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XT660Z T�n�r� Tech Section Tyres, Mods, Luggage & Long distance preparation

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  # 1  
Old 09-05-15, 22:42
UKbri UKbri is offline
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Engine noise/knock

I thought I would post my experience with the good ol loose final drive nut. 'bikemad' did a good job reporting, but mine was slightly different. Mine happened at 149,100 kms. After this many K's I never thought it would happen, so just be mindful that it can happen at any time.
I heard a faint knock, and vibration just as I was pulling into Iguazu Falls (Yes I am Bragging). Turned it off and forgot about it. Came back a few hours later and rode off as normal forgetting about it. It was then clattering like a bastad. I nursed it 10 miles back to the hostel having a pretty good idea what it was. I tried 'bikemads' method of holding the front brake and loading it up but it made it better? This made me nervous that it wasn't the 'loose nut' as this method was supposed to make it worse!
I pulled the cover off and hoped for the best/worst?
I didn't remove the foot peg, but i did remove the two allen bolts that hold the rear brake slave cylinder on to drop the brake pedal down and give me clearance. I also didn't remove the clutch cover to remove the crankcase housing. Don't do this! You will never get it all back on in one piece. Easier to put them back on seperatly.
Luckily for me it WAS the loose nut and lucky for me the local Yammy dealer in 'Foz de Igaucu' had a crankcase cover gasket in stock. I also befriended 'Rod' who organises the local 'Horizons Unlimited' meetings down here. He is friends with the dudes at Yamaha and we managed to borrow a torque wrench and 36mm socket off them.
I re-used the old lock tab as one side was unused and they didn't have one in stock anyway. I had to use gasket sealer to glue the clutch cover on with as it ripped in half when i removed it. So my advise is get the 2 gaskets ordered up before you start.
Torqued it up to 120nm by stuffing rag between the gears to stop it moving. A trick i used to use when I was a car mechanic.
Got it all back together after 76 attempts to align the poxy clutch back into position. Sounded good and felt strong after.

Time to strip the engine, in a Brazilian Hostel-


Crankcase cover off in one piece, stupid idea-


Removed with fingers, No Bueno-


Its good to have friends that have friends of friends-


It be a 36mm I tells ya-


Stuff some rag in the gears to lock them up when torque-ing -


Where's my apprentice when I need him? Gotta love gasket cleaning -


Nearly back to normal-


Its all good, LETS RIDE !
  # 2  
Old 09-05-15, 23:21
bikemad195 bikemad195 is offline
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Quote:
Originally Posted by UKbri View Post
I thought I would post my experience with the good ol loose final drive nut. 'bikemad' did a good job reporting, but mine was slightly different. Mine happened at 149,100 kms. After this many K's I never thought it would happen, so just be mindful that it can happen at any time.
I heard a faint knock, and vibration just as I was pulling into Iguazu Falls (Yes I am Bragging). Turned it off and forgot about it. Came back a few hours later and rode off as normal forgetting about it. It was then clattering like a bastad. I nursed it 10 miles back to the hostel having a pretty good idea what it was. I tried 'bikemads' method of holding the front brake and loading it up but it made it better? This made me nervous that it wasn't the 'loose nut' as this method was supposed to make it worse!
I pulled the cover off and hoped for the best/worst?
I didn't remove the foot peg, but i did remove the two allen bolts that hold the rear brake slave cylinder on to drop the brake pedal down and give me clearance. I also didn't remove the clutch cover to remove the crankcase housing. Don't do this! You will never get it all back on in one piece. Easier to put them back on seperatly.
Luckily for me it WAS the loose nut and lucky for me the local Yammy dealer in 'Foz de Igaucu' had a crankcase cover gasket in stock. I also befriended 'Rod' who organises the local 'Horizons Unlimited' meetings down here. He is friends with the dudes at Yamaha and we managed to borrow a torque wrench and 36mm socket off them.
I re-used the old lock tab as one side was unused and they didn't have one in stock anyway. I had to use gasket sealer to glue the clutch cover on with as it ripped in half when i removed it. So my advise is get the 2 gaskets ordered up before you start.
Torqued it up to 120nm by stuffing rag between the gears to stop it moving. A trick i used to use when I was a car mechanic.
Got it all back together after 76 attempts to align the poxy clutch back into position. Sounded good and felt strong after.

