Clunky gears help
 

Hi guys I have a 2009 xt660r in excellent condition only 7500 miles give it a full service around February runs well my only niggle is the gears are very clunky going in is this normal or is something wrong it goes in gear ok butt ust feels clunky going in

A clunky gearchange can be because of a poorly adjusted chain (too slack).

I'm not sure why, but simply adjusting the chain improves the gearchange. You may also want to check the amount slop in the cush drives.

Old oil, wrong oil, contaminated oil, oil too viscous - sticky/swollen friction plates and/or clutch drag?

Too much freeplay in the clutch cable - plates not fully disengaging?

Missadjusted clutch - lever arm in the wrong position? Do the punch marks line up on the arm and casing?

Gears
 

Thanks for reply it's got new oil in I put 5000 motul in new filter new chain and sprockets which has right adjustment . I think it could be the clutch needs adjusting when I start bike put it in gear it wants to jump forward

I've got the same xt 660z.:tank:

My clunky carry on diminished after I started using 10W50 fully synthetic...using it for the last 20000kms without issue..touch wood :)

Just say'in like....

:)


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Your clutch not slipping at all Ohlins ? I've heard of them slipping with fully synthetic as opposed to semi-synthetic ? Maybe its the ambient temperature that makes it Ok in your bike.

My clunk was all but gone for doing the Kev's Cush drive, & Twist grip Mod's.I also found riding like you stole it made for smoother changes rather than being a bit tentative. Not sure if its just me but it also feels a lot happier on the rough stuff than tarmac.

Thats the trick with all big singles..... to easy to use to lower revs
really they don't like it.. they are torquey but NOT flexable...
big singles are not nice motors...



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Hi

Nope..never had clutch slip at all....46,000kms on the moto...it's ridden hard too especially in the twisties here lol

:)

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Clutch
 

Thanks for response guys mine been clunky since I got my bike last year just thought it was normal I have just put new chain sprocket new Cush drive rubbers oil change 10/40 semi motul 5000 new k/N oil filter still the same bike goes well just these annoying clunky gears

Get the clutch set up spot on, from operating arm to lever. See how you go with that first. I reckon it'll make a positive difference...

Gears
 

Cheers Pleiades readjusted clutch cable has made a difference and adjusted chain still a bit clunky but know we're near like it was my bike is a 2009 was wondering if mine hade a problem with oil feed to gearbox as I have seen on the forum on this year xtr

Good stuff.

I shouldn't fret about that. That related to a tiny number of 2014/15 bikes! ;)

The 2009 3rd/4th gear issues only affect Teneres, mostly blue ones, and only a handful at that.

I find the gear change on my xtr 2009 amazing and smooth. Sometimes it just falls into gear and you can't feel it like it has synchromesh!
clutchless up changes also work like a dream


I never touch anything other that premium full synthetic oil for my bikes and cars. I have used elf 10/50 full synth which is excellent but no longer available.


motul 10/40 7100is very good and much cheaper than 300V if you cannot afford it as is silkolene pro4 plus


correct chain adjustment and alignment also affect the quality of the change

+1. I also use full synthetic apart from a brief experiment with mineral and semi. Found that both of those lasted a very short time before the gearchange went 'off'. Penrite has since marketed a fully synthetic, motorcycle-specific, 15W-50 which my bike seems to thrive on. I have never had any clutch issues with full synthetic, MA-rated oil in any bike.

I think the only proven danger mechanically is bore glazing under continuous, extended slow running/light throttle conditions, which isn't applicable to my Tenere.

However, it is to my main work bike (WR250R), so it runs on mineral oil, changed every 50hrs.

My old and battered TTR250 has always used full synthetic, apart from trying it briefly on mineral oil, and is still on its original clutch after around 74,000km and about 6000hrs. It has an iron barrel liner, so is less prone to glazing imo. They just don't make bikes like that any more for my application.