Tenere engine overhaul - .: XT660.com

buzzlightyear · # 1 21-09-11, 21:15

I would like to know how many people have had their engines overhauled due to dust in the airbox. Also please state the mileage at which it was overhauled.

The reason why I'm interested in this is that we've had a couple of the first 09 models to arrive here overhauled due to dust and grit in the airbox, this was with the std airfilter and snorkel, Yamaha SA then did a recall and all was kitted with DNA stage 2 filter and topcover. However, I'm not sure the real cause has been addressed yet, so I'd like the input from the broader user base.

Hunday · # 2 21-09-11, 21:52

My bike started using oil at around 16000 km , and the agents replaced my barrel a,pistons and rings at 32 000 km,
I have since put red rubber grease on the LH and RH Air filter side covers , I have fitted the YZ 450 Quad foam filter over my DNA filter to ensure no dust enters the box.

The air filter box drain pipe is too long , it catches on any bush or rock you ride over and either pills the blank plug out or splits the pipe when a rock squashes it against the frame , solution , cut it shorter , fit a 8mm bolt as a plug ans a decent hose clamp.

Finally , I dont get anymore dust in my air filter.

PS , I did 74 000 km on my previous XT660R with no problems at all.
So I know these motors rock !!!!

dallas · # 3 23-09-11, 19:26

With my june �08 XT660Z Tenere, I�ve done 65.000km�s so far and bike is still runnin� just fine. Still very smooth(for a thumper!), good fuel economy(1lt:25/26km on backroads, runnin' between 3500-4500rpm; highways 1:20), no oil consumption, hardly no vibes. Engine is standard, only got Leovinces. Just got my fourth set of tyres&chain/sprockets(so an average of around 20.000km for both; now K60 Scouts instead of Tourances). Very reliable bike, never let me down(no electrical problems with mine, just take care with it the right way) and still lotsa fun to ride. WHOAA!!
Greetz, Hans.

Kev · # 4 23-09-11, 21:43

Yamaha South Africa knew about this problems a fews years back & did nothing to recall these bikes to get them checked out, DNA responded straight away when the problem came to light with a bigger seal. South Africa was the only country I know of that had this problem in 09/10, hopefully your pole will show the regions that had this problem more clearly.

The problem was the air box moldings were made to different dimensions & were not consistent in size which could allow for unfiltered air past the main filter, Australia responded with all the OEM fitter being removed at PDI & replaced with a Australian brand foam filters.

Also know of one or two side panels not sealing on the XTZ air box's, I would remove them & seal them up with water proof grease to be on the safe side.

66T · # 5 25-09-11, 10:39

I'd just like to say that Kev and hunday are right; except that not all Teneres had foam filters fitted from new. I know of three that weren't, including mine. I had to buy my foam filter. Small price to pay for peace of mind.

I agree about the oil drain pipe - it is a menace. Hunday has the solution and everyone should seal the airbox sidecovers and do the pipe mod before there's a problem. I used blue (O2 sensor-safe) gasket sealant on mine. Fingers crossed...

buzzlightyear · # 6 30-09-11, 16:28

Quote:

Originally Posted by Kev

Yamaha South Africa new about this problems a fews years back & did nothing to recall these bikes to get them checked out, DNA responded straight away when the problem came to light with a bigger seal. South Africa was the only country I know of that had this problem in 09/10, hopefully your pole will show the regions that had this problem more clearly.

The problem was the air box moldings were made to different dimensions & were not consistent in size which could allow for unfiltered air past the main filter, Australia responded with all the OEM fitter being removed at PDI & replaced with a Australian brand foam filters.

Also know of one or two side panels not sealing on the XTZ air box's, I would remove them & seal them up with water proof grease to be on the safe side.

So you're saying there was an actual problem with the DNA topcover seal? First word I'm hearing about this in SA?

Kev · # 7 30-09-11, 23:29

Quote:

Originally Posted by buzzlightyear

So you're saying there was an actual problem with the DNA topcover seal? First word I'm hearing about this in SA?

It was an isolated problem back in 2009 which we covered in detail & would affected most brands of air filters fitted to the early Zed's as the air box was at fault.

A hand full of air boxes from Yamaha seem to have had bigger dimensions where the filter is placed by a 1 to 2mm, DNA responded straight away with a bigger sealing air filter foam for it's brand which would cover all dimension air boxes.

My advice is if you are riding in dusty conditions on any bike is to check the air box is dust free in the filtered area. On the Zed remove the air box side cover & inspect, remember to reseal the cover with some grease when fitting it back.

View Poll Results: Has your Tenere been overhauled due to dust in the airbox causing excessive wear?
engine overhauled - dna stage 2 filter	1	3.33%
engine overhauled - dna stage 3 filter	0	0%
engine overhauled - std filter	1	3.33%
engine not overhauled, using oil	0	0%
no problems	21	70.00%
what you on about	7	23.33%
Voters: 30. You may not vote on this poll

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