Hi

I have manage to cause some damage to my XT's motors sleeve and need to replace the pistons and rings. I would like to go a little bigger on the piston size.

So far all I could find is the Raptor oversize kits from Wiseco and JEPistons.

The 102mm overbore is what I would like to use on the standard XT motor. Has any of you done this before?

Could anyone please advise me on a few small things I need to know before I start and just any help/info on doing this would be good

Firsty the Piston Pin - 22 x 14 x 57.15mm SW that comes with the kit seems to be smaller than the one in the standard XT660R piston. Am I correct? This pin will not fit on the conrod? The one on my standard piston is 23mm and the kit says 22mm? Looking at this it will be a problem for fitting.

The overbore is 2mm. Will taking off this aluminium cause the engine to overheat or not?

Thanks

I just found this piston kit. Will it work?

http://www.wiseco.com/ProductDetail....09&AppID=28655

http://www.off-the-road.de/de/XT-660...660-R-X-Z.html

There are a few of us that have done a 102mm conversion. I am helping with a 105.5mm XTX conversion next weekend.

You can use any Raptor 700 piston, if you are using 98 or 95 RON fuels you can run a compression ratio up to 11.5:1.

I would only use a CP piston as this piston has the longest piston skirt out of the JE & Wisco Raptor 700 pistons. My last JE 102mm piston kit only lasted 10000KMS (6K miles) & developed a rattle because of the short piston skirt. You can buy a corrected deck height 11.5:1 or normal 11:1 CP piston I would only use one of these. You can bore the standard XT660 cylinder to 103mm to make it a true 700cc, this has already been done read below.

Have a read in the modification index you will find more info on big bores.

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

http://www.xt660.com/forumdisplay.php?f=52

__________________
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

Hi Kev

I live in South Africa and we are a little limited to suppliers. I deal with a supplier that only get parts from Wiseco pistons.

Can you maybe give me a part number of the piston kit and gasket that you would recommend I get. If you know of a USA company that will ship to South Africa I would then buy direct if possible.

I had a look at the other pages/threads you posted and this looks wow?
Raptor 660 Cast Cylinder Kit 727cc .
http://www.whiteknuckleracing.com/index1.html

Will this work? Otherwise I will just go for the 102 overbore.

http://www.wiseco.com/ProductSearch.aspx
http://www.wiseco.com/ProductDetail....09&AppID=28659

I appreciate your time and input. Thank you.

None of the Raptor 660 pistons fit the XT660, so look at the Raptor 700 pistons as they fit. Send Freez a PM he will know of a local CP piston supplier in SA.

USA Ebay CP 11:1 piston kit.

http://cgi.ebay.com/Raptor-700-CP-piston-stock-bore-102mm-11-1-comp-NEW-/290548089746?pt=Motors_ATV_Parts_Accessories&hash= item43a6040392

http://cgi.ebay.com/ebaymotors/Raptor-Rhino-700-102mm-11-1-Std-Bore-CP-Piston-w-Gasket-/350365325365?pt=Motorcycles_Parts_Accessories&hash =item5193669835

If you are running a 102mm piston this is the one I would use.

http://www.tqsatv.com/proddetail.php?prod=RAPTOR-700-TECH-PISTON

__________________
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

Here is a picture of my XT660R. Not a pretty one! I am doing some mayor mods and repairs for more extreme terrain riding.

In that case go for one of these, you will need to machine the XT's casing to fit a 104mm & bigger cylinder.

http://shop.ebay.com/i.html?_nkw=raptor+700+cylinder&_frs=1&_trksid=p32 86.c0.m359

__________________
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

What you think of this one Kev?

http://cgi.ebay.com/ebaymotors/RAPTO...cessories#shId

Will I need to get any more things to make this work besides machining the engine?

Sorry for all the questions. It is my first time doing this kind of thing and there don't seem to be anyone around my area that has done this on a XT before.

I am helping fit that exact kit to a XTX next weekend.

The only problem with 12.5:1 compression you can't run normal fuel you will need race fuel 100 RON or more.

__________________
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