hi kev, you say you've come across this before, the gear problem or the timing chain issue?.
I am suprised the tensioner guide is not more positively mounted, the bracket is kind of weaker than i expected, as for the gear, i have broken xr400 gearboxes years ago. more recently a gasgas 300. in hard use they fail.

in the bike's defence it has faired VERY well, it was not designed as a race bike and i have not held back, it's not through ham fisted use just pushing to it's limits

just thinking, i was using the ten on a mates motocross track last week, well for once it was dry!

actually the parts price was a suprise, very reasonable from our dealer. should have them friday

Looks a bit like this (my other bike):
http://upload.maniacsmedia.nl/thumbs/bwy1310496040v.jpg
Good luck with the repairs.

glad its fixable,

when you say reasonable ?

give us a ball park figure

reasonable in one mans eyes can make another cry

http://www.xt660.com/showthread.php?t=17351

seems like this has happened to someone else

http://www.xt660.com/showthread.php?p=159815#post159815

is this guy suffering the same fate as you ?

Thanks for the old thread, i'll be looking into it...

My bike hasn't got through the biopsy yet... the shop i bought it from and did all the maintenance by now got somehow closed... or at least for a while... and when i got it to another i found out it's holiday time :) so at least a week until it gets opened then wait for the pieces to come and so on...

Back on the street bike now, it kind of sucks. No idea how i rode it and was very happy with it 2 years :P

I'd estimate a max of 5k out of the 27k being done off the asphalt and it was pretty mild mostly, so I don't think it failed due to abuse.

I'll post more details as soon as I find out more, for now I'm gonna check the older thread.

hi, it is quite possible a simular failure has occured, when the other is stripped we'll find out.

as for my parts, 2 gears, timing chain, guide, 4 gaskets and the gear stopper lever came to �170, the most expensive was the headgasket at �28 +vat. i collected the bits today. though there was a mistake made with the stopper lever and it may take a while to get, the parts guy recons there is no stock of the part in the main store in holland, i hope he's wrong. anyhow the engine is assembled bar the gear mechanism and clutch casing. all looks well

at the start of the year my gasser broke the main gear shaft and corresponding gear, for just those parts it was �235, not good

fair play that aint bad, did you need any specialist tools to strip the engine ?

hi'ya, very reasonable indeed!

the stripdown was very straight forward, the only stumbling block was the generator/ flywheel, first i tried my 3 legged 10ton puller, chickened out before i caused damage and then fabricated a copy of the yamaha puller thats is shown in the workshop manual, which is a must for the various torque settings and the odd washer or shim that falls out! :laughing5:

btw the timing chain has a lifespan of 30,000 miles[manual again] so it was due a change anyway

a pile of bits in my untidy garage
http://i192.photobucket.com/albums/z...rebuild008.jpg

by heck you dunt do things by halves

good luck with the re build