XT660Z gear box problem � 3rd feels like neutral!
 

Hello, I would appreciate any advice on my beloved XT660Z.


3rd gear feels just like neutral. It happened all of a sudden, accelerating up through the gears and 3rd wasn�t there, with the engine revving like it had slipped into neutral. All the other gears feel normal, there is no clunckiness to the gears, no strange noises when in 3rd.



The bike has 26k miles, and is a 2009. I have read on the site that 2009 versions are prone to gearbox issues, but can�t find an issue similar to this one. Maybe it is a problem with the gear selector mechanism rather than the gears themselves(?)


I have some mechanical knowledge, but have never taken a gearbox apart :-/. My current plan of action is:


1. 1. Drain the oil and remove the clutch to take a look if there are any metal bits inside, like with some of the other �09 gearbox issues.
2. 2. Start the process of removing the engine so I can either open the crankcase up or hand it to a specialist.



Can anyone suggest what the problem may be? Could it be solved without removing the engine from the frame?


Thanks, Mike

if your engine number is between 6200 and 9500 it's more than likely your motor has broken a third gear. But have a look at the spring on the stopper arm mechanism. Look up A J Sutton. UK for this part to see what we're talking about.

Thanks Chalk Two. It is one of those motors :-/

I'll give the spring a check anyway. If i'm opening up the gearbox, are there any other weak points I should look to replace?

The bike is awsome and i want to put another 20k miles on it before I even think about putting it into retirement..

This exact same issue happened to a mate of mine in June, 3rd gear just spinning out. The problem was the three pegs that hold 3rd gear to the shaft, all failed and the gear was just spinning.

�700 or so later and the bike is sorted..... it has to be said he has neither the time or skill to repair this so it went to a mechanic. whilst it was stripped it had a full check over, not sure if any other bits were replaced, at that price I would guess it did (I'll find out this weekend). He was pretty lucky in that it didn't destroy anything else.

It's a 2009 bike too.

Very interesting. At least I know what i should be looking for now when I open her up!


I'm about to remove the engine from the frame. Nothing out of place when i checked the gear selector.
I have the skills to take it all apart...putting it back together again might be a different matter..! haha

Looking forward to hearing if he had any other work done while in there. Cheers