Few problem with R
 

Hi.
For now my XT660R with 84k km and i have some problem. Maybe you give me some advice.

1) Vibration. High frequenсy vibes on handlebar and footpegs. I use xt for traveling and vibes make a serious problem. After a few days of riding, my hands start hurts. Previously, there were no such vibration. I found on the forum a message, in which they write that this may be because of worn bearings in the motor. I see that many people wrote about such symptoms at the forum. Has anyone figured out the reason for such vibrations for sure?

2) Start without dashboard. Is this is possible? After mounting roadbook holder and tripmeter i don't have space to locate the dashboard, but if just disconnect it, moto don't start.

Vibrations are part and parcel of riding a big single cylinder...

I filled my handlebars with silicone which helped but didn't stop it. I dont have bar end weights either.

I assume you do have bar end weights?

A recent thread talked about changing the grips/re-positioning the bars and changing them to Renthals.

Have you physically gone round the bike checking/tightening all the bolts?

Kev has designed/made some extra bar endweights too..ALL available when you join the forum(if you havent already) and then buy his modificationcd/download.

I know about vibes on big single, but the impression is that it gets worse every year (riding on XT already 6 years).
Yes, i have the bar end weights. Install it with the handguard.
I change the triple clamp with usd fork. This triple clamp don't have the rubber bushings and earlier i thinking that vibes come from this.
I already install "grip puppies", brp mount for handlebar with rubber bushings and this not solve the problem. I feel vibes not only on handlebar, but on footpegs and tank.
I'll tighten all the bolts with torque wrench and do the test on this weekend.

I remembered another problem ) I can't adjust the idle speed. Enter in diag mode, switch to rev counter (it show 0). But when i start the engine, dashboard switch to normal state and show me speed and odo. I have the "tired" battery. Maybe this happen because of the battery?

If you have a tired battery its only going to get worse so imho I'd change it as a priority...Again if the triple tree clamp has no isolating rubber dampers then it stands to reason that it could increase any vibes.

Another recent post indicated that the bike wont start without the clocks/dash as it has some connection to the immobiliser system..i think.Do a forum search..its ALL here ..somewhere.

Tightened the bolts on the frame. On weekends I went to another city. When I went there, everything was fine. When I went back, again there was a high frequency vibration. On the handlebars, footpegs and even a tank. This is not an ordinary vibration from a big single, because I clearly feel the difference. When I press the clutch on the move and open the throttle, vibrations also appear. Maybe is something wrong with the engine?

So you tightened up what you could and went for a long journey...and all was well.
On the way back the vibes were there again?...
Probably a very silly question BUT did you remove the nuts/bolts and clean them up at all..used a threadlock?..

Clutch adjuste ok?
Chain tensioned and aligned ok?
Oil ok/filled?..esp after a long ride...

No, just tightened.
Journey is not long, only 60km.
Clutch is ok. Oil is ok. The chain is slightly worn out and rear rubber damper is worn.
Hm... maybe my chain is over? Perhaps she quickly stretches. I'll try to check and test on road. Ufff..

IF the rubber shock absorber's rear wheel are worn then IMHO this could cause the problems your talking about. Combine that with a potentialy worn chain and maybe even sprockets then the vibes are gonna be noticable.

Chain maintenance is often overlooked. Cleaning and lubricating it is high on my list of bike prorities.

My only moan about the R is it has no rev counter,so its hard to identify when the noises/vibes appear.

TBH I have noticed that if Im lazy and dont use the gears in the correct range etc then my R does kinda vibe BUT if Im on it then she's sweet.

FYI there is a 'fix' for the rubbers. Basically an old inner tube cut into sections and placed between the rubbers and the casings. Cheap and cheerfull.

After a weekend trip, I think the problem is with the vibration due to the frame or engine. The motorcycle vibrates even standing still and If i open the gas at the neutral point, the vibrations become stronger. Perhaps the navigation bracket gives such vibrations. It will be necessary to further check.
I wrote in another topic. Should there be any play in the clutch basket? If not, why does it appear?

