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-   -   2009 xt660z tenere RTW mods & upgrades after 50,000 miles (http://www.advrider.com/forums/showthread.php?t=782959)

rtwpaul 04-18-2012 08:35 AM

2009 xt660z tenere RTW mods & upgrades after 50,000 miles
 
I bought the 2009 XT660Z in mid 2010, i was in England for a few days got to see the bike for about 5 minutes based on the agreement that they would hold the bike
for me until i needed it shipped to Ushuaia Argentina in early 2011, it had 12,000 miles on the clock already

it looked like this...

http://dmh65.smugmug.com/photos/i-ZD...-ZDLLwGB-L.jpg

as i didn't get to go over the bike i rode it exactly as you see it for 38,000 miles

http://dmh65.smugmug.com/Other/RTW/i...0/L/2011-L.jpg

it had a a few mods done and it saw me thru the mileage, there is a ride report here of that ride http://www.advrider.com/forums/showthread.php?t=668901

once i was finished it was time to strip the bike and do some modifications and upgrades before i carry on riding

here are a few shots from the trip...

http://dmh65.smugmug.com/Other/some-...SAM0053-XL.jpg
http://dmh65.smugmug.com/Other/ridin...65_3ajdb-L.jpg
http://dmh65.smugmug.com/Other/some-...SAM0446-XL.jpg
http://dmh65.smugmug.com/Other/some-...SAM0504-XL.jpg
http://dmh65.smugmug.com/Other/some-...SAM3011-XL.jpg
http://dmh65.smugmug.com/Other/some-...SAM0044-XL.jpg
http://dmh65.smugmug.com/Other/some-...SAM0377-X2.jpg
http://dmh65.smugmug.com/Other/some-...SAM0711-XL.jpg
http://dmh65.smugmug.com/Other/some-.../tetons-X2.jpg
http://dmh65.smugmug.com/Other/some-...SAM3443-X2.jpg
http://dmh65.smugmug.com/Other/some-...SAM4500-X2.jpg
http://dmh65.smugmug.com/RidingRTW/u...SAM5389-X2.jpg
http://dmh65.smugmug.com/photos/i-VD...VDWnnKp-XL.jpg

so after all of THAT its time for some work....

twin wall bars - DONE
heavy duty risers - DONE
dual gps set up - DONE
high out put spot lamps - DONE
front turn signal relocation - DONE
crash bars - DONE
barkbusters - DONE
exhaust
front suspension
rear suspension
side stand foot enlarger
center stand foot enlargers
chain guard
cush drive
kev fuel mod
new swingarm
swingarm bearings
new hard luggage
chain roller
chain and sprockets
quick fuel disconnect
valve adjustment
brake and clutch levers
...and probably a few more things - need to get this list done first!!!

time to get dirty

http://dmh65.smugmug.com/photos/i-Mp...Mp8HPNm-X2.jpg

mickd 04-18-2012 03:13 PM

keep it coming :lurk:lurk:clap

Ni3ous 04-19-2012 03:35 AM

:ear
connected...
:ear

MadMax 04-19-2012 07:47 AM

I'm IN!
 
Very interested in seeing this done by a professional who also happens to have a ton of seat time on the subject!

divimon2000 04-19-2012 08:00 AM

:lurk

rtwpaul 04-20-2012 10:41 AM

the cockpit
 
Here we go, the cockpit...

http://dmh65.smugmug.com/photos/i-zq...zqwNbFV-XL.jpg

i did riser and bar upgrades...the stock risers are made, from one piece, this is good in some ways but not in others...if you are in the middle of nowhere and you have an off and one or both get snapped you are stranded, period. Some small villages/town might have only one drill, and chances of them having the right size tap to fix it...unlikely

http://dmh65.smugmug.com/photos/i-sV...-sV8g69F-L.jpg

so i changed to some heavy duty risers that use a thru bolt design, for less that $50 its a good swap, same height as the stock ones, but i got 1 1/8 so i can fit Renthal twin wall RC922 bars, about 30mm higher than stock but the stock wiring and cables still fit

http://dmh65.smugmug.com/photos/i-BZ...BZDq5NJ-XL.jpg

along with this i added new barkbusters hand guards, after a good off in Argentina and another in Bolivia the old ones were done!

http://dmh65.smugmug.com/photos/i-JS...JSffN6K-XL.jpg

New levers $41 inc. shipping - they are a perfect fit, no cutting or filing required like some had people that i know tried to fit. I ordered black with red adjusters and the shorty version

the ebay link is for US ebay but they say they ship worldwide

http://www.ebay.com/itm/170694297800...#ht_6597wt_960

these are the parts you need as they don't specifically stock for the XTZ

Suzuki - GSXR 600 1997 - 2003 Clutch
Yamaha - FJR 1300 2004 - 2008 Brake

once i sent them this info they sent me a money request via paypal, it took about ten days to get them

once i got them about 3-5 minutes to fit, brake side just becareful the piston rod in the master cylinder come out its on a spring, on the clutch side, reduce the pressure on the bar adjuster and fit, readjust clutch back to spec...easy

