Absolute Legend!
You’ve given me great confidence, can’t wait to get it back together and never hear that knock again!
I’ve also just made my own key using key steel, it’s a much more snug fit, so there won’t be any play!
I think I’ll loctite the key in as well, to fill any gaps there may be, any ...

It’s apart at the moment but once I’m sure 120Nm is alright and I get the key machined, I’ll put it back together and hopefully won’t be able to make that video because the noise will be gone

Just a recap of everything:

Engine knocking on 2009 Yamaha XT660Z Tenere with approx 60,000kms.
- Took it to the shop and they found the crank nut was loose, tightened to spec and loctited it.
- A year later the noise returns, so I found the nut loose again and tightened it to 90Nm and used ...

May be a glitch in the manual there.
From the factory workshop manuals:

XT600Z: M20x1 120 Nm
XT600E: M20x1 120 Nm
XTZ660: M20x1 120 Nm Use lock washer
XT660Z: M20x1 80 Nm ("Use the lock washer")

Andy


Oh thanks for that Andy, just to clarify though, are you saying that it should actually be ...

A friend has told me to do some maths/engineering/ on the thread dimensions and qualities to see what it should be able to handle, he recalls doing his up above 100Nm. But the last thing I want to do is mess up that thread! So I’ll do lots of research and see what I find . If anyone on here has ...

Thanks!

I think I’ll pull it apart and get someone to machine a key that fits more snugly, and I think I’ll tighten it up to 100-120Nm this time (80Nm is spec)

The link doesn’t seem to work for me, “database error”. I read elsewhere that it’s normal for this key to have a bit of play in it, not that it’s good, but it is normal. Thoughts?

Oh, is this thread for my bike or the old Tenere?

Here’s a YouTube link to the movement in the keyway (this is how I found it, I then tightened it, but the play will be the same now that it’s loose again)


https://youtu.be/lJSQMFPSlPs

That’s something I should mention yeah, the key seemed to be completely fine, I couldn’t see any wear on it besides a slight mark of where it contacted, but nothing that would significantly change its width. However, there was 2-3mm of play in it. This puzzled me for a long time, and I ended up ...

Help!
I have an ‘07 Tenere with this same issue. First time I heard the knocking, I took it to the shop and they tightened the crank nut to spec (80Nm) and used loctite. Maybe 6 months to a year later, the noise came back, but I decided to do it myself, sure enough the crank nut was loose again, but ...