DR650 3rd gear blowups - Page 4

NordieBoy · 02-07-2009, 09:35 PM

Quote:

Originally Posted by edf

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.

DJ'd stock carb.

So far it's bikes from 99-05 that have blown. They changed the gear part number in '06.

Quote:

Originally Posted by plugeyes

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

But in NZ half the bikes we get are US spec.
The '97 I bought to nick the engine from is a US one.

NordieBoy · 05-27-2009, 01:28 AM

Been having a bit of a think on this whilst lying in my sleeping bag staring at the ceiling on a 3 day adventure ride this weekend...

96-97 seem to be susceptible to 3rd gear "whine".
I've ridden 3 that have it including mine.

The whine is caused by loosing the hardening?

Suzuki re-harden the gear making it more brittle?

2006 Suzuki re-re-harden/fix the 3rd gear.

Of the 12 bikes in the list <98 and >05 are conspicuous by their absence.

LukasM · 05-27-2009, 04:27 AM

My 96 with unknown kms (probably 30.000+) has no whine, shifts smoothly and never jumps out of gear. Knock on wood!

But when I take the whole thing apart to put a 725cc kit from Procycle in, I'll upgrade to the newer 3rd gear for sure.

bluebye · 08-19-2009, 05:50 PM

04 Dr650. 23000 miles. 99% commuting. Daily rider. No engine modifications. Always use cluch to shift. Maintained meticulously. Shift to 3rd accelerating and bang, clank, etc. Engine goes dead. No compression sounds bad when I pushed the starter button. Rolls freely to a stop. !st engages, 2nd engages, third in like neutral. Fuck. To the OP, can you post pics of your blow up or a link? Thanks.

NordieBoy · 08-19-2009, 07:52 PM

Quote:

Originally Posted by bluebye

04 Dr650. 23000 miles. 99% commuting. Daily rider. No engine modifications. Always use cluch to shift. Maintained meticulously. Shift to 3rd accelerating and bang, clank, etc. Engine goes dead. No compression sounds bad when I pushed the starter button. Rolls freely to a stop. !st engages, 2nd engages, third in like neutral. Fuck. To the OP, can you post pics of your blow up or a link? Thanks.

Hmmm...
Doesn't sound as catastrophic as some have...

All my pics are here...
http://www.photostorage.nelson.geek....ine/index.html

NordieBoy · 08-19-2009, 07:59 PM

NordieBoy (NZ) 2001 60,000km
Transalper (NZ) 2001 55,000km
Rosscoact (AU) 2004 13,000km
Mardy (US?) 1997 53,000km
TH (NZ) 1999 40,000km
RubberCow80 (AU) 2001 25,000km (2nd gear?)
Philth (AU) 3 bikes <20,000km (2nd gear?)
BikeRooter (AU) 2006 10,200km
Madsdad (US) 2005 16,000km
briangv99 (AU) 2006 21,000km
bluebye (US) 2004 37,000km

oldturtle · 08-20-2009, 09:33 AM

I was parked on slight down hill paved incline and decided to just bump start rather than to use starter. I may have been in 3rd gear but not sure. The bike just came to violent stop as though I reached end of Exxon Valdez anchor chain. I will probably not bump start on pavement any more and if necessary I will be sure to be in 5th gear. This has got to be hard on tranny.

Cathalp · 08-20-2009, 10:41 AM

The CCM R30's out of Blackburn had and still have DR650 motors.
My contribution is in this thread along with what 5th gear looks like before taking out the whole engine.

http://advrider.com/forums/showthread.php?t=492372

NordieBoy · 08-20-2009, 01:07 PM

Quote:

Originally Posted by Cathalp

The CCM R30's out of Blackburn had and still have DR650 motors.
My contribution is in this thread along with what 5th gear looks like before taking out the whole engine.

http://advrider.com/forums/showthread.php?t=492372

XF650 motors.

Re: That pic of 5th gear. What do the dogs look like on the 3rd cog?

Cathalp · 08-20-2009, 02:12 PM

Don't have a pic of 3rd but CCM riders forum has plenty of exploded gearbox stories and pics. Apart from the carbs and valves,the DR and the XF are the same gearbox and engine to the best of my knowledge.

lastmanout · 08-20-2009, 07:07 PM

Howdy All, So i am not the only one who has seen tranny failure in a DR650. I bought a clean used 2005 DR with 400 miles from my dealer. Wonderful bike. Months later, Salesman says " Need a parts bike ?" OH YEAH