...and this is what they looked like

http://dmh65.smugmug.com/photos/i-cH...cHxLXSn-XL.jpg
http://dmh65.smugmug.com/photos/i-mZ...mZSW6NN-XL.jpg
http://dmh65.smugmug.com/photos/i-dx...dx4gKj4-XL.jpg
http://dmh65.smugmug.com/photos/i-wT...wT4nGDC-XL.jpg
http://dmh65.smugmug.com/photos/i-Kj...KjLZSxd-XL.jpg
http://dmh65.smugmug.com/photos/i-CQ...CQXTbpq-XL.jpg
http://dmh65.smugmug.com/photos/i-z3...z3PCqxc-XL.jpg
http://dmh65.smugmug.com/photos/i-K6...K6pw2nZ-XL.jpg

lots more to come...

bobfab 04-20-2012 11:45 AM

Great thread and travels, keep it coming!

Ni3ous 04-21-2012 03:20 AM

Quote:

Originally Posted by 5kadv (Post 18503714)
i did riser and bar upgrades...if you are in the middle of nowhere and you have an off and one or both get snapped you are stranded, period. Some small villages/town might have only one drill, and chances of them having the right size tap to fix it...unlikely

http://dmh65.smugmug.com/photos/i-sV...-sV8g69F-L.jpg

so i changed to some heavy duty risers that use a thru bolt design, for less that $50 its a good swap, same height as the stock ones, but i got 1 1/8 so i can fit Renthal twin wall RC922 bars, about 30mm higher than stock but the stock wiring and cables still fit

http://dmh65.smugmug.com/photos/i-BZ...BZDq5NJ-XL.jpg


Great info man!
I have found the same issue with one piece handlebar holders...

please give more info about the risers you bought, any link?
Can I fit original handlebar on it? I already have risers from off the road for original 22 mm handlebar, also rised it for 30 mm and it works great.

Kepp it comin...
:lurk

rtwpaul 04-21-2012 12:48 PM

the 1 1/8 inch risers i have are here - LINK

the 7/8 inch are here -LINK

rtwpaul 04-21-2012 01:51 PM

first rule of Adventure riding...don't ride at night! Besides the fact its dark so you can't see anything...in the undevloped world there are lots of dangers on the road be it dirt or black top, animals, cars with no light, road debris, potholes, kids etc, etc

the XT has a good looking light that works well in low beam but on hi beam not so good...time for lighting upgrade

i added 3600 lumens each spot lights from ADVmonster link to these lights is here...and BTW if you get these DO NOT look directly into them, they have the potential to damage your eye sight!!!

these photos were take at 125th of a second for a comparison

before - standard HI beam

http://dmh65.smugmug.com/photos/i-FR...FRNF3c5-XL.jpg

after just spot lamps

http://dmh65.smugmug.com/photos/i-9n...9nFsd2k-XL.jpg

i built a separate wiring harness which included a relay and a waterproof switch, the switch for them is below the speedo

http://dmh65.smugmug.com/photos/i-qn...qnWb8s3-XL.jpg


http://dmh65.smugmug.com/photos/i-FB...FBc7dWf-XL.jpg
http://dmh65.smugmug.com/photos/i-cM...cMnVSvs-XL.jpg
http://dmh65.smugmug.com/photos/i-ZD...ZDV4LhP-XL.jpg

if you know the bike or looked at the older photos you will notice the spot lights are where the turn signals used to be, i moved the turn signals into the area where the running lights were, as the low beam is on all the time anyhow. if you do this make sure you have a quick disconnect on the spot lamps. If for some reason you have to take off those panels you don't want to have to cut the wire, i use deutsch connectors that are waterproof.

so take the wiring from the side lights and turn signals and simply swap there locations...easy. Two connections per light. You will need new orange bulbs, they are part number 194NA and cost $2 per pair

http://dmh65.smugmug.com/photos/i-L5...L5X2vkm-XL.jpg
http://dmh65.smugmug.com/photos/i-pt...pt58j9S-XL.jpg

i added new crash bars from SW Motech, LINK the stock ones had a broken tab, even though one of my trades is welding i didn't want to fix them because they block the access on the left side of the motor to cover for the crank, so when doing a valve clearance adjustment you have to remove the crash bars!!! Great design Yamaha, or was it on purpose so the dealer can make more money to stop people doing their own adjustments?

http://dmh65.smugmug.com/photos/i-Rs...RsRth8b-XL.jpg


still lots more to come...

NACO 04-26-2012 01:46 AM

Quote:

Originally Posted by 5kadv (Post 18511676)
still lots more to come...

Come on, keep on coming!
great ideas, great work till now :clap

Rafael Martins 04-27-2012 06:29 AM

Nice mods!

Which model of tyre are you using? What about the 12v plug?

Great job, I can only envy you with this milage around Americas...

rtwpaul 04-27-2012 06:44 AM

Quote:

Originally Posted by Rafael Martins (Post 18555771)
Nice mods!

Which model of tyre are you using? What about the 12v plug?

