xt660 engine reliability concerns
 

After viewing threads about engine problems or even failure I have some doubts about reliability of this bike. I never heard so far about other motorcycle engine fatal problems e.g. honda, triumph etc. My question is were these cases only some specific year model related problems and it is now fixed or it is rather random?

I placed an order on new xt660z and have cold feet to be honest...

Mine was 2009 with 12000 miles when gearbox fall apart. Some offroad riding and some light jumps though.

It was ridden this way ( Mine is blue one - its last action - about two weeks after this it was death):

https://www.youtube.com/watch?v=5c2c...qEhM9Qy091yaQA

And onboard:
https://www.youtube.com/watch?v=uIdz_QMbLwU

I would not say bike was too much abused.

Scary stories
 

If you want to find scary stories of bike problems, come to a forum! But remember, all bikes have issues and for everyone who comes to a forum to post on an issue, there will be hundreds (maybe even thousands) that never even visit a forum. Basically, forums can give you a distorted view of problems since that is where they tend to get reported.

If you looked at the UKGSER forum you'd never buy a BMW. But thousands have and have been happy. But the forum makes it look like you are guaranteed a life of pain and sorrow.

If you take that view and then review this forum what you'll soon see is that XT ownership appears to be a pretty reliable and hassle free experience. Of course there are the odd problems. I've never seen a bike or car forum where that's not the case.

I'd be sleeping easy if I were you. Chances are you have nothing at all to worry about.

12k miles that freaking low mileage for any engine/clutch problem not to mention failure...

Nice videos BTW, indeed you din't abuse it in any way.

yeah, but like 50/50 or more chances? LOL

Of course you're right with forums opinions but show me any adventure bmw, ktm, suzuki, honda, triumph threads with engine failure at that kinda mileage
because I couldn't find it. Other problems yes, like BMW broken forks etc.

My 2010 Tenere has just turned 42,000 miles, it's been heavily abused off road, been to Nordkapp in 2012, (5000 mile trip taking in most of Scandinavia), loaded with camping gear. Last year I rode from Ireland to Italy with two other XT660Zs and an XT660R and completed the Stella Alpina off road event, well over 9000 feet in altitude. All four bikes performed faultlessly and 3 of them had over 30,000 miles on the clock. Engine and gearbox still trouble free. Only problems have been a dry head bearing which was replaced by Yamaha and a derailed chain that caused damage to the rear suspension arm - this could have been prevented by myself being more diligent with adjusting the chain. With doing so much off road work I tend to run with the chain a bit looser than Yamaha recommend. A chain guide has since been fitted. I fastidiously change oil and filters at the recommended mileage and often do an extra oil change between the recommended ones. My experience of 660s is that they are extremely reliable and rugged engines. Kev's fuel mod and O2 mod really help to get the best out of them too.

I wouldn't worry too much, especially if you're buying new.

:-)

I done a lot of research into the reliability before buying mine, for a single cylinder engine they are one of the most reliable out there.
I also change my oil more frequent than recommended.

+1 We have 9635 members here (at last count) and just a handful of cases of 3rd gear failure and two or three iffy main bearings, so let's say ten cases of engine failure for argument's sake. Now that equates to somewhere around 0.09%! (Alright, I know not all members have owned/do own an XT, but most do, or have done and it gives a reasonable illustration of pifflingly small the issue really is in numbers.)

Now if you had owned the bike from new, then I guess you could say this with some authority, but you bought it at 3 years old if I recall? So how can you be sure? You might service it fastidiously now, but anything could have happened before, regardless of "service history" too. The other recent 3rd gear failure (Chenko's) also relates to a previously owned bike.

I'm not really trying to suggest or infer anything other than it is impossible to be objective about engine/gearbox failures with a pre-owned motorcycle. Yes failures might be down to manufacturing/assembly faults, but they could be just as likely, if not more so, be down to a clumsy-shifting previous owner...

I have just read here
this thread

I don't know...you guys call that engine bullet proof???
Actually it looks like the hole from the bullet...

All I know if I read these threads a year ago. I would have chosen a ktm.