I fitted a PCV to my XT660 Tenere today and thought I'd share some tips with you.

The instructions say that you have to remove the tank to connect all of the cables. I didn't want to go through with the faff of draining the tank, removing the hoses/connectors, etc. I managed to do all of the job without getting the tank off which was a result. A small bit of wood wedged under the rear of the tank allows it to be jacked up by a couple of inches and gives just enough space to get the job done.

All of the connectors are locking so have a look at the connectors on the PCV loop to work out how to unlock them. You'll need a small screwdriver and a bit of perseverance.

The instructions also recommend that you fit the PCV unit to the rear of the bike under the seat. The loop on mine wasn't anything like as long as that so it wasn't an option. I nearly placed it on the flat area in front of the airbox but then spotted that it wedges perfectly with an interference fit into the space where the toolkit should fit. It's a clean fit and doesn't contact the seat at all.

Another note is that if you feed the PCV connectors through the thin, top end of the rubber boot that covers the original connectors you can side the boot back down and cover them again. I found that unbolting the rear brake reservoir gave much better access to that area too.

I hope those tips might save you some time.

I can remove the tank on my Z without draining it all the connectors are self sealing with no leaks

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XT660z NO MORE.

Is that standard or something that you fitted? I was just going by the instructions in the service manual.

No, the pump seals if it's not running. What's in the hose will drip out of course, but that's a fairly insignificant amount. It's still worth trying to have a fairly empty tank, because 23 litres of fuel is heavy!


You must have insanely small, double jointed hands. I fitted my PCV over the weekend, and ended up taking the airbox out to get at the TPS connection.

(Conveniently, I had the undertray out anyway)

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I spent a lot of money on travel and racing motorcycles - the rest I just squandered.

XT660Z - Commuter, Adventurer...Racer?

www.dashmoto.net

Other bikes >> MT-03 / CG125BR-J / ER-6F
Departed >> ZXR400L3 / EC300 / DR-Z400E / DR800S / GPZ500S / GS400

And be a Jedi master........

It was a while ago, but I recall using some tyre levers to assist in re-connection, and lucky for me it was stupidly cold, so I couldn't feel my fingers which made bending them backwards easier as I couldn't feel the pain.

On reflection, given that it takes a few minutes to take the tank off, I should have removed it. Of course, this is once you know how to take the tank off....

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>-------<

Never underestimate the power of stupid people in large groups.

Damn - that could have made the job a little less fiddly

I have nimble fingers fairly small hands and a lot of perseverance!

Where did you mount the PC in the end? Were you able to use the mounting point in their instructions?

I haven't actually mounted mine anywhere yet, as I'm doing some other stuff to the bike while it's apart. It will be going in the tail under the seat, but that's because I don't have a standard undertray any more, and thus I actually have some room under the seat.

The instructions for my PCV relate to a Raptor Quad, so they weren't much use to me

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I spent a lot of money on travel and racing motorcycles - the rest I just squandered.

XT660Z - Commuter, Adventurer...Racer?

www.dashmoto.net

Other bikes >> MT-03 / CG125BR-J / ER-6F
Departed >> ZXR400L3 / EC300 / DR-Z400E / DR800S / GPZ500S / GS400