So I picked up my 2012 xt660x with only 800 miles on the clock toady and I'm loving it so far. I'm not even sure if this is a problem but changing gear makes quite a loud clunk sound. My old WR250x did the same thing but only when downshifting into first. The xt660x seems to do for every gear. Is this normal? Is it because the gearbox isn't fully broken in yet? Cheers guys.

Hey man, I'm a new xt rider as well but as far as I've heard it's not been any particular clunking noise when I shift gear, will take a spin today and listen more carefully though. Maybe some of the veterans can give you more info. Hope it all works out

Whilst not the silkiest of gearboxes, the XT's shouldn't clunk excessively when the engine is warm. If yours is excessively clunky then something isn't quite right and I think there is a clue in what you have revealed about your bike...

Now 800 miles in four years is not a lot - the motor (and gearbox) are hardly run in! Crucially when was the oil last changed? Never mind the miles, the actual date. How long has it been sitting in there? Do you even know if the right grade is in it? It is quite probable, with the bike having sat about doing nothing for a good part of its life, that the clutch plates are sticky, contaminated or even swollen causing clutch drag, in turn making the gear changes less than smooth.

First thing I'd do is (for the sake of �25) change the oil and filter and see if that improves things. Also check that the clutch is adjusted properly with not too much (or too little free play) so you know the plates are disengaging properly.

Whilst you're at it, check the chain tension and condition and cush drive/sprocket carrier for rotational play. Both these factors contribute to sloppy on/off drive and make it hard to change gear smoothly. Your chain may well have stiff links and tight spots through lack of use.

__________________

Well I got the bike from a dealership and they did a full service and a 50 point check kinda thing so the oils been taken care of. I have emailed them and will get them to have a look at it because somethings definitely not right. I'm glad you guys said something becomes I probably would have just assumed it was normal. Cheers for your replies, I'll keep you informed.

In addition, I suggest you check your chain for tension, rust and tight spots and lubrication.


I find chain lubing and tension setting affect my gear change a lot

These guys are the best, great replies. I too would say that the cables need WD40, chain needs loads of good lube and bike needs some miles so that she frees up. Chain may even need to be replaced. I would use some Redex or STP in the tank too. To be honest it needs oil and filter too and use a good oil (Castrol or similar) and dealers are often full of **** so even if they promise on the bible that they did it, I would change oil and filter myself without delay.

__________________
(Now sold on, sob) 2011 Blue XT660X with gold wheels, was 26,500 km.
Engine mods: K&N Stage 1 filter, DNA Stage 2 filter, snorkel removed, Kev fuel mod fitted.
Plus: smoked Puig screen, Yam aluminium sump guard, Yamaha / Acerbis handguards, Givi Trekker aluminium side cases, Leo Vince X3 cans plus Kev front fork mod and Fender Xtender. Just fitted Michelin Road Pilot 3 tyres.

SOLD the XTX for a Super Ten 1200. And just bought a Raptor 700 so staying on here for some tips....

chain free play, clutch cable, motul 10w40 2,6 liters

__________________

Hi guys, thanks for all your replies. Sorry I didn't get back to you, I've been away for a wile.
So the bike has had pretty much every bit of basic maintenance done to it. (Oil, oil filter, chain tension plus clean and lubed.) I'm still not convinced the bike is sounding as it should. I've noticed that the lloud gear change sound seems to happen once I've been riding for about 10-15 minuets and it's had a good warm up. I've also noticed that I can hear a rattling sound that comes when warmed up too. This new sound doesn't sound like a engine nock or tap but more of a loud rattley chain and only on acceleration. I'm quite sure this sound isn't coming from the main chain but who knows. I've had a look in YouTube and there doesn't seem to be any videos replicating this sound and I'm not sure how to record it myself as it only happens when riding and accelerating. Cheers guys