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

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  # 1  
Old 13-10-17, 14:04
Tobers Tobers is offline
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Location: Guildford
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Tobers' Tenere Strip & Rebuild

Hi all - just joined after buying a rather well known Tenere that has just completed a massive TET journey and has previously enjoyed numerous enduros.

The bike has about 28k miles on it, and needless to say it requires some care & attention after such a long offroad trip.

With previous owner Ian after he completed his TET ride.




It has been extensively modified with a WR450 front end, 18" rear wheel, extended dash, Akra exhaust, uprated rear suspension, onboard air compressor etc etc etc etc. Just what I was looking for, and easier than spending big ���s on a newer bike and then having to add all the mods. It's going to be my go-anywhere bike as I have got a bit of wanderlust and want to get off tarmac (my other bike is a 2015 Ducati Multistrada - daren't fiddle with it or do anything remotely challenging off road). I also want a hobby bike to fiddle with.

I need to register it as a UK bike before I can ride it, so first thing is a strip and rebuild to service it and get it through its first MoT test. I'll document things in this thread as I go along.

The bike was involved in an accident when another rider hit the back of it, and the extended sidestand foot punctured the swingarm, so the first job is to strip the rear end and get that fixed.

But first, a clean so I could figure out what is under the caked on dirt.





Some time later...





Not looking too shabby.
  # 2  
Old 13-10-17, 14:13
Tobers Tobers is offline
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Next job, now I can actually find the nuts & bolts, is to remove the rear swingarm and get it repaired.

There's an excellent guide for rear swingarm and suspension removal here.

Wheel off


Inner-tube cush drive mod in place


Big bar for the swingarm removal after undoing the dogbones.


Super condition underneath it all. Shows the value of good prep. No corrosion, everything well greased. Nothing seized.




Swingarm off in about 30 minutes.


The damage that needs cutting out and welding.


Cleaned


The swingarm is now with a metalworks firm nearby who will do the repair for about �200. A new swingarm is �830.

Next up is the rear brake for a clean & service, and then the rear shock and linkage assembly to be removed, cleaned, serviced and replaced.
  # 3  
Old 13-10-17, 18:13
Tobers Tobers is offline
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As well as the swingarm being damaged in the accident, the rear plastics were shot and a jerry-rigged repair had been done so the journey could continue. I wanted to strip the rear plastics to see the extent of the repairs required.

Still full of dust


Not too bad really


It's just the rear number plate holder that is smashed. It's in the bin now. I'll just screw the new plate to the remaining mountings and figure out how to rig a number plate light. Still need to check the rear light mounting.
  # 4  
Old 13-10-17, 18:26
MarkXT MarkXT is offline
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Location: Ayr
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Firstly welcome to the forum. I'd seen the post on the TET Facebook page, glad to see you made it over to the forum.
Good luck with the strip, clean and repair and hopefully won't be long until you can get out and enjoy the tenere in its natural habitat.
You certainly will have a great bike by the looks of all the toys and mods on it.
  # 5  
Old 13-10-17, 19:34
greatescape greatescape is offline
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Welcome to the forum! Great looking bike! ...by the way how are you posting your photos. ...? Steve
  # 6  
Old 13-10-17, 20:21
Tobers Tobers is offline
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Thanks!

I'm uploading my pics to Flickr and linking from there.

Can anyone recommend a tail tidy? Seems I'll need to replace the rear plastics so might as well do a proper job as currently there is no number plate light (= MoT fail).

EDIT > looks like you don't need a rear number plate light to pass the MoT. Will have another look at the broken bits to see what can be salvaged.

Last edited by Tobers; 13-10-17 at 20:49.
  # 7  
Old 13-10-17, 20:58
greatescape greatescape is offline
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You can get some neat stainless number plate bolts that have an led light in the bolt...it's a neat solution I've used on my Tenere. Steve
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  # 8  
Old 14-10-17, 09:06
Tobers Tobers is offline
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Join Date: Oct 2017
Location: Guildford
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Quote:
Originally Posted by greatescape View Post
You can get some neat stainless number plate bolts that have an led light in the bolt...it's a neat solution I've used on my Tenere. Steve
Cool - will look for those. Thanks.
  # 9  
Old 14-10-17, 11:44
Cozi70 Cozi70 is offline
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Quote:
Originally Posted by greatescape View Post
You can get some neat stainless number plate bolts that have an led light in the bolt...it's a neat solution I've used on my Tenere. Steve
I used to run these and replaced them with the twin led ones recently which are much brighter,and I see they even do triple led bolts now.

https://rover.ebay.com/rover/0/0/0?m...2F362127697439

Might get me some of those boyos
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  # 10  
Old 15-10-17, 18:11
Tobers Tobers is offline
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Further progress as I stripped off the rear suspension linkage and shock while the swingarm is away being repaired. Something nasty lurks therein.

To start with, the rear linkage looked like this:


Now removed from the bike


Cleaned up. Note the grease nipples added by the previous owner.


Some wear evident on the arm. Oil seal fell off on disassembly - note that the bearing is either not pressed in properly or has worked its way out. Grease was rather washed out and horrible on this pivot.


Needle rollers rather pitted (from the same pivot as above)


Rather more nasty wear on the arm


And a lot worse here - maybe 1mm of material has been ground off at the connection with the rear shock bracket.


So, new bearings and seals are on their way. I'm not sure what to do about the wear on the arm. They are quite pricey to replace. I may just shim it for the time being as the idea isn't to spend a lot of money on the bike - just get it MoTd so I can register it. I can sort these bits out later.
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