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Performance Modifications & Enhancements Engine, Fuelling & Throttle performance mods

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  # 1  
Old 22-07-06, 02:14
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CaptMoto CaptMoto is offline
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Faulty ECU affected range

The 2 attached documents I have got from JMC are leaked internal Yamaha UK memos to all dealerships and service workshops.

They show the range of the faulty ECU's up to frame number related, best thing to do is to check if your frame number falls within this range and if so print these 2 documents and take them to your dealer and they shall have no problem in sorting you out with a new ECU

The quality is not perfect but you can just about make out the frame numbers. Sorry but this was obtained by a mechanic and not officially from Yamaha.

For the benefit of all please note these are the affected frame numbers

XT660R Up to frame no. DM015-007858
XT660X Up to frame no. DM014-006257




And thanks very much to JMC for helping me with this even though now you are on the other side of the world, its great that you kept these things safe.

Last edited by CaptMoto; 17-06-11 at 00:53.
  # 2  
Old 22-07-06, 14:41
g-tec g-tec is offline
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When you say faulty do you mean-cutting out because i think that my XT-R is in that range(it is 2005.) and it's not cutting out
  # 3  
Old 22-07-06, 14:56
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Quote:
Originally Posted by g-tec
When you say faulty do you mean-cutting out because i think that my XT-R is in that range(it is 2005.) and it's not cutting out
Dear g-tec, the XT660X & R were put on the market in mid to late 2004, as you can see from the attached fax, the first batch of bikes came with a faulty ECU that fault was in the fuelling setting, most of these bikes had serious cut out issues at low rpm, hence Yamaha recognized the problem and offered a free ECU replacement to all owners. Supposedly all bikes built after 2005 should come with the new ECU, however we have heard stories of bikes built after '05 with the same problems which is why I have decided to post this message for owners.

The old saying: "if it ain't broke don't change it" means you are one of the lucky few so don't worry. or..... perhaps your bike was within the range and if you have bought it 2nd hand someone has already changed it or... Yamaha replaced it from the dealership before selling it to you. Open the right hand side panel under the seat that covers the air box and read the number on the ECU to see if its the new or old one.

Last edited by CaptMoto; 22-07-06 at 15:01.
  # 4  
Old 22-07-06, 17:42
g-tec g-tec is offline
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I am first owner,bought it in july last year,i will check that number Thanks for fast reply
  # 5  
Old 22-07-06, 20:54
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I didn't saw nothing on right side,i think that you ment left side because there is something that looks like ecu if i am not wrong
  # 6  
Old 22-07-06, 21:08
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depends on your definiton of left and right in relation to the bike lets simplify this by saying look on the gear lever pedal side of the bike as opposed to the brake pedal side, i.e. the side where your chain and sprockets are.
  # 7  
Old 09-04-07, 10:43
shamusxtx shamusxtx is offline
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Quote:
Originally Posted by CaptMoto
Dear g-tec, the XT660X & R were put on the market in mid to late 2004, as you can see from the attached fax, the first batch of bikes came with a faulty ECU that fault was in the fuelling setting, most of these bikes had serious cut out issues at low rpm, hence Yamaha recognized the problem and offered a free ECU replacement to all owners. Supposedly all bikes built after 2005 should come with the new ECU, however we have heard stories of bikes built after '05 with the same problems which is why I have decided to post this message for owners.

The old saying: "if it ain't broke don't change it" means you are one of the lucky few so don't worry. or..... perhaps your bike was within the range and if you have bought it 2nd hand someone has already changed it or... Yamaha replaced it from the dealership before selling it to you. Open the right hand side panel under the seat that covers the air box and read the number on the ECU to see if its the new or old one.
I agree , as posted elsewhere , my 05 XTX ran sweet ( i.e no cutouts ) untill yamaha replaced the TPS ( recall ) , now it cuts out and runs like a bunch of monkies arggggggggghhhhhhhhhhh
  # 8  
Old 09-04-07, 12:16
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Quote:
Originally Posted by shamusxtx
I agree , as posted elsewhere , my 05 XTX ran sweet ( i.e no cutouts ) untill yamaha replaced the TPS ( recall ) , now it cuts out and runs like a bunch of monkies arggggggggghhhhhhhhhhh
Mine also ran fine until Yamaha fitted the recalled TPS sensor. What I found was they fitted the old faulty type that has a A1 stamped on it, instead of the new recalled A2 TPS. I made them change it again & hey presto, no more cutting out.

So check your TPS, you will have to remove the TPS as the A2 number is stamped on the in side.
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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


Last edited by Kev; 09-04-07 at 14:55.
  # 9  
Old 09-04-07, 17:54
Kawas Kawas is offline
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Hi guys!
I've bought my xtx 4 days ago - 2nd hand without warranty. I didn't notice any cutting and surging. Only when I ride on 2nd gear at very low rpm (without touching the throttle) and then try to accelarate slowly - it starts to surge.. Maybe it's because the rpm are too low?
Anyway my frame number is within' the faulty range, don't know about ecu yet..
EDIT: just checked my ecu No. - it's the bad one
Tommorow I'll visit my dealership - wonder what they say - without warranty..

Last edited by Kawas; 09-04-07 at 18:29.
  # 10  
Old 30-08-06, 15:59
Lubko Lubko is offline
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Quote:
Originally Posted by CaptMoto
The 2 attached documents I have got from JMC are leaked internal Yamaha UK memos to all dealerships and service workshops.

They show the range of the faulty ECU's up to frame number related, best thing to do is to check if your frame number falls within this range and if so print these 2 documents and take them to your dealer and they shall have no problem in sorting you out with a new ECU

The quality is not perfect but you can just about make out the frame numbers. Sorry but this was obtained by a mechanic and not officially from Yamaha.

For the benefit of all please note these are the affected frame numbers

XT660R Up to frame no. DM015-007858
XT660X Up to frame no. DM014-006257




And thanks very much to JMC for helping me with this even though now you are on the other side of the world, its great that you kept these things safe.
Dear CaptMoto ,

As Tiny I have XT-R dated with 2006 year but with frame number string with 011 - that could mean the bike is actually 2004. I am about to have the first service, so would like to have the documents you attached while asking the dealer to check my ECU and replace it if necessary.

Do you have those documents scanned with better quality � I personally almost can read nothing from them.
Thanks in advance.

Thanks,
Lyubomyr Humetskyy .
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