You just have to take the crankcase cover off on the clutch side. It's well documented in the manual and easy.

Decision made... shopping around for KTM 690 Enduro R begins... In the mean time without the rush i will try to sell Tenere as a non runner. Shame, as i was very happy with Tenere until she proves that biggest selling point over KTM - reliability - it's only a myth.

Shame about your Tenere... fix it & yer have a reliable bike...
The 690 is a good bike..but are not without there issues...

+1. As a matter of research (!) I looked at a 690 forum. Seems to me they have their own raft of problems, like a percentage of every brand.

Bad that your Tenere has gone wrong - the above comment doesn't help that issue much.

I wonder if the shift drum stopper bearing fails due to inevitable falling down issues on the trail. There must be a reason other than general crappiness, because some owners don't seem to have the problem even after big miles.

To be honest i was riding rather aggressive offroad... with some jumping and hard accelerations over harsh bumps which was putting loads of force over the rear wheel - clutch - gearbox. Many of my riding mates has said that they never seen someone on this type of bike riding so fast off road. Looks like i was having a wrong tool to my type of work. But then again - it wasn't rallying...
And i know - all bikes has their own problems, and i can understand that. I can cope with electrical regulator fault, with rear shock going bad after 20000 or other issues, but gearbox... That is a bit too much for me.
Now i got a real big problem - 690 is too small (i like bigger bikes) 990 had a long list of common issues and f800GS sounds and look grim... Still think Tenere is the best dual sport bike and i was planning to stay with her for at least two more years (even spend 530 quid on proper service with trusted mechanic two weeks before she decided to blow). :icon_neutral:

Yes, it's a shame that a cheap part failing causes so much damage.

Would hard riding damage the shift drum locator? I don't really know, but it seems unlikely. Others here will know more than me, though.

Could it be the nut on the crank shaft coming loose perhaps???? I would not sell it as a non runner cos you will get peanuts.......Always worth fixing.

Think outside the box - fit a 690 ktm engine into the xt660z!

Already take out right hand crank case cover - crank nut is nice and tight with washer bend on on one side preventing to loosen up.

That is actually very good idea :-) But for someone with good garage equipment and some welding skills... and offcourse lot of money as this wont be cheap.
... it would make a cracking bike, but will have to stick some decent WP forks and rear shock. But then - is it not cheaper to buy 690 enduro and chuck some rally raid tank/fairing kit?


In regards to 690 enduro - i have done a test ride on it last saturday.
In the end i didn't fall in love due to couple of things:

- small... i know - small means lighter and this is better, but God, how i love the size of tenere :-(

- traction on the tarmac - due to light weight and off road tires this bike traction on tarmac was totally rubbish. From 70MPH front end gets very light and catch the shimmy even on a straight road... I have a TKC 80 on my tenere on the front, and yes - it was bad, but not as bad as with 690.

So now i have a big problem - get 690 and stick some rally raid fairing on it or get 990 adventure...