I have noticed a few posts recently regarding 2in1 conversions. I thought I would add my experience modding my '04 XTX with a raptor 700 quad 2in1 header.

The headers fitted very neatly with the obvious problems of the radiator hose, the clutch cable and rear break fluid reservoir.

Re-routing the radiator hose and break fluid reservoir is no big deal, the biggest problem i found is the heat generated from the headers. I.e. Idling for about 2 mins melted the radiator fastening rubbers and any longer, the header would have glowed. With all that soft rubber and plastic around that area, not to mention the clutch cable running very close, I just never had the confidence it would not melt something. I did not however exhaustively look into the heat shield option but I cannot see anything as thin as tape shielding that much heat.

On the plus side, I did go for a short ride once mocked up and the bike went very well - very load tho. I thought that I would have to invest in a power commander but thankfully I did not. The CCC stainless ovals worked a treat and I have the kev fuelling mod so maybe that helped (cheers kev!).

I will probably try again as it can be done without too much bother and I do think it looks the dogs.

OK, just thought I'd share that.

Craig

Hi Craig, thanks for your input. This mod has been done already have a look in the mod section under Exhausts, as Marcel found a way around the water pipe with the Raptor headers.

http://www.xt660.com/showthread.php?t=630

http://www.xt660.com/showthread.php?...ed=1#post81267

__________________
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

again, no melting issues on my bike. Just make sure your header won't touch the radiator bolts/rubbers. Use a grinding machine to fix that. Make the collector in that way so it's as far as it gets from the filter element. Also put in a sensor hole so you can easily do dyno runnings/mappings, see pic.
Do a lot of offroad events, the engine runs at high temperatures, but still no melting issues regarding the clutchcable/filter elements or radiator hose/rubbers. If you need anymore information pls let me know.

Marcel

__________________

Thanks for the heads up fellas.

The header I have was sent to me by a bud in South Africa. I therefore don't know exactly what raptor it came off but it is not the same as the one in the photo. It runs very neatly to the engine and makes contact with a fair amount of the clutch cable.

Anyhow, I'm gonna try it again!

Cheers
Craig

I am about to try the same, but with a stock standard Raptor 700 header.
I dont have the header yet, but want to try it. I will be watching this thread.

I am sure that the headers I have are stock.

I have ordered some heat wrap for the headers and heat shield for the hose and clutch cable. The guy I spoke to assures me that the combination will reduce the heat seep by 95% - should be no problem then.

I will post updates.

Oh and another thing rudiedj, if you need a good guy in Cape Town, let me know. An old school pal of mine specialises in XT's and thumper's. He is in Table View. He's the guy that sent the headers...

hi, i would like to know how runs your bike about handling with the 17 " xtx tires, because angle of the front are very different between r and x, isnt too heavy to move going slow your bike with those 17" tires? did you change the 298 mm front disc for a 320 mm disc,,with an extension ?
Thanks.

bike handling is perfect
you cannot use the x front disc, have to put on the r disc.

more info can be found here

http://www.xt660.com/showthread.php?t=7483

__________________

At the risk of stating the obvious, why has noone tried using XTZ 2-1 headers, which go around the left hand side of the engine, where there are fewer obstructions?

__________________
-- Triumph Explorer 1200 --

that's impossible due to the airfilter case. Otherwise we could have Barker's duals exhaust headers fit on these bikes.

__________________