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Please make sure your bike has an O2 sensor before buying this mod, this mod will only fit a XT660 with a O2 sensor.

 Installation INSTRUCTIONS can be downloaded to your PC not phone from the link below.

The Kev 2012 XT660 O2 Controller Mod fits all models XT660 X /R/ Z  from 2007 onwards that have O2 sensors. Due to constant request I have now included my Adjustable Kev Fuel in this sale. My fuel mod is able to adjust the A/F ratio in the open loop, I have been selling this fuel mod since 2005 with a 100% success rate, you can see how it works from this you tube clip https://www.youtube.com/watch?v=glkdBO8aZm0  :   http://www.youtube.com/watch?v=0OHzpRrZMnA     This fuel mod has been Dyno tested with completely standard XT660's, mods with stage 1, 2 & 3 air filters + after market exhausts, the fuel mod is fully adjustable & be adjusted to the correct setting for the mods installed on your  bike, the mod comes with full fitting & tuning instructions so you will know exactly where to set the fuel mod for your mods on your bike.

The O2 controller mod :

Don't be fooled or conned by the other O2 Eliminators on the market they don't work on these XT660's,  I have been working with these 660's since 2005 & have done just about every mod know on them.

Why do we need this O2 controller.

There are 2 sides to a fuel map, closed & open loop circuits.

A Power Commander or any other type of fuel mod can only adjust the fuel map in the open loop, the open loop circuit is when the ECU sees sudden acceleration, any RPM above 4500rpm & all throttle openings over 20%, cruising or not cruising.

The closed loop is used for emission control, it comes into effect after a coolant temp of 70 degrees C, when the ECU sees a constant throttle opening of below 20% & below 4500rpm, the ECU takes voltage readings from the O2 sensor & will lean the A/F ratio out until it sees a A/F ratio of 14.7:1.

The resistor type Eliminators do not work we have proven this, at the time of proving they do not work Dynojet pulled all the XT660 resistor type O2 eliminators from their for sale lists, this controller is a voltage divider that works in conjunction with the O2 sensor offsetting the sign wave voltage signal from the O2 sensor & sends a different sign wave voltage to the ECU. 

The ECU constantly looks for 0 to1 volt square wave signal, by unplugging the O2 sensor& fitting a resistor it sends a constant voltage signal to the ECU, after a few Min's the ECU see this as an corrupt signal & then constantly switches the A/F ratio up & down, in this state the bike is not tunable. The controller controls the O2 sensor wave signal via a voltage divider principal.

 By controlling the closed loop circuit we are able to reduce the surging when you are cruising, with one of my O2 controller when the ECU switches between the open & closed loop circuits the transition is much smoother as the A/F ratios are closer to each other.

 This O2 Controller mod can be used on a completely standard XT as well any XT with extra filters & pipes, can be used with my fuel mods + PCIII & PCV.

The O2 Controller is only part of the equation to reduce the surging but is one of the most important ones in reducing the surging. A good fuel map for open loop tuning + a good chain & sprockets correctly adjusted & no free play in the rear sprocket holder rubbers. Do all the above & your bike bike will ride like a dream.

Some feedback from the O2 controller mod. All the details can be found at this link on the www.XT660.com forum http://www.xt660.com/showthread.php?t=14746&page=17

Suitability

This O2 Controller mod & Fuel mod can be used on stock motorcycles, as well as any 660 with extra filters, pipes for motorcycles.

2007> to present with O2 sensor XT660X, XT660R

2009> to present with O2 sensor XT660Z

2008> to present with O2 sensor MT-03

The Adjustable fuel mod & O2 Controller are only part of the equation why these XT's surge, the controller will sort the closed loop A/F ratio out but cannot fix mechanical surging from the drive line.

DISCLAIMER: The O2 Controller modification is sold only for race use. The O2 Controller modifies the closed-loop fuel injection mapping and it may not comply with emission control regulations in some countries. This modification is installed and used at your own risk. The manufacturer assumes no liability or responsibility for the use of this modification on your own modification.

Motorcycle modifications and maintenance should only be performed by a qualified person. Some modifications may void your warranty and/or your insurance cover. Consult your motorcycle specialist if you are unsure. I cannot be held responsible for any modification done to your own motorcycle, and am not liable for any claim arising from the fitting of these modifications. The reader assumes all responsibility for the use of these mods.

Q&A

Hi Kev.
Just bought a 2009 XT660X.
6000miles on the clock.

1st of I must say by the looks of it you have a fair Idea what's going on with these bikes. Specially with the down low shudder.

I have done a fair bit of reading to get to you. :-)

I'm looking to purchase this if it will help a little with this shudder.
Only thing im asking, Is::
Will this make a great deal of difference as the Only MOD.. ??

I haven't done any mods yet,
I've only Had it 2 weeks, and the bike is still Factory standard.

I look forward to your reply Kev. And hope to purchase this if it helps.