Great job, I can only envy you with this milage around Americas...

there are more to come...

tires, i used conti trail attack when i knew i was doing about 80% road riding, i got over 10,000 miles on the rear and 20,000 on the front, when i switched to dirt i used TKC80, the best i could get from a rear was almost 5000. I did a tire swap in Newfoundland and the only tire they had was Kenda k270, the rear on the bike is the one i got, it has more tread on it still after 6000 miles than a TKC80...

12 volt, its a touratech unit, two minute install, it has an inline fuse, but i add a 4 in one charger if i need to do any additional charging when i am riding, it plus to that and has 3 12 volts plugs and a USB, i'll add a photo for you

rtwpaul 04-27-2012 11:10 AM

this is the unit i take along $1 on ebay!!! no great loss if it get broken...obviously not for use for anything that generates heat

http://dmh65.smugmug.com/photos/i-ZW...-ZWtMnMv-L.jpg

rtwpaul 04-27-2012 11:47 AM

suspension upgrade and swingarm swap
 
I did a tear down of the complete rear end to do a rear shock upgrade from the stock Sachs shock to a custom built Ohlins unit FA817...the difference from stock Ohlins was i got them to replace there standard spring with an upgraded unit and do some testing on the bottom mount and have everything set to be able to carry the weight of a RTW rider and all his luggage

the shocks...
http://dmh65.smugmug.com/photos/i-2G...2GmXQKk-XL.jpg

i also did a front end spring upgrade to Hyperpro progressive springs but forgot to take photos when i did the swap, sorry about that

before i do the swingarm write up and show how its done

have a look at this, this is my front sprocket that i changed, this one has 35,000 miles on it...

http://dmh65.smugmug.com/photos/i-Mx...MxDCcHK-XL.jpg

so the new swingarm arrived very early so i have time to do a swap before the bike goes off to a show in a couple of weeks

http://dmh65.smugmug.com/photos/i-BD...-BDCqhrN-L.jpg

the new one on the left and the old one on the right with the crazy damage
http://dmh65.smugmug.com/photos/i-6Z...6Z5qHwc-XL.jpg

http://dmh65.smugmug.com/photos/i-gn...gnN4B8h-XL.jpg

i ordered new needle bearings, spacers and seals to do a complete refit

http://dmh65.smugmug.com/photos/i-pt...pt4H4XK-XL.jpg

these are the main set for the swingarm pivot

http://dmh65.smugmug.com/photos/i-Tt...TtHGvjv-XL.jpg

as i doubt any off you took your bike apart before riding it, this is what the needle bearing look new

http://dmh65.smugmug.com/photos/i-H6...H6F5SJ6-XL.jpg

i asked the dealership if they would put the bearings in for me, they quoted 75 pounds and told me it would take 1 1/2 to 2 hours!!!! Having owned a motorcycle shop i know it doesn't take anywhere near that, i think they were trying to get some money back for selling me the swingarm so cheap

so here it is, using a hydraulic press

http://dmh65.smugmug.com/photos/i-B5...B5SpDc5-XL.jpg

http://dmh65.smugmug.com/photos/i-Vh...VhCHCsS-XL.jpg

take measurement as you go along so the bearings are in the same location and there is enough space for the seal

http://dmh65.smugmug.com/photos/i-W8...W8vSGcZ-XL.jpg
http://dmh65.smugmug.com/photos/i-sN...sN6jhGQ-XL.jpg

there is a lot of space in the swingarm for additional grease to be in there, so again make sure the bearings are in the right place with measurements
http://dmh65.smugmug.com/photos/i-t9...t9tr44H-XL.jpg
http://dmh65.smugmug.com/photos/i-vq...vqvCGMM-XL.jpg

the whole job of putting all the bearings, spacers and seals in a new swingarm took me about SEVEN minutes

and just for reference i use Timkin premium hi temp red bearing grease

http://dmh65.smugmug.com/photos/i-QP...QPTVHfV-XL.jpg

to do a swingarm removal take out the rear wheel, i put zip ties over the sprocket to the spokes so keep it all together for an easy refit later, i have the cush drive rubber mod and it want to spring apart, this stops that happening

http://dmh65.smugmug.com/photos/i-Wb...WbhVs5W-XL.jpg

i this in my tool kit, if there is a problem getting the pivot bolt out this fits in the open end and it long enough to hold everything in place when putting it back together as well

http://dmh65.smugmug.com/photos/i-TP...TPJ4gvB-XL.jpg
http://dmh65.smugmug.com/photos/i-JC...JCxhmBM-XL.jpg

get anything out of the way that is in the way!!! brake caliper and rubber protection

http://dmh65.smugmug.com/photos/i-tt...tttHd7T-XL.jpg
http://dmh65.smugmug.com/photos/i-KP...KPc4CCB-XL.jpg

undo the lower dog bone bolt and remove it
http://dmh65.smugmug.com/photos/i-KX...KXSSFk4-XL.jpg

once this is taken out then remove the pivot bolt and the swing arm can be removed, chain does not need to be take off.

...continued in next post


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