Hi folks, after just ordering one of Kev's magic boxes to make my 09/10 XT660z run a bit "smoother" than it already does I have another thing I would like to sort out.
The bike seems to pop & bang a lot from the exhaust which I'm led to believe is normal anyway. It is totally standard but would prefer not to have this noise.
I read somewhere (can't remember where now) something about to cure it to block off the air injection system with an m10 cap screw & the popping/banging goes away.
Is this correct & if so can anyone tell me where exactly I can find said hose to "block off & if I do so will it effect the running of the bike in any way?

Ta muchly

P.s The popping & banging from the exhaust doesn't affect how the bike rides in any way, it's more of a preference for me, thats all.

Hi mate,

Seems you are running rich in fuel/air mix. To cure you should set back the Kev's mod to, let us say, six o'clock and see what happens. Play a little with the settings for best effect I.e. Fuel economy, power delivery, smoothness.

If you are running standard exhausts cans you should not try to block the AIS (the tiny pipe that goes out of the engine between the two exhaust pipes and connects to the air box), as this will eventually clog your catalyst and make the bike run worse. However if you change to aftermarket cans than you are more than ok to remove/block the AIS. The standard system is designed for letting air in the exhaust which actually helps the catalyst to warm up fast and work more efficiently.

Hope this helps.

Enjoy the holiday season.

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Mods so far:
Hyperpro front springs; Hyperpro rear shock spring; modified air box; LED tail light; LED indicators + new relay; YZ pegs; Lucas aluminum bar; brisk spark plug; snorkel removed; DNA stage 1; second hand DynoJet O2 mod; crash bars; front and rear steel braided brake lines; soft EBC brake pads; mitas 07 tyres, 2in1 Metal Mule exhaust, Blocked AIS, tall OEM screen, OTR bash plate

Block off your AIS pipe that will stop the banging & popping. http://www.xt660.com/showthread.php?...d=1#post101266

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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

Thanks Kev.
I assume this is the pipe I will need to block or plug up either from the airbox hole or the pipe itself? It's at the very top right side (if sat on bike) with a mesh like material around it


Kev one thing I did notice when I took the side casing off the air box was this (see pic) someone has sealed the breather hole/pipe up with what looks like araldite, properly sealed.
Why would anyone actually do this, I mean is there a benefit to this & should I just leave it?
(The air box itself is clean, dry & oil free btw)
Thanks again.

Yes, it is the braided hose that needs blocking or clamping.

That "T" connector in the air intake pressure sensor vacuum line is normally connected to something I hope? Looks suspiciously like someone has tried to block it with some sort of goo? Maybe you have a Scottoiler fitted and the vacuum take-off was removed in the photo, or perhaps it did have one fitted and a previous owner has attempted to block the connector?

As for the airbox drain, I can't understand why anyone would block it off? It does still have the rubber bung in the other end? If I were you, I'd unblock it as it is the only visual tell-tale that you have water or oil in the airbox. I know you don't at the moment, but best to prepare for the future.

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Hi, that "T" connector was there when I purchased the bike & no scott oiler fitted, doesn't mean it didn't have one fitted at some point tho.
Apart from looking untidy I assume its ok to leave as is?

I'll have to look at removing what they've sealed it with, it's properly set like stone so god knows how to get it off. we'll see.

More questions from the newbie.. (mudguard went on with some persuasion Pleiades, thanks!)

I'm pretty happy with everything, but am planning to do the TAT with the bike and want to have everything squared away. I'm also having trouble with popping and banging. It did this with the stock exhaust. I've now added an Exan oval classic and the popping is a bit obnoxious, particularly for long distance trail riding. I have made no further mods. Does this means it is running rich? Does this cause long term problems, or just scares yorkshire terriers?

Any ideas and solutions would be appreciated by all!