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  # 1  
Old 28-02-09, 11:18
Kev's Avatar
Kev Kev is offline
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Rattle in my motor

Since I bought my bike & before I did the Raptor 700 conversion I always had a small rattle in the motor on start up from cold.

Of late it has started to bug me & has got worse, so I had a look into the problem. What I found was the oil was draining back into the motor when it stood for a few days & would rattle until it had oil pressure. I removed the oil filter & found the oil was draining back through a oil gallery that has a one way valve in it, this gallery should always be full of oil no matter what.

I ordered the parts a few weeks back from Japan & removed my clutch cover, to replace the ball, spring & seal that hold the oil in the gallery. I retested for the oil draining back & it has stayed full after the repair, so I am happy again.

As you can see I always full the oil tank with 1500ml of oil & the remaining 1200ml I full through the engine breather. Start the bike then adjust the level as needed. Much easier this way, no messing around.















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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

  # 2  
Old 28-02-09, 11:31
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CaptMoto CaptMoto is offline
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Excellent work as usual Kev!!
  # 3  
Old 28-02-09, 12:10
Worry Brother Worry Brother is offline
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Nice one Kev,

So wish you lived in the UK mate!!!

Cheers

WB
  # 4  
Old 28-02-09, 20:21
NickW909 NickW909 is offline
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Great work Kev.

I hope you washed that Pyrex dish before you gave it back to the wife.......



Nick.
  # 5  
Old 28-02-09, 22:46
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Kev Kev is offline
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As any good mechanic knows, make sure you use your wifes best Pyrex jug in the house she won't mind. One needs to measure things correctly, I best put it back before my wife fines me using it.
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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; 21-08-09 at 09:07.
  # 6  
Old 10-03-10, 09:21
Piipz Piipz is offline
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Ok, found the thread myself (already sent a message to Kev about where did it go :P)

About those parts - do I have the part numbers correct:
583-13113-00 SEAT, CHECK BALL
93503-08007 BALL
90501-04X01 SPRING, COMPRESSION
  # 7  
Old 14-03-10, 18:08
gianni1951 gianni1951 is offline
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[quote=Kev;84279]Since I bought my bike & before I did the Raptor 700 conversion I always had a small rattle in the motor on start up from cold.



ote]
Hi, Kev,

a question. What is the insert in the water tube upper water pump. It's seems like a radiator. Is a commercial part, or you have done by yourself ??

Thank you. Ciao.
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  # 8  
Old 14-03-10, 18:17
maxwell123455 maxwell123455 is offline
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Its an extra water cooler which kev made and sold a few on the forum
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Plough on
  # 9  
Old 14-03-10, 19:26
gianni1951 gianni1951 is offline
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Thanks, Maxwell.
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  # 10  
Old 15-03-10, 01:19
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Kev Kev is offline
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ote]
Hi, Kev,

a question. What is the insert in the water tube upper water pump. It's seems like a radiator. Is a commercial part, or you have done by yourself ??

Thank you. Ciao.[/quote]

I got them made up myself, just another XT Kev mod I did.

http://www.xt660.com/showthread.php?t=11154
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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

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