Hi there guys, this is my first post, so I'll begin with a short introduction, and apologize if I've put this thread in the wrong section, it's a little confusing this forum :

I'm a 24 y/o guy from Sweden, and am currently on my fourth (out of five) year studying to get my masters degree in industrial engineering. I deeply enjoy building things in my spare time and I'm quite the gear head. Previous projects have involved a 100kg rc wheel loader, a 200kg rc combat tank, a downhill bicycle frame, a snowmobile and this very small (but fully driveable) rallykart, all of the projects have been built from scratch.

Below is a set of images of the kart:











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If you want to see more images or details, you can do so here: http://www.antondanielsson.com/

I'm currently at the stage were I need to sort out the wiring loom and engine to be able to perform a first testrun, I've never fired up the engine and bought it second-hand (low mileage I was told, but who knows).

The info I've got from the seller was that it was a XT660 2009 engine. However, I've not been able to locate the O2 sensor.

UPDATE: My ECU is a 5VK-8591 A-00, which should therefore be a 2004-late 2005 model. So thats settled then. Sad to find out that this ECU is worst in regards to the surging problem.

In fear of damaging the engine, I have a few questions that I'd like to run past you guys with more knowledge about this engine:

1. See update above.

2. I need an air filter, I haven't got the stock air box so I'm probably looking at buying a universal filter much like the Stage 3 filter (but without all the air box things). I have an exhaust (If my memory is correct) from a Raptor 600. My goal is to get it started and test-driven before I jump the gun on an expensive Power Commander. But is there a great risk of damaging the engine if I run it with a S3 filter + Raptor 600 exhaust without a power commander? Oh and I will plug the AIS hole.

3. Oil filter/system. I have a suspicion that previous owner had an oil cooler mounted on this engine, and as far as I'm aware, the stock bike has sort of a built in oil cooler in its frame? I've bought a standard oil cooler which I'm planning on connecting (the blue thing right in front of the engine in some images). But I'd like to be sure I've understood everything correctly. Therefore i've made a couple of images with a unique number assigned to each hose, so lets play "identify that hose"







1. Oil?
2. Cooling water (to bottom radiator)?
3. Oil?
4. Vacuum(to airbox?)
5. Vacuum(to airbox)?
6. Cooling water (to top radiator)?
7. ?

4. Fuel system. UPDATE: I've now bought a second hand original fuel pump, I'm hoping this will just be a plug and play installation once I manufacture a tank to fit it in.

5. Electrical system. Are there any potential problems I might face when adopting the loom to this kart? As far as I know, I need to pay attention to the stand switch and tilt/angle cut off switch. Other than those two, It should be just "plug and play" if I understand correctly.

Any other advice or heads up?

Phew, that's about it I guess. I'll probably have more questions later on. Really very big thanks in advance.

bUMP...

__________________
2005 XT660X
" My mouth was drier than an Egyptian�s sandal and my palms sweatier than a fat girl�s bra". Jamie Robinson.

Welcom, and nice project!

I dont i can help you with your questions though, your skills seem to be more advanced than mine...

If you modify airfilter and have aftermarket exhaust, fueling needs to be adjusted. So you will at least need Kevs fuel mod, and perhaps the O2 sensor mod aswell, but of that i'm not sure.