Originally Posted by Zapp22
If one were to pro-actively rebuild the Transmission, and wanted to make sure its as bulletproof as possible, would you use aftermarket parts or not?
I realize our friends at Procycle [and maybe others?] have a super high-quality 3rd gear kit, but I'm wondering if the collective really KNOW FOR SURE what causes the 3rd gear to detonate the trans??? Its just really hard for me to fathom that Suzi would manufacture all the parts for the trans, and keep on manufacturing just one defective component... it does not pass sniff test.
So if rebuilding with Race-proven Baja-capable parts is the ticket - is there any science on how many of them blowup for one reason or other? how many units have been tested, in-service, for long periods of time as have the Suzuki parts? its a rhetorical question....
you who have done the job, what did you use?
Originally Posted by neoxaero
I'm in the process of having mine rebuilt right now. I was having some issues with it falling out of 2nd gear so I decided to just bite the bullet.
From the reading I did prior to getting the work done, it seems in 06 or 07 suzuki released a new 3rd gear that replaced the old one. I'm assuming it was done in an effort to address the issues with the gear blowing up. I decided to go a head and replace my gear with the newest one instead of buying the billet unit. Hopefully I don't regret it, but I couldn't justify replacing a $50 dollar part with one that costs $500 when the stock one may or may not blow up at some point.
Obviously, If I trash the engine in the bike due to a 3rd gear failure I'll be kicking myself.
I may consider doing the nice 3rd gear when I put the 790 kit in the bike as a little bit of extra insurance
i still don't think anyone knows for sure what is the cause of the 3rd gear blow-up - whether there is something specifically wrong w/the way the trans loads 3rd gear, or whether it's a mfr'ing defect w/the 3rd gearset, or something else. and, as there is no data on use of bikes w/the custom 3rd gears, no one yet knows whether this is a good "fix", or whether it will simply shift the (unknown) problem elsewhere and cause something else to grenade. these new 3rd gearsets are simply too new for there to be any "1st hand experience". i have not heard of anyone w/a dr650 having a complete custom racing gearbox done up for them. i guess if you have enough money to buy a 2nd new dr650, you could have a custom gearbox done for you - a 6sp box would sure be nice!
there is also no info confirming that the "new" suzuki 3rd gear was anything more than a vendor change. there's no evidence of its being strengthened in any way, and there's plenty of "post-'06-'07" dr650's that have had 3rd gear grenade on them.
that said, the "plenty" i am referencing is something on the order of 1 in a 1000, so i am really not sure it's a potential problem that is worth addressing. there is no way i would be paying $600 for a pair of matched third gears, when you can get a factory pair for a fraction of that price. especially since there is no data that it's even a fix for the problem. if i were into my engine for any sort of major refurb, i would have my stock 3rd gears professionally checked/magnaflux'd, to be sure they're ok and then have the entire gearset cryo'd, replacing the existing 3rd gearset w/factory parts if there were evidence of wear on them. (whatever you do, if you are replacing 3rd gear, be sure to buy the pair, not yust the one gear, if you go for replacement w/stock parts.)