Hello people,

my XT660Z ran 100.000kms witout any real issues. My engine runs fine, no oil usage but I'm never stressing it.
My next trip will be another 50.000km.

What do you suggest what mainentance I can do at home? Do I need to check the engine's internals? What are the weak parts? How about internal filters, clutch, fuel pump, etc.?

Although not officially stated by Yamaha it is recommended that for a single cylinder bike that has such a high level usage that you do interim oil changes at ever 6 months instead of every year or 12'000km it won't break the bank and it will ensure that your most delicate parts are always working with clean oil without debris and other offending particles that can slowly reduce your engine life.

These bikes have a very solid clutch system so plates last a really long time.

Inspect your spark plug regularly for a nice tan colour not too dry or not too black.

Wash you air filters regularly and inspect and empty the drip oil container at the bottom for your air box.

Ride and enjoy.

Leave it alone inside. Just keep up with the normal regular maintenance in the handbook and as the Captain says, change the oil and filter preferably more often than scheduled. Also swingarm, suspension linkage and headrace bearing benefit from being done twice, if not three times as often as Yamaha recommend.

Remember: If it ain't broke, don't fix it!

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Use a good oil and change it regularly I guess as well as the filter. But where are you heading for a 50k km journey?????

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(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....

My plan is to ship the bike to/from Cape Town and drive around the continent for a year.

That's why I started this thread. My bike has already done 100.000km. Any weak parts I can swap now is easier than waiting a month for new parts to arrive in the middle of nowhere.
I do oil every 10K, filter 20K. Clean air filter as needed. Already greased swing arm and steering head and changed both wheel bearings front/back.

I Personally change oil and filter every 5 thousand miles,allways have on any bike.
whats �30 every 6 months against the cost of an engine?..

Maybe it is worth to check compression of the engine, condition of oil pump gear and water pump impeller. Not that they are weak points, but because of the length of planned journey. Have you checked cush drive rubber?
Have a nice trip.
Petre

I am a bit outside of chorus, my father is a mechanic so its a family madness, but with such a long trip in mind and with this high mileage, if you have time and money I'll go for a complete engine check:
Check and clean/rectify/sobstitute: valvels, head, cylinder, piston, piston rings, clutch, gears and gear selector.
Change all the fluids and check every pipes for cracks.
Check all electrical, sobstitute if necessary, spry all connectors/connections.

Consider checking and re-torquing the crank nut if it hasn't already come loose. Mine came loose after 149,000 kms so it can happen at any time. Super quick and easy job if you have the tools, parts and somewhere to do it. Takes days to do in a foreign country with the language barriers and sourcing the parts and tools.
http://www.xt660.com/showthread.php?t=23951

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http://www.onepistononeworld.com/
http://advrider.com/forums/showthread.php?t=988891 'South Dakota to South America'

Thanks! Got some good advice. Already checked;

Cush drive is checked and okay. Wrapped in bicycle inner tube, ran 60K and still almost no wear. Will bring spare.
Water pump checked and all okay. No damage or wear.
Fluids: all replaced and circuits ok.

Will check;
Gearing oil pump (i guess connected to main engine like water pump)
Check crank nut.

As I have lots of time left, I will do grease/clean of all o-rings, gaskets and do a visual inspection of the engine's inside wear.
Will bring new clutch with me so we'll see how many kms I can still do on my old one.