2010 660 tenere Clanking feeling ?
 

Hello folks so over the last two weeks ive had some issues with my 2010 660 tenere. I replaced my rear disc and pads as the disc was worn but nothing terrible and plenty of miles left on the pads. I also fitted a brand new Anakee 3 tyre which has served me well so i got another one.
I fitted the wheel and checked my chain tension and made sure it was all aligned i used a ruler as well as the marks on the swingarm and its bang on.

The problem i have is a weird knocking/clanking feeling when i let the bike just roll for example pulling the clutch in and coasting. I have even turned off the ignition and let it roll down a hill and i can feel something is clanking there is a thump every now and again. I checked the front sprocket nut and it was lose. Luckily the washer did its job and kept it in place.
I re tightened the nut to spec and again re checked my chain to make sure it was aligned and at the correct tension.
I have also checked my brakes are moving free and not seized up. They are not binding on the front or rear discs.
The bike has 18k miles and runs great engine wise did the valves about 3 months ago and also do oil and filter changes every 3.5k miles. It runs fine at motorway speeds and starts and stops with out any issues just this strange rumble feeling you can feel it on the pegs. I am starting to wonder if it could be a bolt a bolt lose somewhere. Ran out of things to check so i would be really grateful if anyone could give me some advice.
Any ideas whats causing it ??
Cheers :)

Seems we have the same problem, I call it a rattle
But, your description of clanking is more or less my problem, will follow this with great interest
I'm in the process of getting new cush rubbers and chain and sprockets

Its kinda of a thump now and again. Its really hard to explain without someone sitting on the bike. I just changed my cush drive rubbers and added a bit of inner tube. But i dont think its that making the thump/clank/rattle as i had a pair of worn out ones and they didnt make any difference. Hopefully someone will know :)

could it be the infamous loose crankshaft nut ?..

The most common cause of clanking and banging (after fitting new discs and or pads) is that the pads have not been located (hooked over) properly in the front of the caliper. Also check that the caliper is located properly in its slot in the swingarm.

Thanks for the advice I will check it them tomorrow the brakes do feel a little different as the brake pedal seems to move down further than before. I just put this down to the new disc. But maybe I have not got it full inserted into the swing arm. Also noticed the the spacer on the sprocket side is very lose theres about 2-3mm of movement when its in the sprocket carrier.

I have checked the rear bearings and they feel fine nice and smooth. I have not re greased the swing arm bearings and wondering if it might be something to do with that.

With the bike on the center stand the rear wheel moves freely without any noise just a faint sound of the pads on the disc and the chain but nothing more than any other bike ive owned.

Really want to get this sorted asap worried about it locking up :(

Update
 

Had a look today and the brake caliper is in place fine with no movement.
Banging got louder on my way to work this morning so managed to get it into a yamaha dealership on my way home. They were kind enough to stay open late for me to check it over for free.
They checked over the bike and said my chain was to tight however i had adjust it this morning before work so its tightening up somehow. They reckon its the chain and sprockets thats gone bad. They did say it was really clean and shouldn't be gone with only 6k miles on it.
They re adjusted my chain again which made no difference at all for me but the guy there tried it and it was less bad for him than the first test ride he had on it.

They reckon its something to do with the chain and sprocket cant get it in till Saturday so ill update this thread then to let you know what the issue is. That is if they find it.

I've been told that my cush rubbers are shod, ordered a set and will try, seems it's a mystery
Good luck, will also report back after installing rubbers

Ive got a brand new set of cush rubbers fitted. Plus my chain has no tight or seized parts so im totally out of ideas. Defo not the cranshaft nut as there is no engine rattle and the engine runs sweet as a nut and the valves are all within spec. Im worried it might be the gearbox thats causing it but i have no idea. Hopefully they will find out and get it sorted on saturday. Need to use the bike 40 miles a day till then tho so im hoping its not going to get worse.
Hope its just the rubbers you need good luck.

"Im worried it might be the gearbox thats causing it but i have no idea"

Thought crossed my mind but was too afraid to mention it

Im sure its not the gearbox i can change gears without any issues and it feels fine. Just getting worried with the clanking rattle getting louder and more common. Seems to be worse when i pull the clutch in at under 10mph and let the bike coast. It sounds like the rear sprocket might be distorted or at and angle but if it was that it would be making the sound all the time.