. In the back room was a 02 DR650 with bald tires, some road rash, and a crack in the right engine case. Motor was locked. $500 USD bought it with a good title. Spliting the cases I found that #3 gear had broke into three pieces and wreaked SOME damage. A few months later, $1100 in parts (tranny gears, shift fork, tires, sprockts, chain, brake pads, cables, battery,etc. previous owner 'hammered' this one hard ) It was a whole bike again. Ran the '02 for 4000 miles trouble free before I had to sell. Got real lucky saving the cases, piston, and cylinder. Washed metal shavings out of the bearings for days. If you need new cases, piston or cylinder-- part the bike out - fixing it makes no economic sense. I still like the DR650's, just don't have one at the moment.

neepuk · 08-20-2009, 07:45 PM

Quote:

Originally Posted by NordieBoy

NordieBoy (NZ) 2001 60,000km
Transalper (NZ) 2001 55,000km
Rosscoact (AU) 2004 13,000km
Mardy (US?) 1997 53,000km
TH (NZ) 1999 40,000km
RubberCow80 (AU) 2001 25,000km (2nd gear?)
Philth (AU) 3 bikes <20,000km (2nd gear?)
BikeRooter (AU) 2006 10,200km
Madsdad (US) 2005 16,000km
briangv99 (AU) 2006 21,000km
bluebye (US) 2004 37,000km

Hmmm, Looks to me like only 2, maybe 3, in the US and the rest on the other side of the world. I wonder if that's because you guys use them harder, or got a bad batch, or just a matter of very few being reported here in the US... They're probably all exactly the same all around the world but there have to be way more DR650's in the US than Down Under just based on the populations alone. Seems that we'd have a higher # of US blow-ups too.

rivercreep · 08-20-2009, 08:12 PM

F.W.I.W.
I had a 91 I traded in on a 97 way back in the day (it had just over 50,000 MILES on it and was still going pretty strong. (only ever replaced the cam-chain and tensioner around 40,000 mles).
The 97 was just a tick under 50,000 MILES before a Subaru totaled it out back in 2000. Bought her back from the Insurance company to part out and I tore it down to inspect things (with a micrometer, not by eyeball) and aside from the crankshaft end play being almost out of spec (as well as the timing chain, tensioner and camshaft) everything else was still fine.

Sooooo, I'm now on my third (just unloaded the 08 xt250) and we'll see how it goes if they've cheapend anything up on the inside of the engine/tranny.

In all honesty, I've never beat the piss out of my DR's off road (I ride at an exploratory pace) but did take them places they never really belonged (single track). I DID however, ride the shit out of them on the street.

I sure hope this one turns out to be as reliable as DR's of the past.

NordieBoy · 08-20-2009, 09:13 PM

Quote:

Originally Posted by neepuk

Hmmm, Looks to me like only 2, maybe 3, in the US and the rest on the other side of the world. I wonder if that's because you guys use them harder, or got a bad batch, or just a matter of very few being reported here in the US... They're probably all exactly the same all around the world but there have to be way more DR650's in the US than Down Under just based on the populations alone. Seems that we'd have a higher # of US blow-ups too.

We'd hear about them if the riders are on AdvRider/ThumperTalk/KiwiBiker

LukasM · 08-20-2009, 11:10 PM

I read about a few cases on the German DR forum as well....

05-27-2009, 04:27 AM	#48
LukasM Beastly Adventurer Joined: Nov 2006 Location: Vienna, Austria Oddometer: 4,927	My 96 with unknown kms (probably 30.000+) has no whine, shifts smoothly and never jumps out of gear. Knock on wood! But when I take the whole thing apart to put a 725cc kit from Procycle in, I'll upgrade to the newer 3rd gear for sure. __________________ 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

08-19-2009, 05:50 PM	#49
bluebye Skin it back Joined: Mar 2004 Location: 'neckville is where you hang your hat, Rolling Oddometer: 1,437	mine fragged today 04 Dr650. 23000 miles. 99% commuting. Daily rider. No engine modifications. Always use cluch to shift. Maintained meticulously. Shift to 3rd accelerating and bang, clank, etc. Engine goes dead. No compression sounds bad when I pushed the starter button. Rolls freely to a stop. !st engages, 2nd engages, third in like neutral. Fuck. To the OP, can you post pics of your blow up or a link? Thanks. __________________ Faster you fool!

