Hi all,

This is my first post on here, so please be gentle :-)

Recently bought an XT660Z as my first ever motorbike, going to take it to Capetown in October...

Got an engine warning light come on after about 2 weeks. The code is 22, which is "intake air temperature sensor error". Also, the bike seems to intermittantly surge when cruising at about 65 mph; could these be linked? I know the sensors provide fuel management information.

Is this a common problem? Any ideas on getting this sorted other than a trip to the garage (under dealership warrantee) and getting the sensor replaced? The bike's only done 4400 miles.

I'm a bit novice at all of this...

Ta!

Will

Hey Will...
Sorry I can't answer your question ..but if you are in Cape Town , look me up , I would love to show you some of the best riding country in the world.

Firstly - Welcome to the forum Will

Error code 22 is not a common fault, but it does happen and could well be the reason for the surging as the failsafe is for the ECU to assume a fixed air intake temperature at 20C. If you're much outside of 15-25C the bike will surge a little.

Most commonly this error occurs when a Kev mod is fitted and the connections fail where they are spliced into the AIT wiring. It has happen to me and a few others I know of. All you have to do if this is the case, is find the Kev mod (a little black box with a dial on top), trace the wiring back to its connector and re-make the connections. Sometimes they are soldered, but more often than not, a block connector is used.

If you've recently bought your bike, and you can't find a Kev mod under the seat, then it may well have had one fitted at some point in the past and it has been removed and sold on separately from the bike. It is not unheard of for people to make a bad job of reconnecting the two ends of the AIT where the Kev mod was fitted (in series). If this fails then you will see a code 22.

It is highly unlikely that the AIT sensor itself will have failed.

What I would do first, is check for a Kev mod and check closely the wiring to the AIT sensor which inserted into the back of the LHS of the airbox. You will need to remove the seat. Look at the intake hose and look to the left. I'll try and find a picture for you...

Here is the AIT sensor and it's soldered Kev mod connections. The blue/black wire is the one that gets cut to fit the Kev mod in series and this is potentially the area you should investigate. You can just see on the left the hole it plugs into...



The kev fuelling mod looks like this...



Its function is to kid the ECU into thinking it's colder than it actually is, thereby richening the fuelling.

Read this thread for full details on the mod and how it is fitted: http://www.xt660.com/showthread.php?t=11641

__________________

I guarantee somebody has not made the connections properly in your kev mod. Simple.
Follow the guide by my good friend Pleidaes.


Currently, mine is doing funny things because we're above 25�C here, but at least I fixed my wiring.

__________________
Bike: 2013 XT660Z, TKC70 tyres

Mods:
Barkbusters, Scottoiler, DIY Tail Mod, DNA Stage 3, Power Commander V & O2 Eliminator, Exan X-Black Stainless exhaust, Tool tube, Ohlins linear front fork springs, Nitron rear shock, JT front and Supersprox rear sprockets, D.I.D. VX 520 chain, Adventure Spec bashplate, DIY USB Outlet, DIY chain guide, Kev's Throttle mod

http://www.facebook.com/onemooseonemotorbike

Just to set the record straight I have never had a Fuel mod fail in the 9 years of making them, but we have seen one or two poor fitments of the mod by the rider in not securing the connections securely.

Let astatine that the bike has been fitted with a fuel mod.

__________________
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! Had the same error code 22 but this error only showed with ignition on and before I start the engine. After the engine started only showed light sometimes when I was off the throtle. First I swapped the old battery (4,5 years), then searched the web and finally found this topic! After 2 years of offroad abuse the wire broke from the connector that I used to install the kev mod. I assume the light only showed when I was off the throtle because off the vibration.
Anyway, thanks for the precious help!

Hey now, just thought I'd post a (very late!) reply.

The issue was indeed with some Kev Mod wiring. Thanks for your help! Got this bit sorted now. Currently just trying to fix some pinking ( http://www.xt660.com/showthread.php?t=24395) and my LCD display not working ( http://www.xt660.com/showthread.php?t=24406).

Onwards and alongwards, learning all the way :-)

I am emigrating, and would like to invite myself to take you up on you offer of showing off those back roads sometime.

catch up with you in December?