Hi all,

Having some problems with the bike. XT660R 2004. (has had TPS sensor warranty replacement)

It had been idling high when in gear for a week or two, would return to normal idle speed when knocked into neutral.

Then it stalled at the lights, didn't think too much of it, maybe me?! Then 3 days later, got out to bike after work and struggled to start a little, then stalled immediately as I pulled away, started back up and then died as riding along at slow speed out of car park. Would not restart at all...

Left bike at work and got lift home, read error codes before I left. Only one, #30 (bike went down). Got back in the morning and cancelled codes, bike started, still hesitating but managed to limp the bike back home.

Checked the voltage reading on channel 08, lean angle safety switch control and was in normal range, so assume this code was just an old on from a laning off...

Since then bike has just been in shed awaiting time to fix. Tried starting it a couple of times, couple of times refus to start (just cranked over), sometimes starting up then stalling, when it was last running it had the same high idle in gear.

So seems I have some sort of sensor related intermittent running problem.

I have got the Ignition system Electrical troubleshooting pages to go through and check resistance of Coil & Crankshaft position sensor, will also check lean angle switch.

Has anyone seen similar symptoms/know where to start?

Firstly welcome to the forum.

Just a pointer we have a search bar at the top of the page which comes in handy when finding posts on the forum, I typed in fast idle & came up with these posts.

http://www.xt660.com/search.php?searchid=1835576

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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've been a lurker for a while....

Yep I had a look on search but couldn't find anything identical to my issue, did point me into looking at CPS & Coils. Just found this one through your link:

http://www.xt660.com/showthread.php?...ight=high+idle

Added Clutch, Sidestand & Neutral switch onto my list of things to check.

Also check for faults in the dash.

__________________
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

Right had a look at everything I could think of today.

Other strange thing today was that it started ok (ish, still struggled a little) and would sit there and idle by itself. But still reliably idling high in gear. When you rev in neutral it returns to normal idle speed, when put in gear it stays at normal idle, once revved it doesn't return to normal idle until you knock it back into neutral.

Started by checking for faults in the dash, nothing recorded. Whilst in diagnostic mode check all other channels, Throttle angle, lean angle switch voltage, vehicle speed pulse etc. Also checked the sidestand & neutral switch were operating correctly through diag mode.

Also checked for clutch switch operation. It registered continuity part way through pulling then clutch and then died off when closer to the grip, don't know if this is normal.

Checked Crank position sensor. Range 192 - 288ohm. Read 280ohm.

Checked Ignition Coil.
Primary coil resistance range (@20c which it wasn't today!) is 3.4 - 4.6 ohms. Read 5.0ohm.
Secondary coil resistance range 10.4 - 15.6 kohm. Read 23.42 kohm
Pretty far out of range, anything to do with closer to freezing temps today??

Checked as much of the harness as I could for any frays/rubbing etc.

What do you reckon?

Have ordered myself an ebay coil to give a go.

Other thing worth mentioning was that when I measured the resistance on the CPS, it was slowly decreasing as I was reading with the multimeter.

Going to try it again tonight and see if I can get the bike to stall, then take the measurements again.