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Old 12-27-2009, 10:12 PM   #91
NordieBoy OP
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Joined: Dec 2006
Location: Kiwiland
Oddometer: 7,125
Whine

My '01 never whined but went bang at 50,000km or so.
My '97 has whined since I've known it and is at about 46,000km now.
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Old 12-28-2009, 02:31 AM   #92
DRjoe
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Joined: Sep 2007
Location: Sunshine coast qld
Oddometer: 4,981
Quote:
Originally Posted by Pike Bishop

I'm sorry to hear about your loss, DRJoe...did it lock up the rear wheel?
I felt something go through the gear shift lever and i thought the chain was coming of so i pulled the clutch and let the throttle of pretty quick and i'm pretty sure the engine was still running for a few seconds after that.


This gear box didn't wine and it was nice and smothe to shange gears my old gear box never wined either but it did have a very notchy change.

I dont hink there is any ryme nor reason to it appart from suzuki made a bum gear.
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Old 01-18-2010, 12:59 PM   #93
NordieBoy OP
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Location: Kiwiland
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Another one...

NordieBoy (NZ) 2001 60,000km
Transalper (NZ) 2001 55,000km
Rosscoact (AU) 2004 13,000km
Mardy (US) 1997 53,000km
Haddon (NZ) 1999 40,000km
RubberCow80 (AU) 2001 25,000km
Philth (AU) 3 bikes <20,000km
BikeRooter (AU) 2006 10,200km
Madsdad (US) 2005 16,000km
briangv99 (AU) 2006 21,000km
bluebye (US) 2004 37,000km
Coyote X (US) 2007 33,800km
DRjoe (AU) 1997 100,000km
DRJens (SE) 2001 23,000km
DRjoe (AU) 2003 15,000km
Helicopter (NZ) 2002 ???km
Klay (US) 2001 29,000km

NordieBoy screwed with this post 01-18-2010 at 01:14 PM
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Old 01-18-2010, 01:12 PM   #94
Klay
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Joined: Nov 2005
Location: right here on my thermarest
Oddometer: 100,137
Quote:
Originally Posted by NordieBoy
18,000 miles - What year?

2001 model. (sorry for the delay in response) I've since put 11,000 miles on the rebuilt motor.
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Old 01-19-2010, 01:21 PM   #95
galusham
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Location: VA
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Not sure if this has been mentioned yet, or how accurate it was, but several months ago, I read an article that explained why 3rd gear was susceptable to damage in the DR650. From what they explained, the design of the transmission placed some sort of stress on 3rd gear when you were in 3rd, 4th, or 5th gears. I don't have much knowledge of transmissions so maybe some experts on here can investigate/elaborate. Unfortunately, I can not find the article.
Thanks.
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Old 01-19-2010, 01:24 PM   #96
galusham
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Quote:
Originally Posted by galusham
Not sure if this has been mentioned yet, or how accurate it was, but several months ago, I read an article that explained why 3rd gear was susceptable to damage in the DR650. From what they explained, the design of the transmission placed some sort of stress on 3rd gear when you were in 3rd, 4th, or 5th gears. I don't have much knowledge of transmissions so maybe some experts on here can investigate/elaborate. Unfortunately, I can not find the article.
Thanks.
I found it again. It was on the DR650 wiki. See below. Heck, maybe one of you guys posted it on there...
  • 3rd gear issues- Some DR's can have a pronounced whine in 3rd gear which can be caused by the hardening wearing off or a badly cut gear. Not catastrophic but annoying anyway.
3rd gear has also been known to disintegrate in a small number of cases. Unfortunately whine or lack of is no indication either way something is going to happen. So far there have only been 18 or so documented cases (Jan 2010) in the US/Oz/NZ out of the many thousands of DR's running around out there and some racking up very high mileages with no problems at all.
Riding conditions may play a part as the Australian bikes affected seem to be at about 20-30,000km whereas the New Zealand/US bikes were between 40-60,000km.
Suzuki changed the part number for 3rd gear in 2006 and 2008 and so far the years represented in the failure list are from 1999 to 2006.
The 3rd gear cog is under load in 3rd, 4th and 5th gears and is the hardest working of the cogs.
If you are going to have the cases apart for any reason, for peace of mind it would pay to replace this $70US part.
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Old 01-21-2010, 08:09 PM   #97
NordieBoy OP
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Location: Kiwiland
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Quote:
Originally Posted by galusham
I found it again. It was on the DR650 wiki. See below. Heck, maybe one of you guys posted it on there...
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Old 01-23-2010, 08:11 PM   #98
AdvRonski
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Joined: Feb 2007
Location: Wishing I was back in Grand Junction, now in MN
Oddometer: 688
I'm doing a 3rd gear replacement at about 14,000 miles, just to be safe. I've heard that cryo-treating gears will make them less brittle, more durable, and less susceptible to the propagation of surface cracks. Since 3rd drive gear seems to be the weak link in these transmissions, I'm wondering if anyone here has had the new superseded gear treated before installing it.
Here's one of the places that performs cryogenic treatments-http://www.cryoplus.com/advantages.html

