2009 xt660z tenere RTW mods & upgrades after 50,000 miles

Discussion in 'Thumpers' started by rtwpaul, Apr 18, 2012.

  1. Dotbond

    Dotbond Africa, Africa

    Joined:
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    Dunedin. New Zealand
    Can't beat good luck on your part regarding the dual citizenship! :1drink
    #21
  2. Salami

    Salami n00b

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    To save the cushdrive rubbers I modified the rear hub, with another bearing on the inside. I did this at work but any metal shop can do this for you, just create another bearingchamber and make the spacer fit again.
    You also can replace the original bearing by a INA 3205-2RS F0712 this is the one BMW uses on some bikes. This is a double bearing and works well too, best thing is the drive chain lasts much longer too:evil
    #22
  3. Rafael Martins

    Rafael Martins Adventurer

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    Hi Pal,

    Which brand is on the brake and clutch lever?

    The link on ebay is not working...

    Nice job on the rear suspension!
    #23
  4. rtwpaul

    rtwpaul out riding...

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    #24
  5. rtwpaul

    rtwpaul out riding...

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    the stock exhaust was harder to get off than the new one was to put on...the retaining bolts on the exhaust clamps had rusted solid so had to be snapped to get them off. I replaced them with nickel plated grade 8 so it won't happen again.

    the stock rear exhaust hanger is replaced with the new unit, i'm doing a single stainless can, ordinarily you would cut the other side off if its not being used to hang an exhaust but i am contemplating making an auxiliary fuel tank in the space left by the right can

    once the stock system is taken off you can see the heat resistant pad which is silver colored, i sprayed it with hi temp black paint to help it disappear a little but still have the same effect if required to protect the electrics

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    before the rear wheel went back on i did the kev mod on the cush drive rubbers, it looks oily, its not its soapy water to help it slide together easier...oh, and by the way those cush drive rubbers have 40,000 miles on them!!!

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    just realized i forgot to mention tyres...i did a front tyre change to match the rear, the front has zero miles but the rear has 6000 on it, Kenda K270, i did maybe 2500 miles off road...the wear is good but they are a bit noisy on the tarmac, but cheap - pros and cons!!!

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    ...and if you are wondering what the white patch is on the left side of my tank it a customs sticker from flying the bike bike from columbia to panama, it looks like $hit but kind of reluctant to take it off
    #25
  6. rtwpaul

    rtwpaul out riding...

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    had some spare time this week so when i found a crack in the chain guard it was time to make a new one

    took a template from the original trimmed some aluminum sheet to size and bend it in a sheet metal brake

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    drill some holes and used a dimple die, they look like this

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    so basically lightened it up a little but the dimple adds strength to the piece

    this is what it looks like against the original...not sure if i like it or not, or if i need to paint it black, or add another hole or more in the "V" area

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    got this finished quicker than i thought so i had a template for the head light, so started to make a rock guard, with the XTZ headlight being a complex shape it was easier to make a generalized shaped around the template

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    in the last photo you can see another one i was making as well...choices????
    #26
  7. rtwpaul

    rtwpaul out riding...

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    the bushings were out of stock and on back order, as the old ones were unusable i had to make new ones on the lathe in the shop where i work, the originals were made from 308 stainless which has a small amount of carbon hence the rust, i made the new ones from 316 S/S

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    yamaha paper weight

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    pull out the swing arm...that's it, about 15 minutes for it to be out, do some cleaning and regreasing if you haven't done it before, when you put it back in i use that rod to locate everything and check the side play and make the adjustment on the nut on the inside of the right frame rail to get it to spec

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    so do all steps in reverse to put it back together, this is the new one back in place with the new chain guard painted with an additional hole!!!

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    #27
  8. 150ron

    150ron Long timer

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    That is one sick bike :clap
    #28
  9. Ni3ous

    Ni3ous Double Axle Rider

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    Do you have any pictures?
    I will have to do this mod also. Soon.




    5kadv, always happy too read about your progress, explanation and pictures.
    By the way, chain guard in black looks much better now.

