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XT660Z Ténéré General Discussions Everything and anything of general topic in relation to the new Ténéré is discussed here

View Poll Results: Has your Tenere been overhauled due to dust in the airbox causing excessive wear?
engine overhauled - dna stage 2 filter 1 3.33%
engine overhauled - dna stage 3 filter 0 0%
engine overhauled - std filter 1 3.33%
engine not overhauled, using oil 0 0%
no problems 21 70.00%
what you on about 7 23.33%
Voters: 30. You may not vote on this poll

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  #1  
Old 21-09-11, 20:15
buzzlightyear buzzlightyear is offline
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Tenere engine overhaul

I would like to know how many people have had their engines overhauled due to dust in the airbox. Also please state the mileage at which it was overhauled.

The reason why I'm interested in this is that we've had a couple of the first 09 models to arrive here overhauled due to dust and grit in the airbox, this was with the std airfilter and snorkel, Yamaha SA then did a recall and all was kitted with DNA stage 2 filter and topcover. However, I'm not sure the real cause has been addressed yet, so I'd like the input from the broader user base.
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  #2  
Old 21-09-11, 20:52
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Hunday Hunday is offline
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Oil Usage

My bike started using oil at around 16000 km , and the agents replaced my barrel a,pistons and rings at 32 000 km,
I have since put red rubber grease on the LH and RH Air filter side covers , I have fitted the YZ 450 Quad foam filter over my DNA filter to ensure no dust enters the box.

The air filter box drain pipe is too long , it catches on any bush or rock you ride over and either pills the blank plug out or splits the pipe when a rock squashes it against the frame , solution , cut it shorter , fit a 8mm bolt as a plug ans a decent hose clamp.

Finally , I dont get anymore dust in my air filter.

PS , I did 74 000 km on my previous XT660R with no problems at all.
So I know these motors rock !!!!

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  #3  
Old 23-09-11, 18:26
dallas dallas is offline
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With my june ´08 XT660Z Tenere, I´ve done 65.000km´s so far and bike is still runnin´ just fine. Still very smooth(for a thumper!), good fuel economy(1lt:25/26km on backroads, runnin' between 3500-4500rpm; highways 1:20), no oil consumption, hardly no vibes. Engine is standard, only got Leovinces. Just got my fourth set of tyres&chain/sprockets(so an average of around 20.000km for both; now K60 Scouts instead of Tourances). Very reliable bike, never let me down(no electrical problems with mine, just take care with it the right way) and still lotsa fun to ride. WHOAA!!
Greetz, Hans.
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  #4  
Old 23-09-11, 20:43
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Kev Kev is offline
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Yamaha South Africa knew about this problems a fews years back & did nothing to recall these bikes to get them checked out, DNA responded straight away when the problem came to light with a bigger seal. South Africa was the only country I know of that had this problem in 09/10, hopefully your pole will show the regions that had this problem more clearly.

The problem was the air box moldings were made to different dimensions & were not consistent in size which could allow for unfiltered air past the main filter, Australia responded with all the OEM fitter being removed at PDI & replaced with a Australian brand foam filters.

Also know of one or two side panels not sealing on the XTZ air box's, I would remove them & seal them up with water proof grease to be on the safe side.
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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


Last edited by Kev; 30-09-11 at 22:15.
  #5  
Old 25-09-11, 09:39
66T 66T is offline
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I'd just like to say that Kev and hunday are right; except that not all Teneres had foam filters fitted from new. I know of three that weren't, including mine. I had to buy my foam filter. Small price to pay for peace of mind.

I agree about the oil drain pipe - it is a menace. Hunday has the solution and everyone should seal the airbox sidecovers and do the pipe mod before there's a problem. I used blue (O2 sensor-safe) gasket sealant on mine. Fingers crossed...
  #6  
Old 30-09-11, 15:28
buzzlightyear buzzlightyear is offline
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Quote:
Originally Posted by Kev View Post
Yamaha South Africa new about this problems a fews years back & did nothing to recall these bikes to get them checked out, DNA responded straight away when the problem came to light with a bigger seal. South Africa was the only country I know of that had this problem in 09/10, hopefully your pole will show the regions that had this problem more clearly.

The problem was the air box moldings were made to different dimensions & were not consistent in size which could allow for unfiltered air past the main filter, Australia responded with all the OEM fitter being removed at PDI & replaced with a Australian brand foam filters.

Also know of one or two side panels not sealing on the XTZ air box's, I would remove them & seal them up with water proof grease to be on the safe side.
So you're saying there was an actual problem with the DNA topcover seal? First word I'm hearing about this in SA?
  #7  
Old 30-09-11, 22:29
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Kev Kev is offline
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Quote:
Originally Posted by buzzlightyear View Post
So you're saying there was an actual problem with the DNA topcover seal? First word I'm hearing about this in SA?
It was an isolated problem back in 2009 which we covered in detail & would affected most brands of air filters fitted to the early Zed's as the air box was at fault.

A hand full of air boxes from Yamaha seem to have had bigger dimensions where the filter is placed by a 1 to 2mm, DNA responded straight away with a bigger sealing air filter foam for it's brand which would cover all dimension air boxes.

My advice is if you are riding in dusty conditions on any bike is to check the air box is dust free in the filtered area. On the Zed remove the air box side cover & inspect, remember to reseal the cover with some grease when fitting it back.
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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

  #8  
Old 20-10-11, 14:47
buzzlightyear buzzlightyear is offline
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Quote:
Originally Posted by Kev View Post
It was an isolated problem back in 2009 which we covered in detail & would affected most brands of air filters fitted to the early Zed's as the air box was at fault.

A hand full of air boxes from Yamaha seem to have had bigger dimensions where the filter is placed by a 1 to 2mm, DNA responded straight away with a bigger sealing air filter foam for it's brand which would cover all dimension air boxes.

My advice is if you are riding in dusty conditions on any bike is to check the air box is dust free in the filtered area. On the Zed remove the air box side cover & inspect, remember to reseal the cover with some grease when fitting it back.
Very interesting Kev, I'll see if I can find some posts related to this. Thanks!
  #9  
Old 23-04-12, 14:22
michaelks michaelks is offline
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I noticed that there was nothing reassuring in the way of a seal between the airbox lid and the filter, so I fitted a soft rubber o ring secured with a few drops of superbonder :

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