Time to strip the engine, in a Brazilian Hostel-


Crankcase cover off in one piece, stupid idea-


Removed with fingers, No Bueno-


Its good to have friends that have friends of friends-


It be a 36mm I tells ya-


Stuff some rag in the gears to lock them up when torque-ing -


Where's my apprentice when I need him? Gotta love gasket cleaning -


Nearly back to normal-


Its all good, LETS RIDE !
the 2nd time mine did it holding the brake dint make it show its head either lol the first time made it knock like hell lol, glad u got it sorted
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Yamaha xt660x 2009 blue/gold mods= iridium plug, stage1+2, removed snorkel, blocked ais, akrapovric pipes, power commander pc3usb (pre made map), adjusted tps, dynojet 02 optimiser 30amp aux relay, smoked puig screen, oxford heated grips and brembo carbon ceramic pads, rfx 30mm bar raisers, puig long adjustable leavers, plus much more and a cheep �30 alarm which stopped it been stolen
  # 3  
Old 10-05-15, 03:07
Desert Racer Desert Racer is offline
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Job well done mate, enjoy the rest of your travels.
  # 4  
Old 10-05-15, 09:19
Ranger6 Ranger6 is offline
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Credit where credit is due.

Fair play there I would not have known where to start cracking job.
Ranger6
  # 5  
Old 10-05-15, 09:38
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Kev Kev is offline
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Great job mate.
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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

  # 6  
Old 10-05-15, 10:27
henston2 henston2 is offline
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Smile Nice work

Thanks for taking the time and trouble to take and post detailed information with pictures.
This could save hours of anxiety and head scratching in the future to us other owners.
Glad it all went well and you got on your way quickly considering where you were at the time.
Appreciated.
Are Yamaha aware of this problem?
Would it be acceptable to use threadlock as a backup?
  # 7  
Old 10-05-15, 13:36
bikemad195 bikemad195 is offline
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Quote:
Originally Posted by henston2 View Post
Thanks for taking the time and trouble to take and post detailed information with pictures.
This could save hours of anxiety and head scratching in the future to us other owners.
Glad it all went well and you got on your way quickly considering where you were at the time.
Appreciated.
Are Yamaha aware of this problem?
Would it be acceptable to use threadlock as a backup?
The first time I did mine I used threadlock and both sides of the lock nut and it still did it again but there was no signs of any nut movement ...... when I was talking to somebody they mentioned crank stretch ........ SCARY I'm going to listen to someone's bike off here that's making strange noises .... IF it's this then I will make a complete step by step guide as I should of done from the start lol
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Yamaha xt660x 2009 blue/gold mods= iridium plug, stage1+2, removed snorkel, blocked ais, akrapovric pipes, power commander pc3usb (pre made map), adjusted tps, dynojet 02 optimiser 30amp aux relay, smoked puig screen, oxford heated grips and brembo carbon ceramic pads, rfx 30mm bar raisers, puig long adjustable leavers, plus much more and a cheep �30 alarm which stopped it been stolen
  # 8  
Old 13-05-15, 18:35
cca cca is offline
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Hi.
My bike recently developed right foot-peg vibration. Can anyone here (who has experienced *loose nut* syndrome) confirm connection between this vibration and nut, please?
Thanks for opinions or experience about the source/reason for this.
  # 9  
Old 13-05-15, 20:10
UKbri UKbri is offline
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Quote:
Originally Posted by cca View Post
Hi.
My bike recently developed right foot-peg vibration. Can anyone here (who has experienced *loose nut* syndrome) confirm connection between this vibration and nut, please?
Thanks for opinions or experience about the source/reason for this.
The whole bike was vibrating when mine went. It wasn't subtle. The noise was more noticable than the vibration
  # 10  
Old 13-05-15, 20:36
cca cca is offline
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Thank you UKbri.
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