Regards
James

Hi James yes it will make a difference to your ride even if your bike is completely standard, this mod controls the closed loop circuit this is the area where the bike would be on the cruise or at small throttle openings, the closed loop is tuned for emission control at 14.7:1 which is very lean my mod changes the A/F ratio in the closed loop to 13.6:1 where the XT produces it's best fuel consumption, at 14.7:1 it burns all the hydro carbons for the greenies but the motor does not like this A/F ratio & responds with a lean surge at part throttle openings.

If you don't use one of my Fuel mods with this O2 mod I would ask you to up the CO in the dash of your bike by 5, I will show you how to do this.

Cheers
Kev

Q:Hi Kev

What else make these bikes surge? 

Hi mark

The chain & sprocket are the second most popular reason why these bikes surge, incorrectly adjusted loose chain or a worn chain that has tight spots, the other thing to look out for is the rear sprocket holder dampening rubbers, there should be no free play in the rear sprocket holder, if you take hold of the rear sprocket & move in back & forwards in the direction that the chain travels in there should be no free play, if there is the rubber need changing, any free play in the sprocket holder or a loosely or worn chain & sprockets will make the bike feel like it is surging. You can refer to my XT660 Mod book for a cheaper repair option to replacing the rubbers.

Cheers

Kev

Q:Hi Kev

Do you have mods for better control around round about (traffic circles) I find I am always on the clutch in the tight stuff. 

Hi Dave

Yes I do, firstly this O2 Controller mod will help you in that area, but I also do a twist grip mod that alters the cam in the twist grip that can give you better throttle control in the tight stuff or when riding off road where you need better throttle control, this mod is dead easy to do all need a drilling machine & a drill bit, I list all these types of mods in my XT660 Mod book. http://www.xt660.com/site/node/325 

Cheers

Kev

Q: Hi Kev

If I get stuck fitting this mod do you offer any after sales help?

Hi Sue

I offer 100% help & guidance with any of my Mods no matter what the problem is, I run the ASK KEV section on the XT660.com forum where I am one of the Administrators & answer in-depth problems on any fault, I know these XT660 back to front technically.

Cheers Kev

Q: Hey Kevin, I have a 2011 xt660x, would I need to buy the fuel mod with the O2 sensor? Or can I just buy the mod? Many thanks Andrew

Andrew the best results are from tuning both the closed & open loop fuel maps no matter what mods you have fitted on your XT660, even a completely standard XT is lean in the open loop mapping. The O2 controller will help the most for surging out of the 2 mods on a standard bike or fully modded bike, if you have any other mods fitted like pipes or filters I would recommend both mods. 

A miss conception is when fitting an exhaust or filter we do not need to correct the A/F ratio, from all my years of tunning bikes the minute we change the air speed or volume into or out of a motor it will affect the A/F ratio, some aftermarket exhaust manufactures state you do not need to correct the A/F ratio, from test I have done the A/F ratio will change from let’s say as an example 13.4 to 14:1 it is still in a safe zone but you will not get the power you want with a 14:1 A/F ratio from the exhaust you have just fitted, correcting the A/F ratio using a fuel mod back to 13.2:1  the bike will deliver the Max HP & Torque.

 Feedback

 1/ 

Hi Everyone,

Iv'e been riding with the new O2 eliminator fitted for the past week. I tested it on my stock standard (Staintune pipes only) xt660x and then with DNA filters and fuel mod etc. Here is my review ...

Day 1) Received the O2 eliminator and fuel mod in the post about 2-3 days after ordering it ( Thanks Kev ).

Day 2) Fitted the O2 eliminator. Took 5 Min's to plug in then about another 30 Min's figuring how/where I was going to tie the small black box that comes with it. I eventually cable tied it to the existing O2 sensor bracket next to the cylinder head.
I went for a 30 min ride around where I live and tried really hard to get into the surging zone but hey presto no surging. Good result! A true test would be my usual 1 hour commute through Sydney traffic each day.

I then removed the snorkel and went for a short ride. Could feel a very small difference with response and still no surging. I then fitted the DNA stage1 filter. Again a bit more power and no surging. I then fitted the DNA stage 2 filter as well as Kev's fuel mod. Took it for another spin and WOW, bike has definitely got more power. In the right rev range any gear, open it up and you start putting serious distance between yourself and anyone following. Very happy!
I was thinking about drilling holes in airbox as well but decided against it.

Day 3) Commute to work.
I have some sections where I am sitting between 50 and 70 kph constant throttle. Before, this is where I would pick up the surging, ( f@%@ing annoying ). Now, there are times where I get into that same zone and you can feel the bike trying to surge but it is hardly noticeable (much smoother). In other words I would say the surging is not 100% eliminated but 90-95% gone which I would say is a big win.

With the filters and fuel mod I would say it makes riding in traffic easier. I am more confident of taking gaps between traffic as I know the power is instantly there.

Well, there's it folks, my 2 cents worth. If you are interested in getting a fix for the surging problem then Kev's mod will do the trick.2/ It is a huge improvement over standard and I am a happy customer.
I will give more riding feedback when I can (our new baby beagle is slowing me up) and try some more roads and conditions. Again a big thanks Kev you have turned a great bike into a brilliant one.

2/

And it works great, thank you Kev.

Only been out for a short ride with it so far but threw a few different conditions at it in that hour.

