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XT660Z Ténéré Tech Section Tyres, Mods, Luggage & Long distance preparation

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  #1  
Old 24-07-11, 14:50
b374 b374 is offline
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Exclamation Gearbox Failure: Oh dear! What's that noise?

The gearbox on my tenere failed at just 27k...

Without any other previous symptoms, I started hearing some rattle while waiting at a red light while the transmision was in neutral. It stopped and rode home without any issues. Next morning I started the engine and while putting the helmet i heard the rattling again... on the road to the dealer it felt like at certain times the transmision was about to slip out of gear while riding constantly at 3k rpm... ironically when i was trying to show the mechanic what the symptoms are it all went smooth for about 20 mins - finally, it started again but this time it was on centerstand so i could see better what happens: bike out of gear, at around 3k rpm it seems like it couples first gear for a fraction of second, rattles and moves the sprocket few degrees...

Bike is left in the shop to open up the gearbox...

I haven't abused the bike much, changed the oil at every 5k and it seems to me a bit earlier for the gearbox to fail at just 27k under these circumstances... any idea for what might cause it?
  #2  
Old 24-07-11, 20:52
stoic bloke stoic bloke is offline
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oh dear! what's that noise?

well to cut a long story short my tenere is in the sick bay, ICU in fact

a month or so ago i was in the south of france doing a week of fairly rough offroading, towards the end the week the gear selector would just jam up neither going up or down the box, fiddle the pedal a bit and it would come fine. so i thought the selector has had a bit of a tweak on a rock etc.

anyhow it got me home fine and back to the usual commute. sarah and i went for a spin today, thankfully we didn't get too far. a crunching grinding noise started on a up change from a junction and loss of drive. ho hum,

on getting it home[trailor] and pulling the clutch basket i have found a part of a broken gear in at the selector drum/ mech [looks broke a while] so after dinner i need to pull and strip the 33,000 mile motor

more fun to follow
  #3  
Old 24-07-11, 23:26
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Kev Kev is offline
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Not good news mate. Keep us all updated.
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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 /
[
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

  #4  
Old 25-07-11, 09:26
uberthumper uberthumper is offline
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Bad news fella. Will be interested to hear what's inside the cases.
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  #5  
Old 26-07-11, 17:18
stuxtttr stuxtttr is offline
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not only does that sound horrible it also sounds very expensive

hope the cure is not too crazy money
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  #6  
Old 26-07-11, 23:10
stoic bloke stoic bloke is offline
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hi, at long last the motors mostly stripped, There seems to be a few issues going on

firstly when pulling the head down i could not believe, the cam was out a tooth, on inspection the tensioner was out to it's last hmmm, with the head and barrel off all became apparent. the timing chain guide[intake side] pivots on a imo flimsy metal bracket which had disintegrated allowing the guide to move up as well as rubbing the back of the chain. not an impressive design!

next the gear stopper bearing has collapsed, this hold the gear selector drum from rotating freely, it kind of indexes it to a set gear. i'm guessing with it being fecked it has allowed the gears to 'auto' change.

the elephant in the gearbox, well thats obviously knackered. it's the '3rd pinion gear', a broken bit has damaged the '4th wheel gear' [yamaha manual names]. so will get on to yam with my list of bit and bobs and all will be well again. hopefully!


.
  #7  
Old 26-07-11, 23:35
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Not good news, have seen this before.
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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 /
[
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

  #8  
Old 27-07-11, 10:48
66T 66T is offline
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Crikey Kev, I hope you haven't seen it too often. I was under the happy delusion that these engines were all but indestructible. Another belief down the drain. Sigh.

I am sorry to hear that you've been stuck with this badness, stoic bloke. Sucks.
  #9  
Old 27-07-11, 11:12
Gas_Up_Lets_Go Gas_Up_Lets_Go is offline
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Quote:
Originally Posted by 66T View Post
I was under the happy delusion that these engines were all but indestructible.
but not Stoic-proof.

Remember this enginge has been pushed hard, and Bernard is a demanding rider, and while I'll stop short of saying he is some kind of 'motorcycle murderer', the bike/engine has been raced from Paris to Dakar (when other more 'germanic' breeds were failing), as well as the daily commute and other long distance trails - so if it's going to fail, it's going to be this one!
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  #10  
Old 27-07-11, 12:50
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Kev Kev is offline
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This is number 3 I know of, but the first XTZ out of thousands of XT660 over the past 5 years, so nothing to worry about.
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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

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