Hi guys

Ive an 06 XTR 35k miles on it, just had a front puncture repaired and noticed that the pinch bolts casting on the RHS fork has a crack on it like what is documented for the X only this is now on an R.

I know there is another guy from Tyneside who came on here recently looking a fork leg who had the same problem with his R.

Im pretty pissed off at the moment as now the milage is pretty high the problems are all showing there faces (bearings, electrics etc) and as the bike is my only means of transport i either have to luckily get a lift into work with my dad (same area of work) or nick my mums car (again luckly im on her insurance but hassle of organising her to get to work etc)

Any body else had this problem on an R?

Am I still safe to ride the bike? (hard question really but need to ask)

Chances of getting this fixed by yamaha? (even though my bikes out of warrenty a good time ago)

Any ideas where and how much a RHS 06 XTR fork leg is? (not yamaha prices as i will just cry)

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Plough on

Hi Maxwell,
sorry to hear of your troubles, I'll have to keep an eye on my 07 though the miles are pretty low. I broke the caliper hanger on mine last year, Yamaha wanted me to buy the caliper and all �280!! Found one on e-bay �20. Although I couldn't see a hanger I just e-mailed anybody with xt parts and got one off a Russian in London!

hi there,

re. your cracked fork leg problem......

I'd definitely say it's not safe to ride, the front wheel spindle might be torqued into the other fork leg but those pinch-bolts will stop the spindle unscrewing!!!!

Yamaha will charge about �292 for just the lower leg
you'll also need enough fork oil to do both fork legs and a new seal for the
new fork leg (you might as well do the other one while you're on too)

Stripping the forks isn't easy but can be done without the Yamaha special tools if you have access to a compressor/air drill

I'll email you more details...... cheers....geordiebandit

We have seen many 04 to 06 models with the right fork leg cracked. Yamaha did change the design, I have not seen any with the new design fork legs break yet.

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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Kev is this R's, X's or both. From my knowledge its only be logged on here with X's and ive only seen one R which was geordiebandits.

__________________
Plough on

There has been R & X's cracking the right fork leg.

__________________
Click here to join the XT Supporter's scheme

Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
[
My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

To keep you's up dated ive got in contact with my local mechanic and he knows someone who can weld anything and he said hes done things like this many a time with no problems. So going to take both forks off thursday night, the mechanics going to strip the right fork and give the guy the fork leg to weld, then the mechanics going to change the fork oil in the left and reassemble both forks.

Ive been told hes a tidy bloke so watch this space.

__________________
Plough on

A friend of mine who I've been motorcycle touring with over the last six or so years (not all on XTs!) suffered a cracked fork leg on his 2008 R.

Whilst we do a lot of our touring on very poor Eastern European and Asian roads (and in the UK!) these are nothing that the bikes were not designed for.

He waged a letter writing campaign against Yamaha and I think they only gave him a small reduction in the new cost of the fork leg, if only to shut him up.

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Simon

Brighton, UK

Unfortunately from a little research in the local market, it seems that it is a very common problem and the used-part dealers are requesting a huge amount of money for this specific part, which in my point of view it doesn't worth to buy, since there is a big chance to have a new crack again after some time.
Since this issue is corrected in the new version of XT's, does the new one fit to older models? (mine is a 2004 model).

Hi guys fast for ward to 2016. My 2006 XT660R fork keg lower has cracked at the pinch bolts. Yamaha no longer sekl the fork leg lower on its own bit will sell the whole fork leg stanchion and innards for �500+ :-o

Local welding firms don't wanna take liability so won't weld. Asked three different firms now.

Rang breakers all over the breakers in the uk. General feedback is not many XT's broken when they are the front ends usually bought by someone pretty quickly.

Any ideas . Really like to get it back on the road unless it's worth breaking and selling to fund another XT? Help. p.s
Are the XT660X fork leg lowers interchangeable with the XT660R LOWERS (eg same stanchion and internal workings and spring dimensions? )