Gearbox Failure: Calling all XTZ owners who have suffered it
 

As you may have read elsewhere, it has become apparent that there are a number of MY2009 XT660Z T�n�r�s that have suffered from premature gearbox failure, usually the dogs shearing on either third or fourth gear. I don�t want to make anyone unduly worried; this appears only to be a problem with a small batch of 2009 built XTZ models, it doesn�t seem to affect XTX, XTR, or for that matter XTZ models from any other years apart from 2009. We are only talking of seven bikes identified on this forum (which has over 10,000 members), so no need to panic! However, there does seem to be a pattern developing that�s worth investigating further and possibly pursuing with Yamaha, especially so if you had the misfortune to suffered a broken gearbox, or perhaps own a 2009 T�n�r� with sticky gears, false neutrals etc.

What I am attempting to do is build an accurate picture of what is happening, and in particular try and determine if there is any pattern to the failures in order to put a case to Yamaha on behalf of all the owners who have suffered this issue. There is greater strength in numbers and when you have the facts at hand.

If you currently (or have) owned a T�n�r� that has had a gearbox failure, I would be very grateful if you could supply me with some basic details of the bike concerned. If you no longer own the bike, it would still be really helpful if you could still provide the details (or as much as you can remember) if you can.

In order to put a valid case to Yamaha, I realistically need as many sets of VIN and engine numbers as possible. The more details we get, the more forcefully I will be able to pursue the issue with Yamaha and the more likely that they will investigate it further, which at this stage, I would suggest is the main aim.

So, if you are one of the unlucky few, and you can help, then please provide me details in the following format by PM (for obvious security reasons):

Forum member/owner:
Engine number:
VIN number:
Date of first registration:
Country of registration:
Odometer reading at time of failure:
Date of failure:
Gear failed:

Note: Do not post this information on the open forum.

Many thanks. I�ll do what I can, as much as anything, because I know how I�d feel if the same misfortune befell me.

I have opened a dedicated thread in the Italian forum of CTI (Club T�n�r� Italia). Thread here: http://www.clubtenereitalia.it/viewt...475601#7475601

I will myself send you the data and possibly pictures ASAP. Thank you for your dedication.

Thanks for that Pepsi. I've got to do the CaptMoto's Facebook group https://www.facebook.com/groups/4737543350/. I have to say I'm not a massive Facebook user and wasn't aware of the other two groups.

Well I've had four replies so far: Niek, Mech, oldmanthatcansee and Mr Konik. :signthankspin:

Not really enough to go on yet though.

@Chenko - I can't get the link to the Italian Tenere forum to work?

Keep the information coming - there are at least three more registered members here who have not come forward yet...

Gearbox failure
 

It happen to my bike. Here is thread: http://www.xt660.com/showthread.php?t=22971

Sorry for getting back so late, I don't have the failed engine myself, it sits at a friend of mine's house and could not get to it until yesterday. I took pictures of engine ID number and some pics of the damage too

http://i959.photobucket.com/albums/a...psvl8peqtn.jpg

http://i959.photobucket.com/albums/a...ps0spxn5jv.jpg

http://i959.photobucket.com/albums/a...psha9zaapu.jpg

http://i959.photobucket.com/albums/a...psuo1ae7r4.jpg

http://i959.photobucket.com/albums/a...psb9hzmsib.jpg

http://i959.photobucket.com/albums/a...psvjbvsome.jpg

Italian forum thread is not accessible because the whole forum was updated recently.
New link is: http://www.clubtenereitalia.it/index...ura-del-cambio

Hi, I had a 3rd gear failure on 2012 xt660z. 3 No. dogs were found in crankcases when clutch cover was removed. Gearbox started making clacking noises which at first I thought was chain clatter, however as noise got worse it became apparent it only happend in third gear. As I was on a european trip I carried on riding the bike for a further 2000 miles with third gear getting harder to select and not being able to change up to 4th. Fortunately the bike made it home and on removing the clutch cover and clutch I found the broken gearbox parts sitting on the bottom of the cases. I haven't got round to stripping the engine yet to see the full extent of the damage. miles 18000.
Engine No: M311E0007353
vin No: ZD0DM021000007619
1st Reg:16/03/2011
Country: UK
Mileage 18000
3rd Gear

Hi, I had a 3rd gear failure on 2012 xt660z. 3 No. dogs were found in crankcases when clutch cover was removed. Gearbox started making clacking noises which at first I thought was chain clatter, however as noise got worse it became apparent it only happend in third gear. As I was on a european trip I carried on riding the bike for a further 2000 miles with third gear getting harder to select and not being able to change up to 4th. Fortunately the bike made it home and on removing the clutch cover and clutch I found the broken gearbox parts sitting on the bottom of the cases. I haven't got round to stripping the engine yet to see the full extent of the damage. miles 18000.

1st Reg:16/03/2011
Country: UK
Mileage 18000
3rd Gear

Thanks for this information. I will add it to the database.

I am still waiting for a reply from Yamaha relatinging to my last communication, which was three months ago! Time to chase them up again me thinks.

BTW, your bike is very unlikely to be a 2012 model as its engine number comes from a sequence issued in... you guessed it 2009! It falls slap bang in the middle of the range of bikes that have exhibited this problem. I would guess that it was unregistered old stock in 2011 and then bought and registered?

FYI - The affected engine range based on data collected is: M311E-006404 to M311E-0009244

Note: I've removed the frame and engine numbers for security - we don't want anyone cloning your bike!