The only time I could detect anything was for example when in 3rd at 60 ish kph under no load (ie; higher rpm lower gears on declines trying to maintain a constant speed) and if felt like it was just trying to surge but didn't really.

It is a huge improvement over standard and I am a happy customer.
I will give more riding feedback when I can (our new baby beagle is slowing me up) and try some more roads and conditions.

Again a big thanks Kev you have turned a great bike into a brilliant one

3/

Got mine installed...
Works great.. no surging..
Far nicer to ride around town
in traffic...

4/

So yesterday I received my O2 controller, Kev mod and stage 1+2 DNA filters - yes it was truly like Christmas :-) I went ahead and fitted the O2 controller alone as I wanted to test that alone (only change one thing at a time, eh). 15 mins later I was on my way - yes its that fast to fit, easy peasy. I zip-tied it to the fan as I didn't wanted it dangling from wires (see pic below).
The low throttle stutter you get from this bike stock is just unbearable. You get physically shaked and you really need to hold tight - its very uncomfortable. That is gone. Not totally but the O2 controller is a huge improvement. You will still experience slight stutter occasionally, but its nothing like before. Its a no brainer and definitely a must have.

On a sidenote I think this mod actually makes me a better rider. Before fitting this I tended to run too fast all the time to keep the bike in open loop mode so I avoided the stuttering (not in towns though). Now on mainroads I can run 70-90Km/h with very low throttle and its just smooth - like it should be.

Thanks for the new bike kev

5/ 

I've already PMed Kev to let him know directly, but I'm posting here too so others get my feedback.

I've fitted the new O2 Controller on my 2011 R - took all of 5 minutes to plug it in and mount it - and took it out for a ride. I was really trying hard to test it at the usual constant throttle positions and rev range where the surging is really noticeable – 2nd & 3rd gear was where it felt worse but now with the O2 Controller it feels great! Heaps smoother no doubt. I think I can still detect a slight surge every now and then but nothing like before... and I mean I was tryin' real hard to notice.

My bike is set up as follow: standard cans, standard air filter, snorkle removed, C1 adjusted up 5 from original. I haven’t done anything to the open loop yet.

So I give it the big thumbs up, this is how it should run straight out of the factory.
Great work Kev!

6/

Been using the dynojet "regulator/modulator" (not the optimizer) for the last 3 weeks on my 2011 XTX, and it has been driving me insane with heavy surging at around 4500rpm.

Got the eliminator from Kev 2 days ago, and all i can say is wow, its a dream to ride the bike again, no more surging in the 4500rpm area (I have tried everything to get it to surge but with no result).

7/

Well Kev, I have now put over 1000km with your O2 controller fitted and all is great.
I have ridden in many different conditions and on many different types of roads from dirt to open country and twisties (also towns and traffic).

You can still find a little surging if you go looking for it, I find it in the lower gears at lower speed with mid rpm (2nd or 3rd around 30-40 ish kph) but it is not to bad (by the way I only notice this in town or at some road works with traffic). There could be other factors that make it seem worse than it is, like drive chain slack .

As I said, if you go looking for it you will find it but on the whole it is so much of an improvement (90%) over standard I cannot fault it at all.

This is in my opinion the best mod you can do to these bikes and also the best value for money mod you can do.

Well done Kev and a big thank you for this mod, it has made this bike even more of a pleasure to ride, cheers.

8/

Got it remapped today with the new O2 controller on the Dyno. Its 13.2-13.6 over the whole range now. and its so much smoother now. It had a dead point at around 5000rpm where it would drop alot in the a/f, but its fixed now and its running so smooth!

9/

Wow Kev, can't thank you enough!! Got the O2 mod fitted in a few minutes and took the Ten for a 300km blast through the twistes around Jarrahdale in WA. What a different bike!
At idle to mid throttle it's like my old TTR, smooth and predictable but with torque on tap!
Can't believe how nice roundabouts and traffic driving are now, no surging or sharp throttle snaps... But the response from 2000rpm up is awesome on the open road, just twist and go, smooth all the way.
Again, thanks heaps.  

10/

Hi Kev

Thanks thousand times for your time to develop the XT660Z-O2-Controller - was riding over weekend for many many hours over the Swiss Alps - in any height over sea the controller is really improving the bike. Was much more then i expected from it.

11/

Just got the O2 mod fitted on my XT660Z this weekend after receiving it last week. Like others on here, I didn't think I needed it for my tenere but after reading what a few people have said I have to agree!!

With the stage 2 and Kev fuel mod, the O2 mod makes this bike smooth. It really makes a difference in the low down revs.

Love it. Cheers Kev!!

12/

Some guys make me laugh.

F'kn love you, man. Got a little parcel all the way from Brissy, it contained the best £120 I've ever spent. I would happily let you marry my sister.
Cheers, mate

 Feel free to ask me any questions.

#### NOTE ####

I do not sell or ship any of my mods to ITALY, BRAZIL, SOUTH AMERICA, or NORTH AMERICA or any other country in that region, I have blocked all Paypal payments from those areas due to copy rights of all my mods.