High Frequency Vibration
 

Sounds like what I had on my z, but check with Kev before you start stripping, as I�d hate be responsible for sending you on a wild goose chase!

I have attached the photo of the back crankshaft washer (RHS of bike) that is located behind the crankshaft gear cluster.
When this rubs on the face of the crank bearing inner race (if stopped due to shaft turning within bearing race) it turns your machine into an ultrasonic transducer!
It was so bad with mine that I thought I was going to get vibration white finger (VWF). Caused my hands to go numb, changed washer and vibration was gone.

If left long it will do you nerve damage and also will give the impression that the crankshaft nut has come loose (even when Loctited and the lockwasher is still intact), when in actual fact the washer has become 5-7 thou (mils Imperial) thinner due to erosion of washer surface.

Thanks for advice. Vibration is become a really problem.
Part number of this washer is 90201-30X00-00? This is it?

What about clutch basket free play? Do you have it? It's normal?

Yes I have a bit, I had to take a dremel to it to round off all the dents made by the clutch disks chattering due to the loose primary drive nut.
Make sure you remove it from the machine before doing this as you don�t want any abrasives in the engine. I used a chainsaw diamond burr sharpener.
Yes if you feel loaded (flush with cash) replace the basket, but mine has been ok, except for the primary drive key which is outside the transition fit tolerances.

https://uploads.tapatalk-cdn.com/201...3f254e3db0.png


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I mean, the clutch basket goes back and forth along the shaft (longitudinally). Do you have this on your basket?
I hope to write correctly in English :)

Never seen that before, stupid question but do you have the washer (labelled as 14 in first photo)fitted between the inner and outer basket?

https://uploads.tapatalk-cdn.com/201...27f371aa11.png

See nothing else to come off after basket in second photo.

https://uploads.tapatalk-cdn.com/201...da025a7453.jpg


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I think yes. I open the right engine side first time to check nut on crank. I don't disassembled the clutch basket. Trying to pull the clutch basket a little bit and found that she has free play. Maybe that washer also has wear?

The only other thing that could have happened is the locking washer has failed and the nut holding the center has come loose. The only way to know this is to undo the front clutch cover helps by the 5 bolts and clutch springs; make sure you undo these in a cross cross pattern 1/4 -1/2 turn at a time until fairly loose then you can use a turn a time until the springs are loose.
This bit should have a lock tab washer and be tightened to 90Nm.


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I think i have a couple week good weather. After that i close the motorcycle season for winter break and start disassemble my engine. I'll write later.
Thanks for advices.

Can not very well be seen, but the knock from the backlash is heard clearly.
https://youtu.be/LutwFRNR8EM

****** just had mine in bits, meant to check this with the basket on, with the basket off, there was 1-2mm longitudinal play in shaft, which I agree will affect clutch operation, hence I had to readjust my clutch.
But didn�t check with baskets on and torqued up.....so apologies. My wife has said my bike is knocking again (I hope not!).
See my post here:

https://www.xt660.com/showthread.php...ferrerid=20974


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I read that you changed the washer 3 times. After how many km does it wear out?

Funny you should ask, the first time was around 28,000 miles then the secobd and third times got shorter and shorter (the last time wa 500miles!)
Hence have torqued the nut up to 120Nm.
MikeinNZ said he had his up to 140Nm before selling, as had same issue, and spent a fortune on a rebuild which turned out to be the washer.
But what causes the washer is having a loose key.....as I found out, hence having to make a custom key...
Current mileage is 32800miles.

I disassemble the clutch and found that is free play of main axle.
https://youtu.be/j7UN7AoMx5w
Anybody know, is this is normal?

P.S. How add youtube video in message not like a link?

I removed the sprockets and everything looks fine. Waiting now for new washers. The red substance in the photo is the factory grease?
http://ipic.su/img/img7/tn/IMG_20181...1542438850.jpg

Update.

A few words about the problems I mentioned here:
- Moto don't start without dashboard. I think only reflash (immoblilizer off) can resolve this.
- If you diag mode switch back to speedo when you try to adjust idle speed, that mean you battery have low voltage (need to replace)
- Vibration problem not solved. ((( I changed the washer and this not help.