    Where do you keep tools and what tool you carry on long trip?
    #29
  10. kemizz

    kemizz noobest

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    belgium , Grimbergen (yeah that nice beer)
    looks so cool , and I'm damn jaleous you can do all these things yourself


    I have a question on the chain tensioner , this is one from R&G , any info on model , supplier ? fitting ?

    thanks !
    #30
  11. jtw000

    jtw000 Survivor

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    This was one of my choices for overland bike but I didn't like it, the power was a bit low. A friend of mine rode one from london to Thailand and I rode his with some decent mods and what a difference. It was really woken up and gave me a whole new respect for these things. I love what you're doing, it looks like a very thorough job.
    Just one question. My brother had one of these, his mate, I met two Europeans in India and my Australian mate, all riding the Tenere and every single one of them had dropped it and the ones I knew well were not guys to drop their bikes. Did you find any balance issues with yours at all?
    #31
  12. enkil

    enkil Been here awhile

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    Awesome mods and adventure..
    #32
  13. rtwpaul

    rtwpaul out riding...

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    its not a chain tensioner its a toe guard, to stop you foot going in towards the sprocket if you come off, i had a very close call in Bolivia like this so it is really just personal preference, it is a universal fit
    #33
  14. rtwpaul

    rtwpaul out riding...

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    i find it well balanced, it comes down to packing, maybe their luggage was the issue? yes power is not great but once you get away from civilization a lighter bike is better in the long run, and as i look at it, i am heading out on the road for years, its not a race, my average speed for the first 38,000 miles was less than 40 mph
    #34
  15. Salami

    Salami n00b

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    I have to admit I made a mistake in my explanation, what I discribed was the original plan:wink:
    But plans are to change and that's what happened. Instead of a second bearing on the inside of the hub I made the original bearing chamber 15 mm deeper. This way 2 bearings fit in the place where once was only one :evil
    With some luck I'll be able to place a photo too:hmmmmm
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    Take a close look and you can see the second bearing under the first one.
    #35
  16. rtwpaul

    rtwpaul out riding...

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    the guy who owned the bike before me put on the lowering links on it and lowered the center stand, not a pretty job, basically his welding sucked, this is what a 50,000 mile center stand looks like, lots of abuse

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    also some of the gussets had welds missing, so i corrected it all and added BIGGER feet

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    made some slug to lengthen the stand and welded it all back together and repainted it

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    regrease the bushings when it was reinstalled

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    now the rear wheel isn't on the ground like it was before with a new knobbly, when i make new jack up links and add an 18" rear when i get to Europe i now have space

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    #36
  17. Rafael Martins

    Rafael Martins Adventurer

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    What a greet job!

    I'm very happy to have found your post!

    Can you show us how the front light protector looks like in the bike? What you make to hold this in the bike?

    Congrats!
    #37
  18. Ni3ous

    Ni3ous Double Axle Rider

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    Slovenia

    You have put a lot of extra weight with those thick plates in the bottom, upper reinforcement and with two round iron extensions. Tube shaped extension would be lighter choice.
    I know this, because I extended my side stand that way (with gearbox axle-also heavy) and because of that heavy extension the side stand is also heavy, and spring is too weak now. Result is that side stand is jumping when riding on bumpy road. I have put stronger spring, but problem is not removed completely.

    We all know best is to make it lighter, when making upgrades, but sometimes its difficult.
    --
    5kadv check that central stand spring, if you did not already. If it is too weak because extra weight, it might sag too much and you can hit an obstacle one day when riding on bumpy tracks.

    Wish you all the best, and give us some more juice about you upgrades!



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    #38
  19. rtwpaul

    rtwpaul out riding...

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    just rode 2000 miles and not a problem, 1200 off road on very bad ground...still on the road, when i get back i'll add more

    weight added was less than 1 lb

    #39
  20. rtwpaul

    rtwpaul out riding...

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    i've been away riding...here is the last thing i did i think!!!

    a gas tank mod, the fuel cell (plastic) is stock at 23 liters but its very difficult and slow to get the last few liters in, and even when you do you never get it completely full

    easy one minute fix with a HAND DRILL - no power drills for this otherwise you get to hear an EXPLOSION :kboom

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    now i'm getting about an extra liter and slightly more in the tank...result
    #40