Brains melted for one day fingers crossed it will get me to work tomorrow :)

Main reason i got this bike was for something that would be reliable and simple to work on. Guess thats gone right out the window now haha

knocking noise
 

check your main stand has not lost one of its locking nuts, it does knock on the pillion foot rest on a bumpy road. Steering head bearings collapsed very loose?
loose rear sprocket, knackered rear shock (very unlikely). generally check all major bolts on the frame. You will find it eventually.

Cheers for the advice I really appreciate it. I just replaced my steering head bearings about 1k miles ago. Ive not re checked them since so i will have a look and check to see if there two lose or if there goners.

I will re check my sprocket the spacer that goes in that side is very lose i think that might be the main cause tbh.

The previous owner had a chain snap on him and it destroyed the chain guard and also badly scored up the sprocket carrier. Found a piece of the chain guard hiding behind the rear shock the other day when trying to find the cause of this it was badly chewed up.

It does feel like something is possibly lose. A few weeks ago my side stand almost fell off the two bolts almost totally feel out. The joys of motorcycles :)

i went through the obvious nuts and bolts when i got my bike. Shouldnt have been surprised that things were loose..tis a big single after all.

Yeah shouldve known better. I went from a silky smooth triumph scrambler to the 660 and apart from this i have not regretted it.

Happy to report this
I changed the cush rubbers and gone is the noise, thank goodness for that
So, I'm sorted, also changed rear break pads

Thats great mate glad your all sorted.

Think my gearbox is wrecked had to limp the bike home. Checked my oil and was way under what it should be. Had to put 800ml to get it back up to the full line. Only checked my oil about 500 miles ago and was bang on the full line. Checked today and it was way under so looks like ill be paying for my gearbox to get striped and checked. Ive probly done some serious damage so a lesson learned check your oil level.

Are you saying the drop in oil level has caused a gearbox fault, or are you saying a gearbox fault has caused a drop in oil level?

Do you know where the oil went? Any obvious leaks? Is the engine burning it? It must have gone somewhere? You really should ascertain this before you go any further down the line of condemning components and potentially spending what could be a decent wedge of cash.

I am obsessed with looking after my bikes last checked my oil 500 miles ago and it was on the full line. I changed the oil and filter about 2k miles ago there was no metal shavings and the oil i drained look great. I ride everyday and cant afford for them to get damaged by not servicing or looking after.

I have zero leaks and the bike runs great not burning oil or making any noise (apart from when its rolling with weight on it somewhere near the front sprocket i think).

I have never had any experience with a gearbox going on a bike.

Totally out of ideas im a DIY mechanic not a prof. I can do all the basics but when i comes to something like this I feel its best to get a professional to take a look.

The oil drop really worries me i didnt think for a moment to check it lesson learned.

Cant find any info on this anywhere on the net. I dont know why the oil has dropped or if this has happened to anyone else.

I ride 100% on road with road tires the bikes only got 18k miles on it and its been serviced on time. Im not red lining it or hitting the rev limiter so completely in the dark here.

Now i need to find a way to get the bike to the garage to get it checked over.

Still, if it ain't burning it or leaking it, it must have gone somewhere? Is there a lot of oil in the airbox drain tube? Have you taken the airbox side cover off (LH) and had a look inside? Most of the time "missing" oil ends up in there.

Havnt checked that i will have a look and report back. Thanks again folks for the help really appreciate it :)
I have it booked in tomorrow need to get it to the garage tho still need to figure that out. I have breakdown cover so i might call them up.
I will report back tomorrow.

Update
 

Got the bike looked over today at the yamaha dealership. They have checked the gearbox and its fine. There has been no obvious damage from running it low on oil.

However the couldn't find what was causing the noise. They think it might possibly be the bearings in the rear wheel and sprocket carrier hub are heating up and causing the the noise as the seals were gone and but they still feel not to bad. They are still not sure what it is.

