After 140.000km the gearbox of my 2009 Tenere gives problems. During some upshifting the mechanism blocks and I am unable to **** up. Some poking around frees it up and makes shifting possible again.

When it is shifting oke, everything goes smooth and it does not shoot out of a gear once it is selected. So it think I do not have bended forks but the shifting mechanism itself must be not as new.

Somebody experience with this. Can it be solved without splitting the cases because in that case it will be the end of the Tenere age for me.

No ways you can do proper gearbox repairs without splitting the motor.
Bit of a hassle but fairly straightforward.

Not sure what the xt looks like inside yet but my ktm had a shifting arm in the clutch side case. Might be an idea to have a look in there first as it might just be a broken spring in the shift mech instead of gears / forks

__________________
check out www.redbikejohn.com for all the latest race reports from the CHEC and enduroland.

Found out shifting is doable when shifting really slowly, so pulling the clutch, wait a few milli seconds, shift up and release the clutch. Will see how long it will work this way.

Hi Neik, I had a similar failure 2 years ago, a spring loaded arm with a bearing attached is used to help locate the gear selector drum to the correct position, (peg against a star shape) the bearing on mine fell apart allowing 2 gears to engage causing the 3 gear to fail.
if you remove the clutch cover and clutch it is easily visible, at least it's handy to check before having to delve deeper into the engine!

offending lever bearing


damage to gears

Hmmmm nasty.

__________________
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

Hi Niek, just to add there's a bit about the gearbox overhaul here http://www.xt660.com/showthread.php?t=17351

Wow! Don't think you're going to fix that in a hurry!

I've heard of 3rd gear letting go before, but never anything as drastic or terminal as yours!!

__________________

As well never seen it come through the casing before.

__________________
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

So how many Tenere's with dead gearboxes now?... Mine, Chenko's, Stoic Bloke, and one more if i good remember. Rather shocking.

4 out of 10, 20, 30 thousand ???? How many world wide?? Shocking!!
Imagine if KTM had those stats, people would start to think they were reliable.