Gearbox Failure: Gearbox problems
 

After 140.000km the gearbox of my 2009 Tenere gives problems. During some upshifting the mechanism blocks and I am unable to **** up. Some poking around frees it up and makes shifting possible again.

When it is shifting oke, everything goes smooth and it does not shoot out of a gear once it is selected. So it think I do not have bended forks but the shifting mechanism itself must be not as new.

Somebody experience with this. Can it be solved without splitting the cases because in that case it will be the end of the Tenere age for me.

No ways you can do proper gearbox repairs without splitting the motor.
Bit of a hassle but fairly straightforward.

Not sure what the xt looks like inside yet but my ktm had a shifting arm in the clutch side case. Might be an idea to have a look in there first as it might just be a broken spring in the shift mech instead of gears / forks

Found out shifting is doable when shifting really slowly, so pulling the clutch, wait a few milli seconds, shift up and release the clutch. Will see how long it will work this way.

Hi Neik, I had a similar failure 2 years ago, a spring loaded arm with a bearing attached is used to help locate the gear selector drum to the correct position, (peg against a star shape) the bearing on mine fell apart allowing 2 gears to engage causing the 3 gear to fail.
if you remove the clutch cover and clutch it is easily visible, at least it's handy to check before having to delve deeper into the engine!

offending lever bearing
http://i192.photobucket.com/albums/z...geardoh001.jpg

damage to gears

http://i192.photobucket.com/albums/z...amily11528.jpg

Hmmmm nasty.

Hi Niek, just to add there's a bit about the gearbox overhaul here http://www.xt660.com/showthread.php?t=17351

That is more what I thought. This is located behind the clutch isnt it?

thanks

Nasty for sure....
think I should have a look at mine... Only have 36,000k
on it now...
So thats the de-tent.. that index's the selector drum ?

Hey dont panic Petenz, your mileage is much smaller AND I understand that the gearbox on the XT is really fairly bulletproof so this kind of occurance is a remote possibility. Does Stoic know what caused the failure????

That is more what I thought. This is located behind the clutch isnt it?

HI Niek, Yes, low down behind the clutch. if you have the pdf workshop manual from this forum. the clutch strip down is starting on p226, a good view of the offending gear change ratchet mechanism is on p244. it's fairly straight forward to check the lever bearing, mine collapsed. if that's fine the engine would be as well to be removed and split before real damage is done.

Petenz, chill out! unless you are experiencing gear change problems all's well, I've
done 25,000 miles since, without a problem, in all kinds of conditions

Roma, yes! actually i do know why