DR650 3rd gear blowups - Page 3

ADVJake · 02-02-2009, 03:48 AM

Quote:

Originally Posted by LukasM

To keep this in perspective, we are talking about 10 bikes out of many many thousands across the various forums that Nordie is on (ADV, TT, etc).

another perspective, think of how many who have had the failure who are not on the forums ? and those who are silent or haven't seen the threads...

there are multiple reports of 2nd gear also, was there an updated part # for that?

Curious to find out when they updated that part number. it now shows up on all year models on the fiche doesn't it ?

LukasM · 02-02-2009, 04:01 AM

2nd gear appears to be the same, the only other parts that changed are a bolt and the LH drive shaft bearing.

Unfortunately I can't tell when the part changed from the fiche I am using. Didn't somebody mention it was 06/07

RedLander · 02-02-2009, 05:45 AM

Quote:

Originally Posted by LukasM

To keep this in perspective, we are talking about 10 bikes out of many many thousands across the various forums that Nordie is on (ADV, TT, etc).

At the same time there must be a reason why it's always 3rd drive gear and Suzuki changed the part recently.

GEAR,3RD DRIVE
24231-12D21 (replaces 24231-12D20)

1

$53.39

How "recently" is recent?? Just curious, just picked a '09 & was not happy to see this thread. Even so, this will not stop me from riding it it like it should be!!

Oops, just saw the post, maybe '06/'07. Thanks.

Eugene · 02-02-2009, 06:03 AM

The Ron Ayers microfiche is showing the new 3rd gear in 2006. 2005 and lower show the old gear part number superseded by the newer. Maybe the old 3rd is in some of the 2006 bikes?

Yobob · 02-02-2009, 03:37 PM

It would be nice to have more details on the bikes that have failed. What kind of riding, mostly road, dirt, sand, etc? How much shifting without the clutch (if any)? What type of oil was used in each bike?

RiDR · 02-02-2009, 04:21 PM

Quote:

Originally Posted by Yobob

It would be nice to have more details on the bikes that have failed. What kind of riding, mostly road, dirt, sand, etc? How much shifting without the clutch (if any)? What type of oil was used in each bike?

engine, carb, drivetrain modifications? any stock bikes in the mix?

NordieBoy · 02-02-2009, 10:15 PM

Quote:

Originally Posted by LukasM

To keep this in perspective, we are talking about 10 bikes out of many many thousands across the various forums that Nordie is on (ADV, TT, etc).

12 bikes

NordieBoy · 02-02-2009, 10:16 PM

Quote:

Originally Posted by edf

engine, carb, drivetrain modifications? any stock bikes in the mix?

At least 1 completely stock engine/carb - TransAlper.

Yobob · 02-03-2009, 12:19 AM

NordieBoy,
Have you contacted Suzuki about this? I'm glad it didn't happen in a bad place but if you had been on the road in traffic and had the real wheel lock up it could have been far worse. Even if it's only one in 1000, or one in 10,000 they should know about it. It would sure be interesting to see what kind of response you'd get from the factory.

NordieBoy · 02-03-2009, 09:06 PM

Having a look at the gear cluster today and it seems that 3rd gear is a very hard working gear.
2nd and 4th are freely rotating on the shaft and 3rd is driven.
In 2nd gear 2+3 mesh together sideways, in 3rd gear 3rd is solo, in 4th gear 3+4 mesh sideways.

3rd is under load in 2nd, 3rd and 4th gears.

briangv99 · 02-05-2009, 09:14 PM

Quote:

Originally Posted by NordieBoy

Yep. Thought it was Aussie type distances.

Do you remember what gear you were in when it went? went whilst shifting up from 2nd to 3rd.
Could yours have been a 2005 old stock sold as a 2006?

Might be, I'll check the compliance plate when I get a chance.

Bikes has racked up most miles just commuting to work and back, always use the clutch, do twist the throttle hard though

. Had just switched over to a TM40 and FMF muffler, maybe had 1000k use, but 100 percent stock before that. Never had a bike self destruct as badly as this one

. Had a XR600 that spat teeth from 4th gear, but least the gear remained intact and didn't vandalise every part of the engine.

DRjoe · 02-06-2009, 03:06 AM

i have 97 one with 100,000+k's that is making a very nasty ratle in third (i'm thinking missing teeth or bent shift fork) and also an 02 with 13,000k's which has a worn out second gear dog clutch the rest of the engine is spotless (jumping out of second). two new gears bought to repair it at 80 aud each.

