Sorry, I don't have any pics of the work I did annoyingly.

Cheers matey much appreciated.......doesnt sound like too much hassle as not that fussed about steering lock👍.i will crack on with it now i know and once again thanks i owe you a pint or 5 :YouRock

No problem!

A couple of you chaps have asked for a list of my mods so here you go-


KTM 690 forks and yokes
Easton fat handlebars and risers
Ohlins rear shock
Poly cush drive rubbers (Hunday's)
Sprocket carrier bored to take a twin race bearing
Scorpion 2 into 1 pipe
Off The Road bash guard
Tenere headlight
Adjustable screen
Gillimoto fuel tank
Fehling engine/tank bars (modified to fit the larger tank)
Metal Mule pannier frames and rack
H & B centre stand
Bark Busters
DNA stage 1 and 2 filters
Bored out throttle body
Power Commander V and O2 Optimiser and mapped

I think they're the main ones!

Also here's a little clip of the bike in action.

https://www.youtube.com/watch?v=lXmz...ature=youtu.be