08-20-2009, 09:33 AM	#52
oldturtle Gnarly Adventurer Joined: Mar 2006 Location: Martinez, Calif. Oddometer: 449	Careful when bump starting or avoid altogether. I was parked on slight down hill paved incline and decided to just bump start rather than to use starter. I may have been in 3rd gear but not sure. The bike just came to violent stop as though I reached end of Exxon Valdez anchor chain. I will probably not bump start on pavement any more and if necessary I will be sure to be in 5th gear. This has got to be hard on tranny. __________________ 2004 Kaw KDX220 2004 Hon XR250R 2006 Suz DL1000 2009 Suz DR650 2011 Kaw 650Versys

08-20-2009, 10:41 AM	#53
Cathalp Adventurer Joined: Jun 2008 Location: Ireland Oddometer: 36	5th gear too The CCM R30's out of Blackburn had and still have DR650 motors. My contribution is in this thread along with what 5th gear looks like before taking out the whole engine. http://advrider.com/forums/showthread.php?t=492372

08-20-2009, 07:07 PM	#56
lastmanout Gnarly Adventurer Joined: Dec 2005 Location: NW PA,USA Oddometer: 210	Howdy All, So i am not the only one who has seen tranny failure in a DR650. I bought a clean used 2005 DR with 400 miles from my dealer. Wonderful bike. Months later, Salesman says " Need a parts bike ?" OH YEAH . In the back room was a 02 DR650 with bald tires, some road rash, and a crack in the right engine case. Motor was locked. $500 USD bought it with a good title. Spliting the cases I found that #3 gear had broke into three pieces and wreaked SOME damage. A few months later, $1100 in parts (tranny gears, shift fork, tires, sprockts, chain, brake pads, cables, battery,etc. previous owner 'hammered' this one hard ) It was a whole bike again. Ran the '02 for 4000 miles trouble free before I had to sell. Got real lucky saving the cases, piston, and cylinder. Washed metal shavings out of the bearings for days. If you need new cases, piston or cylinder-- part the bike out - fixing it makes no economic sense. I still like the DR650's, just don't have one at the moment. __________________ Tell me Doctor, where are we going this time.......

05-27-2009, 01:28 AM	#47
NordieBoy ^OP Armature speller Joined: Dec 2006 Location: Kiwiland Oddometer: 6,782	Been having a bit of a think on this whilst lying in my sleeping bag staring at the ceiling on a 3 day adventure ride this weekend... 96-97 seem to be susceptible to 3rd gear "whine". I've ridden 3 that have it including mine. The whine is caused by loosing the hardening? Suzuki re-harden the gear making it more brittle? 2006 Suzuki re-re-harden/fix the 3rd gear. Of the 12 bikes in the list <98 and >05 are conspicuous by their absence.

08-19-2009, 07:59 PM	#51
NordieBoy ^OP Armature speller Joined: Dec 2006 Location: Kiwiland Oddometer: 6,782	NordieBoy (NZ) 2001 60,000km Transalper (NZ) 2001 55,000km Rosscoact (AU) 2004 13,000km Mardy (US?) 1997 53,000km TH (NZ) 1999 40,000km RubberCow80 (AU) 2001 25,000km (2nd gear?) Philth (AU) 3 bikes <20,000km (2nd gear?) BikeRooter (AU) 2006 10,200km Madsdad (US) 2005 16,000km briangv99 (AU) 2006 21,000km bluebye (US) 2004 37,000km

08-20-2009, 02:12 PM	#55
Cathalp Adventurer Joined: Jun 2008 Location: Ireland Oddometer: 36	Don't have a pic of 3rd but CCM riders forum has plenty of exploded gearbox stories and pics. Apart from the carbs and valves,the DR and the XF are the same gearbox and engine to the best of my knowledge.

08-20-2009, 08:12 PM	#58
rivercreep Banned Joined: Feb 2007 Location: S.E. Pennsylvania (Reading) Oddometer: 3,155	I'm not worried......on my third one now! F.W.I.W. I had a 91 I traded in on a 97 way back in the day (it had just over 50,000 MILES on it and was still going pretty strong. (only ever replaced the cam-chain and tensioner around 40,000 mles). The 97 was just a tick under 50,000 MILES before a Subaru totaled it out back in 2000. Bought her back from the Insurance company to part out and I tore it down to inspect things (with a micrometer, not by eyeball) and aside from the crankshaft end play being almost out of spec (as well as the timing chain, tensioner and camshaft) everything else was still fine. Sooooo, I'm now on my third (just unloaded the 08 xt250) and we'll see how it goes if they've cheapend anything up on the inside of the engine/tranny. In all honesty, I've never beat the piss out of my DR's off road (I ride at an exploratory pace) but did take them places they never really belonged (single track). I DID however, ride the shit out of them on the street. I sure hope this one turns out to be as reliable as DR's of the past.

08-20-2009, 11:10 PM	#60
LukasM Beastly Adventurer Joined: Nov 2006 Location: Vienna, Austria Oddometer: 4,927	I read about a few cases on the German DR forum as well.... __________________ 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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