NordieBoy · 02-06-2009, 05:59 PM

Once mine hits 40,000km I'm getting 3rd replaced as the hardening is going and it's whining.

The NSU is missing the lower screw and the upper was loose as well...

RiDR · 02-06-2009, 08:45 PM

Quote:

Originally Posted by briangv99

Might be, I'll check the compliance plate when I get a chance.

Bikes has racked up most miles just commuting to work and back, always use the clutch, do twist the throttle hard though

. Had just switched over to a TM40 and FMF muffler, maybe had 1000k use, but 100 percent stock before that. Never had a bike self destruct as badly as this one

. Had a XR600 that spat teeth from 4th gear, but least the gear remained intact and didn't vandalise every part of the engine.

Didn't the OP also put in a TM40 before this happened? more torque / power than the drivetrain can handle?
I know i'm grasping at straws but you gotta think If nothing's changed on these bikes since 97 and this is a more recent occurance then something new has been thrown into the mix.

plugeye · 02-07-2009, 05:58 AM

[quote=edf]Didn't the OP also put in a TM40 before this happened? more torque / power than the drivetrain can handle?
quote]

the power increase isnt enough to make any difference design-wise.
look at the logistics, most are australian & new zealand. that could be significant.

02-02-2009, 04:01 AM	#32
LukasM Beastly Adventurer Joined: Nov 2006 Location: Vienna, Austria Oddometer: 4,915	2nd gear appears to be the same, the only other parts that changed are a bolt and the LH drive shaft bearing. Unfortunately I can't tell when the part changed from the fiche I am using. Didn't somebody mention it was 06/07 __________________ Proud member of the HUSABERG ADVENTURE TEAM! '12 Husaberg FE570, 09 KTM XC-F/ 450 RFS hybrid, 07 KTM 450 SMR, 08+09 BMW F650GS twins/F800GS conversion, 03+05 YZF-R6

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02-02-2009, 06:03 AM	#34
Eugene - Joined: May 2007 Location: Marion, IN Oddometer: 1,080	The Ron Ayers microfiche is showing the new 3rd gear in 2006. 2005 and lower show the old gear part number superseded by the newer. Maybe the old 3rd is in some of the 2006 bikes?

02-02-2009, 03:37 PM	#35
Yobob Adventurer Joined: Nov 2008 Location: Minnesota Oddometer: 18	It would be nice to have more details on the bikes that have failed. What kind of riding, mostly road, dirt, sand, etc? How much shifting without the clutch (if any)? What type of oil was used in each bike?

02-03-2009, 12:19 AM	#39
Yobob Adventurer Joined: Nov 2008 Location: Minnesota Oddometer: 18	NordieBoy, Have you contacted Suzuki about this? I'm glad it didn't happen in a bad place but if you had been on the road in traffic and had the real wheel lock up it could have been far worse. Even if it's only one in 1000, or one in 10,000 they should know about it. It would sure be interesting to see what kind of response you'd get from the factory.

02-03-2009, 09:06 PM	#40
NordieBoy ^OP Armature speller Joined: Dec 2006 Location: Kiwiland Oddometer: 6,774	Having a look at the gear cluster today and it seems that 3rd gear is a very hard working gear. 2nd and 4th are freely rotating on the shaft and 3rd is driven. In 2nd gear 2+3 mesh together sideways, in 3rd gear 3rd is solo, in 4th gear 3+4 mesh sideways. 3rd is under load in 2nd, 3rd and 4th gears.

02-06-2009, 03:06 AM	#42
DRjoe Beastly Adventurer Joined: Sep 2007 Location: Sunshine coast qld Oddometer: 4,251	i have 97 one with 100,000+k's that is making a very nasty ratle in third (i'm thinking missing teeth or bent shift fork) and also an 02 with 13,000k's which has a worn out second gear dog clutch the rest of the engine is spotless (jumping out of second). two new gears bought to repair it at 80 aud each.

02-06-2009, 05:59 PM	#43
NordieBoy ^OP Armature speller Joined: Dec 2006 Location: Kiwiland Oddometer: 6,774	Once mine hits 40,000km I'm getting 3rd replaced as the hardening is going and it's whining. The NSU is missing the lower screw and the upper was loose as well...

02-07-2009, 05:58 AM	#45
plugeye mc caregiver Joined: May 2007 Location: Garland, Texas Oddometer: 2,590	[quote=edf]Didn't the OP also put in a TM40 before this happened? more torque / power than the drivetrain can handle? quote] the power increase isnt enough to make any difference design-wise. look at the logistics, most are australian & new zealand. that could be significant.