Hi

I have manage to cause some damage to my XT's motors sleeve and need to replace the pistons and rings. I would like to go a little bigger on the piston size.

So far all I could find is the Raptor oversize kits from Wiseco and JEPistons.

The 102mm overbore is what I would like to use on the standard XT motor. Has any of you done this before?

Could anyone please advise me on a few small things I need to know before I start and just any help/info on doing this would be good

Firsty the Piston Pin - 22 x 14 x 57.15mm SW that comes with the kit seems to be smaller than the one in the standard XT660R piston. Am I correct? This pin will not fit on the conrod? The one on my standard piston is 23mm and the kit says 22mm? Looking at this it will be a problem for fitting.

The overbore is 2mm. Will taking off this aluminium cause the engine to overheat or not?

Thanks

I just found this piston kit. Will it work?

http://www.wiseco.com/ProductDetail....09&AppID=28655

http://www.off-the-road.de/de/XT-660...660-R-X-Z.html

There are a few of us that have done a 102mm conversion. I am helping with a 105.5mm XTX conversion next weekend.

You can use any Raptor 700 piston, if you are using 98 or 95 RON fuels you can run a compression ratio up to 11.5:1.

I would only use a CP piston as this piston has the longest piston skirt out of the JE & Wisco Raptor 700 pistons. My last JE 102mm piston kit only lasted 10000KMS (6K miles) & developed a rattle because of the short piston skirt. You can buy a corrected deck height 11.5:1 or normal 11:1 CP piston I would only use one of these. You can bore the standard XT660 cylinder to 103mm to make it a true 700cc, this has already been done read below.

Have a read in the modification index you will find more info on big bores.

http://www.xt660.com/showthread.php?t=630

http://www.xt660.com/forumdisplay.php?f=52

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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

Hi Kev

I live in South Africa and we are a little limited to suppliers. I deal with a supplier that only get parts from Wiseco pistons.

Can you maybe give me a part number of the piston kit and gasket that you would recommend I get. If you know of a USA company that will ship to South Africa I would then buy direct if possible.

I had a look at the other pages/threads you posted and this looks wow?
Raptor 660 Cast Cylinder Kit 727cc .
http://www.whiteknuckleracing.com/index1.html

Will this work? Otherwise I will just go for the 102 overbore.

http://www.wiseco.com/ProductSearch.aspx
http://www.wiseco.com/ProductDetail....09&AppID=28659

I appreciate your time and input. Thank you.

None of the Raptor 660 pistons fit the XT660, so look at the Raptor 700 pistons as they fit. Send Freez a PM he will know of a local CP piston supplier in SA.

USA Ebay CP 11:1 piston kit.

http://cgi.ebay.com/Raptor-700-CP-piston-stock-bore-102mm-11-1-comp-NEW-/290548089746?pt=Motors_ATV_Parts_Accessories&hash= item43a6040392

http://cgi.ebay.com/ebaymotors/Raptor-Rhino-700-102mm-11-1-Std-Bore-CP-Piston-w-Gasket-/350365325365?pt=Motorcycles_Parts_Accessories&hash =item5193669835

If you are running a 102mm piston this is the one I would use.

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

Here is a picture of my XT660R. Not a pretty one! I am doing some mayor mods and repairs for more extreme terrain riding.