As well never seen it come through the casing before.

So how many Tenere's with dead gearboxes now?... Mine, Chenko's, Stoic Bloke, and one more if i good remember. Rather shocking.

I'm very worried. Seems to be related to that one bearing failing on the Stopper lever ass
(part no 5JW�18140�00). I've replaced mine and I'm going to buy a few more.

I wonder what the conditions are to cause the failure. High revs or bad gear shifting.

Dont want to sound bigheaded, but there is realy nothing wrong with my shifting. Never shift without the clutch, never lock the wheel on down shift and very rarely done halfshifts (neutral between gears).

I think in my case load on the transmission from heavy, fast offroad and jumping made contribution. But i think main problem is rather poor quality in modern products.

I Agee with the quality of modern bikes. I just retired a twenty year old bike that I did no maintenance on and screwed the living day lights out of it every single day and the thing would probably do another twenty more years it was just too fast for me and getting me in trouble.
I'm not sure if the tenere can be classed as modern anymore?
Anyway, there must be some other factors at play as a lot of teneres are seeing the world.

4 out of 10, 20, 30 thousand ???? How many world wide?? Shocking!!
Imagine if KTM had those stats, people would start to think they were reliable.

Imagine if you were one of those few. And I'm sure statistically wise the figure is much higher after reading other Australian forums.
Finally, how many bikes fail is incidental, the point is it should not happen under normal riding conditions. Yet modern consumers put up with all sorts of s....
If something similar would happen to me, I would be f.......d. I can't go to work and more importantly I can't by a new ktm I should have bought in the first place

I have the KTM now (and again - should have buy this in first place, not due to reliability, but due to fun factor) and i will be able to see myself if it's better or not if it comes to reliability. One thing i know for sure - i have choose Tenere before because i was able to give up power wheelies from second gear, 135MPH of max speed and acceleration close to sports bike for a price of reliability... now how disappointed i was when after two weeks from spending 500 pounds on proper service i have such serious failure. I'm sure for many people Tenere will serve long years and mileage - i was just unlucky, but this shouldn't happened in Japanese bike.

For those with broken gearboxes, I'd like to say that I feel for you. Very bad news.
I'm just going to throw my 2c worth in here, with the understanding that I'm not pointing finger but maybe offering a reason why the lower-mileage bikes might be broken.
It's my experience that no 'modern' big single engines, ie >500cc, like being heavily loaded at low rpm. I've seen XRs, DRs and TTs with hammered main bearings and broken gears because riders thought that big singles should be able to grunt around under 3k rpm or so. The problem seems (to me) worse in relatively long-stroke engines.
Also, with respect, I think that jumping a heavy bike like the Tenere and subjecting the gearbox to shock loads it may not have been designed to cope with could have something to do with a catastrophic failure.
I had a Husky TE610E which broke a gear dog, which luckily stuck to the magnetic drain plug. It ran fine, and still is, for all I know, without replacing the gear. I did about 15k km after the failure. But this sort of thing should never happen, and nor should engines/gearboxes fail for the reasons outlined above.
The reality is that they clearly do not stand up to severe use, and in some cases normal use, as well as they should.
So any engine which is thrashed offroad will usually have to be rebuilt sooner than one that isn't, I guess.

This is kind of ironic since #1 reason I bought this bike was reliability and low maintenance. So what are in your opinion the most reliable motorbike engines if not big singles? Trying to get some knowledge out of this bad experience.