Kev's latest mod.

As most of us know the XT660 is hard to control in traffic conditions, tight corners or traffic circles. So I have come up with the mod which can be applied to our XT's.

This is a very clever mod & works well if you want more throttle control, I found the idea on the net.

I lowered the cable by 1mm in the grip to try it out first, day 2 of testing I went a further 5mm around the throttle to 20mm, it now has so much better throttle control at low speeds.












My final depth is 2mm deap after testing.



I used a 2mm drill bit to cut the groove, I used the edge of the bit to do the cutting not the tip, I rolled the grip along the side face of the drill bit to keep the circular angel of the twist bit.













On day 2 of testing I have now cut the grove 20mm along the grip to give me a reduced diameter up to 30% throttle opening.

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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 /
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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

Looks like a great idea!

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This mod does work on the XT, I found the throttle is less sensitive at low speed which gives you better throttle control.

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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

I done this Mod this morning and it's a vast improvement over the standard bike especially with your O2 mod as well. I can't believe how different and better my bike is now compared to the standard bike. Many thanks Kev your efforts are appreciated.

Good news, thanks for your feed back. How many mm did you go down to?

Like me I can't believe how this mod has changed my bike when riding in traffic, this is got to one of the best kept secrets.

It would make off road riding so much more controllable.

__________________
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

I went down by approx 2 mm like yourself and was very impressed with the result. I can't believe more people havnt taken up on this mod it's so easy and quick to do !

Hi All, Just done the mod to throttle, definately helped with jerkiness at low openings, I have my co adjusted up to 40 on the dash settings. Don't know if this is ok but seems to be lts better. Started at 15 and worked up with road testing each adjustment. Just to say I did mine easily with throttle in situ using a dremel with small rotary file. Just held Dremel still and rotated throttle. Just saves a bit of time thats all.

Hi all,

Iv'e just done this throttle mod while I had the housing apart but I'm wondering if there is supposed to be something stopping the housing slipping towards the brake lever?

I swapped to a majura bar some time ago, it has a hole that i'm guessing accepts a pin from housing but the xt housing / the bar it came with doesn't seem to have one (pin in the housing or hole in the bar).

Just a heads up as well as when the grip slides towards the brake lever it jams the front brake on (i found out the hard way). I had a fall (over) that must have loosened the throttle grip and it later slid inwards, I never noticed until it did so while riding, jamming fast the front caliper : 0

So is there something I can do to stop the grip sliding in?

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XTX 09

You can make yourself a locating pin out of a self tapping screw inserted into the switchgear and cutting the head off.



Alternatively a bead of Loctite can give just enough extra sticking power to stop unwanted movement.

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Thanks pleiades, I thought I was missing something, the loose throttle housing left me in a dangerous situation, only a simple slide and presto, front brake- full lock.

the majura bars do have a hole but it's not in the right spot (too close to the brake) however a grub screw will act to stop the housing from going near the brake lever. I might try some loctite as well to stop it turning.

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XTX 09