Hi there,

few months since I last visited the forum.

I am doing a big trip from London to Asia. I am right now in Osh, Kyrgizstan.
Few days ago a hit a big rock in the Pamir highway with my XT660z 2009 and made a big hole in the sump of the engine.
I brought the motorcycle to Muztoo workshop where they can certainly do some welding to fix it.
The problem is that during the process, a piece came off the gearbox, and we are not quite certain about what is this piece and what is its function.

Here a picture of the broken part:



I had a look to the parts manual, but still cannot identify it.
Any help will be more than welcome.

THe Tenere has been great so far in the 18000kms we did together in the last 5 months.

Here a few pictures taken after the disaster...








Cheers

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RTW from London to Australia - May 2014 - http://www.hebbortw.com

Firstly, bad luck mate. Seems as though you're OK, which is the main thing, and I hope you get sorted and out on the road soon.

It is almost certainly part of the dogs that have broken off either the 3rd or 4th gear pinion. In basic terms, the function of these dogs, or castellations, is to lock in to holes in the next gear in order to engage it.



They tend to brake off when the is a large of sudden difference in torque between the input and output sides of the gearbox, usually at the point of a gear change. For example, sudden clutchless down shift or up shifts, multiple clutch-in downshifts at speed, output shaft locking up (chain breaks and gets trapped), or something physical stopping either shaft in the gear box turning in relation to each other. The last is probably most likely what happened to you, although it went down on the gear lever yes(??), which could have inadvertently made a sudden gear selection as you crashed?/

I assume that piece fell out of the hole in the crankcase? If it did, that's at least some good news, because there's less likely to be bits in the engine itself and caused damage in there.

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Hi Angel,
Sorry to hear about your mishap, good that you are in one piece.
Since I just replaced engine in my Tenere and I have old one in pieces I just went to see what can I find. Unfortunately I'm 99% sure that the part you need is the same part that failed in my gearbox!

Hi Guys,

I have exact same problem with Tenere (20000miles on the clock). Funny enough mechanic who is looking after my bike said that he had Tenere in garage 3 month ago with same problem and when we were speaking about it another customer joined in who said that he had Tenere which failed from same reason. Unfortunately my engine is damaged so extensively that i need to look for new one. Now I'm not sure If I should even bother. I might buy different bike.

I don't want to jump to conclusions but It seems that these bikes suffer from serious problem with transmission. I'm no expert but because this is happening with relatively young engines I would say that either alloy of that part is too fragile or whole design/concept of that section is bad and not capable to safely deal with forces involved. I have post Tenere Failed in Tenere General forum and I will upload pictures soon. It is exacly same part that broke in my bike.

Thanks

Well, much as I hate to admit it, this is happening too often to be an unlucky thing.

I think I'll be replacing the stopper lever very soon, just in case.

Please bear in mind that this (Hebbo's) example is a bit different - the problem was not caused by failure of a gearbox component. The failure of the dog in this case was a result of physical damage to the crankcase, not because the gearbox failed itself. Read the OP carefully and take a closer look at this image...

What can be deduced with reasonable certainty is that the dogs on 3rd/4th gear are indeed the weakest point of the transmission on the XT motor, and they will be the parts that fail should the drive train become suddenly locked up.

Almost every transmission I have ever come across (Land Rovers, motorcycles and tractors) has a weak point, and will fail at this point in a sudden partial or full lock up; it will be a different part in each case (almost always the rear left hand half shaft on a Land Rover for example), but it will let go at its weakest point.

Being ever the optimist - I still don't think it's panic time!

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We have seen one or 2 XTX's do it over the years but the XTZ seems to be the most affected with the dog teeth breaking off.

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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

I had a 96 Tenere 660 which was mercilessly hammered all its life.

The chain broke one miserable evening in the far north of SA at an indicated 130km/h. It broke the left side of the carrier, the chainguard and ripped the helmet holder off, then bunched up in front of the countershaft sprocket, which stopped the engine dead in an instant from about 5000rpm.

It survived with a tiny oil weep from the cases which wasn't worth fixing.. Nothing else. Made in Japan? Good quality and quality control? Who knows.

Than again, I had a Husky TE610E which broke a gear dog for reasons unknown, apart from the fact that my dealer said there were some issues with quality control, which in essence meant that there was only one dog carrying all the load, and they then fail.

I agree that in hebbo's instance the impact certainly didn't help, but I do think changing the stopper lever might be good insurance... But if it's the same issue as the Husky one, it won't do a damn thing. Hmm.

I hope hebbo's bike gets sorted fast and he's on his way soon. All the best, mate.

Well it was one heck of a determined rock to get past the sump guard and still smash the gearbox. Sorry to hear of you troubles. Good luck.

Oh god what a crash..that must have been massive impact.
It would be great if you let us know how you sort it out in such a remote country..