Strange ticking from transmission area.

Recently swapped out the shaft and differential due to a crack near the drain plug.
I noticed after reassembly the bike was ticking from the transmission area of the case.
Noise is only when engaging gear, and gets louder through the gears. I had a local guy check it out while rebuilding forks. He pulled the shaft assembly and it still does it.
Oil is clean, no shavings, while the cover was off he didn’t notice any play in the clutch.

New to the Tenere, anybody else’s sound like a Ducati?

Welcome to the forum. Please take a minute to add your location to your profile. It gives context to your posts and helps others give you better answers.

What year is your Super Ten and how many miles on the bike?

Ticking varies with RPM or stays the same, but gets louder?

Ticking varies with speed within the same gear?

Ticking apparent in all gears? If not, which ones?

There haven't been many transmission issues reported. Did the local guy remove the U-joint before testing it with the shaft out? U-joint would be a cheap and easy fix, if that's all it is.

EricV said:

Welcome to the forum. Please take a minute to add your location to your profile. It gives context to your posts and helps others give you better answers.

What year is your Super Ten and how many miles on the bike?

Ticking varies with RPM or stays the same, but gets louder?

Ticking varies with speed within the same gear?

Ticking apparent in all gears? If not, which ones?

There haven't been many transmission issues reported. Did the local guy remove the U-joint before testing it with the shaft out? U-joint would be a cheap and easy fix, if that's all it is.

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Updated my location, live in the Fresno area of CA.
Tenere is a 2012 1200cc, with 35k miles.
Varies with RPM and only when engaging/in gear. No sound in neutral. Sounds get louder as you go through the gears. I both rode it and checked the sound while on center stand. Sound was the same both ways and only in gear. The U joint came out with the rear swing arm/assembly and it still made the noise. He showed me the video.
Hope the clarification helps.

@~TABASCO~ Might have a clue. He's had these engines apart more than most.

If you have been running the bike through the gears whilst stationary on the main stand, I wonder if the UJ is complaining & may be off centre. This is a scenario best avoided with all shaft drive bikes. However there are a few inconsistencies in your description TBH,

.............. https://www.fowlersparts.co.uk/parts/5448987/xt1200z-2012-23pb-europe-mat-gray-metallic-3/drive-shaft

Presumably the UJ was checked when the rear drive was changed out & has been correctly relocated. They get a tough time & little attention over the 8 years the bike has been on the road. If you are getting this same noise when riding normally, it is speed not engine rev related & is coming from the left drive side, I would suggest the UJ is your problem. Also make sure the flexible rubber bellows behind the LH heel plate is in good leak free condition.

If it is rev related, then frankly it would make no sense to me given the nature of the recent work on the bike. It could be a CTT issue I guess - maybe a video would help us. I assume the gearbox is behaving correctly & clutch function is acceptable (upgraded?)

EricV said:

@~TABASCO~ Might have a clue. He's had these engines apart more than most.

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He reached out, I wrote back. See if we can head him in the right direction.

I’ll see if I can get a hold of the video. I joint was removed for the video and it still did it. Only happened in gear. Rubber cover is good, no leaks and was off for the inspection. rides fine, I’m just fearful of it shitting the bed while out on a ride.

I’ll have to check with my Dad but I don’t think he did the CCT or clutch basket upgrade.

Here’s the video, hope it works.

Could it just be play in the spring damper in the middle drive gear assembly? Possibly one of the bearings is running rough. Maybe just chatter from the bevel gears that could be shimmed out.

.............. https://www.fowlersparts.co.uk/parts/5448980/xt1200z-2012-23pb-europe-mat-gray-metallic-3/middle-drive-gear

Good to see the shaft disconnected BTW. Have you tried going over the gearbox & middle drive with a stethoscope (or large screwdriver against the ear will do) to see if you can tie down the exact source.

Both, the mechanic listened with a screwdriver and I happened to have my stethoscope on me. Sound was louder/muffled on the left and sharper on the right of the case.

Some new videos I took today.

Is the same sound there while going down the road? Mine clatters some when free wheeling like that, I believe it's the engine pulses clashing the gears. Under a load there is no clashing of the gears. There's a reason you're not supposed to run a shaft drive bike in gear on the centerstand.

I went to the Doc, "Hey Doc, it hurts when I do this" Doc says "Don't do that".

Yes

All I can say is pull the service cover and see if you can see a missing tooth.

Thanks for the help Don, I meant to get into it today but ran out of time.

I helped repair a Yamaha Rhino years ago that sounded like that or worse. the bevel gears diving the dive shaft had broken teeth and the bearing stay and engine case was destroyed that held the main output gear in place. Don't mean to spread panic because the Tenere is a different machine. My drive shaft rattles some with it on the center stand too but it is from not having load on the drive line. Hope yours is an easy fix. Good luck and let us know what you find. I would be very interested in the find.

Those are much better videos this time OP. Seems to be the drive/left side so I guess it could be the middle drive pinion set missing a tooth as Don suggests, but I can't recall ever hearing of any other cases previously. Always a first I guess. BTW, what caused the original crack to the rear bevel box in the first place - was this accident damage, off-roading or a heavy handed tech?

To my mind it's would seem more likely to be a weak/broken damper spring, allowing the transmission damper to clatter as it climbs/descends the cam. Keep us posted.

I'd start with a quick and relatively simple check of the clutch basket fingers for wear. It was a known issue on the Gen1 bikes.

Squibb said:

Those are much better videos this time OP. Seems to be the drive/left side so I guess it could be the middle drive pinion set missing a tooth as Don suggests, but I can't recall ever hearing of any other cases previously. Always a first I guess. BTW, what caused the original crack to the rear bevel box in the first place - was this accident damage, off-roading or a heavy handed tech?

To my mind it's would seem more likely to be a weak/broken damper spring, allowing the transmission damper to clatter as it climbs/descends the cam. Keep us posted.

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My guess was a heavy handed tech, or over tightened from factory. Not sure, my Dad said he never touched it.

Checkswrecks said:

I'd start with a quick and relatively simple check of the clutch basket fingers for wear. It was a known issue on the Gen1 bikes.

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Could be I guess - I only ever had a demo on a Gen1 FE & waited for the Gen2 ES to arrive, so I lack any depth of experience with the early bikes..
I discounted the idea previously as the RHS didn't sound like the primary source. It will be interesting to see if the OP can track down the culprit.