While they were swapping the hub bearing out the hub cracked really badly. Looks like the previous owner had a chain snap and its seriously damaged the hub. It was badly scared on the outside of the hub and when the mechanic removed the bearing the hub basically split right down where the bearing sits. Looks like it must have had a fracture from when the chain snapped on the previous owner. They have gave me a courtesy bike so i can get to work. Will report back after the hub is replaced and new bearings fitted.

Should have the parts in by next weekend so will be report back then.

ouch..are they accepting liability on the hub?..

Nope but its not there fault the hub was badly chewed up from the chain snapping with the previous owner. Plus i watched the mechanic when it happened he wasnt to hard on it and it just gave up. �200 fitted with all new bearings, bolts and nuts. That includes labour and all the parts i thought that was ok. Still not 100% sure thats what was causing the noise but im sure its not helping. Plus got a courtesy bike free of charge which I really cant complain about.

Fair enough..i guess its a lot better than the hub going when your riding it!

dont bear thinking about.

Yeah that was my exact thought when i seen it brake on the bench. Hopefully getting it replaced with new bearings will sort out the noise.

Glad your bikes getting sorted ...hopefully this will cure the clanking. Steve

The rubbers chew into the metal, I'm afraid that the sound has not gone away, hope it's not in the gearbox, still hear it when applying power, from 2 nd to top, quite worried
But, can it be the chain slider on the swingarm that's gone?

https://c8.staticflickr.com/9/8280/3...74a90b96_b.jpg

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Seems this is a weak point on the XT660Z ?

Mines was not as worn down as yours mate. The mechanic still isnt to sure whats making the noise. My bike should be back on the road by this Friday. Mines mainly makes the noise when the bike is in neutral or i pull the clutch in and roll under 20 mph. At speed its fine and doesn't make any noise.
Hopefully i can give you an answer on friday.

The dealer said its not my gearbox on my bike he said it would be making the noise all the time and theres no play on the front sprocket shaft. Its moving nice and smooth.

Its a shame I loved the bike till i started dealing with this getting close trading it in and getting somethings else. Need something reliable to get to my work :(

Good luck, I think it's the chain that stretched on mine

Update
 

Well picked up my bike today and the noise is there more than ever. The mechanic crawled along side me while I was sitting on the bike and its my chain is wrecked. It looks great and theres no stuck links at all however.

The problem is its badly stretched. The when sitting on the bike and checking the chain it turns out that theres loads of play in some bits but when i roll it forward maybe a foot. The chain is so tight that there is less than a millimeter of movement.

So ordered and new chain and sprocket kit and ill update you when its fitted.

Never had a chain look so new and be so wrecked its crazy.

2010 660 tenere Clanking feeling ?
 

Looks like you're getting closer to sorting out your problem. Sure sounds like it was the chain after all. Hope it's sorted now.

You are checking the oil correctly are you? Ie immediately after a ten minute run, if you check it in the morning without running it, it won't show on the dip stick even though there is enough oil in the engine.

I checked my oil after about 40 mins. Did an oil and filter change yesterday as i was a bit worried that there might be some metal shavings from running it low but the oil looked great and the filter also looked good.

its my chain thats gone. When i sit on it and feel down after rolling about 2ft the chain goes from having about 2inch of movement to having none. I dont know what brand the chain is and it was replaced before i got the bike from the dealership. They charged the previous owner �180 for it aswell that didnt include labor for fitting it. There is zero rust on it and it looks almost brand new i run a scottoiler and keep an eye on it thats why i didnt expect it to be that.

Live and learn i suppose.

All FIXED :)
 

So I fitted a brand new DID GOLD chain and sprocket kit. Bike is running great there is no clunking anymore and the bike handles much better its not surging anymore.

Cheers for all the help. Sorry for the late reply but ive ended up with pneumonia so bed bound and on antibiotics.

But on the plus side my bikes all sorted :)

******. pleased its sorted. Its allways summat easy..ish in the end.

get well soon.

All the best for a speedy recovery mate. Chuffed the bikes all good again for you to.

And just think, you nearly had the engine stripped looking for a gearbox fault! Lucky all it turned out to be was a goosed chain. Glad its all sorted.

Get yourself well, and get riding...

Good result....get well soon! Steve