If you can believe the hype, not only will your bike go faster and last longer, but you'll stop losing your hair, and women will find you irresistible!
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Old 01-23-2010, 08:15 PM   #99
shrubber
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Oddometer: 59
Quote:
Originally Posted by AdvRonski
I'm doing a 3rd gear replacement at about 14,000 miles, just to be safe. I've heard that cryo-treating gears will make them less brittle, more durable, and less susceptible to the propagation of surface cracks. Since 3rd drive gear seems to be the weak link in these transmissions, I'm wondering if anyone here has had the new superseded gear treated before installing it.
Here's one of the places that performs cryogenic treatments-http://www.cryoplus.com/advantages.html

If you can believe the hype, not only will your bike go faster and last longer, but you'll stop losing your hair, and women will find you irresistible!
Sweet, I need that. But what are you talking about?
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Old 02-19-2010, 03:37 PM   #100
Jammin
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Joined: Jan 2006
Location: New Delhi - new 'home' for post RTW
Oddometer: 1,528
Engine Rebuild

In preparation for an upcoming trip I got the engine rebuilt to replace this suspect 3rd Drive Gear. Engine had 26K miles on it, 1998 model year.

Parts needed:
24231-12D21 Gear 3rd Drive ($58)
09380-25003 Circlips (at least 2) ($2)

Parts recommended:
25211-37401 Fork, Gear Shifting No. 1 ($44)
25221-37401 Fork, Gear Shifting No. 2 ($44)
16321-32E00 Oil Pump Plastic Gear ($15)

Oil Seals: there are 3 oil seals that should be replace if splitting the cases
09283-25096 Oil Seal, Drive Shaft to Sprocket 25x44x7 ($6)
09282-16002 Oil Seal, Crankshaft to Clutch Cover 16x30x6 ($5)
09285-12006 Oil Seal, Gearshift Cover 12x22x9 ($4)

Gaskets to be replaced when splitting the cases:
11400-32874 Gasket set (includes below items) ($76)
11485-12D01 Gear Shift cover Gasket
11241-04F20 Crank to Cylinder Gasket
11141-32E00 Cylinder to Head Gasket
11482-32E00 Clutch Gasket
11483-32E00 Magneto Gasket
11177-44B01 Valve Inspection Gasket
12837-24A10 Tension Adj Gasket
14181-22D01 Exhaust Gasket
09280-15007 Oil Filter Gasket
09280-17003 Oil Filler Gakset
09280-46002 Intake O-ring
09280-72001 Oil Filter O-ring


Tools needed:
50 mm Rotor Remover Tool, Dennis Kirk P/N 281965 ($80) (Note: 09930-33720 PN from manual is a 42 mm wide tool that will not fit)
09917-23711 Ring Nut Socket Wrench (or make your own)
Plate to split the cases
Transmission puller tool


My mechanic charged me $450 for the rebuild. He let me help out as much as I could and also taught me how to go about this in case I need to do this on my own.



Removing the engine from the frame. Pushed up from the bottom as she was slid out the side.


On the workbench at my mechanic friend's place. Her home for the next 2 1/2 months.


Old piston being replaced. 1998 stock with 26K miles, not bad.


The 50 mm rotor puller


The engine sitting level with bolted supports


Special tool made to release the ring-nut from pipe section


Ring-nut socket in place


Puller plate with threads to match the DR (also used for SV650 motor)


The cases being split.


Gus, twisting the threaded rod to split the cases.


And Voila! beautiful internal engine components.


The transmission. Left side: Drive gears (3rd gear in the middle), Right side: Driven gears (output shaft)


Cases put back together. Parts and new gaskets installed.


Putting the clutch basket on


Cam and chain installed


One sweet rebuilt DR650 engine


Spinning the crank around and going through the gears to make sure everything is in its proper place.


Putting the engine back in the frame with the help of a buddy who acted as an engine hoist while I lined it up. Went in much easier than I was expecting, took about 15 mins only.

She fired up on the first try and sounds so sweet


My original 3rd Drive Gear looked good, along with everything else in the engine: cylinder walls, valve seats, stems, cam, chain, etc. No marks or damage on any gears or parts . Good to know that there'll be no surprises from the engine (touch wood )
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Trip Website: JamminGlobal.com
Current Ride Report: Global South | Past Trips: CDR '09, Alaska '08, Mexico '07 | YouTube Videos

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Old 02-19-2010, 04:49 PM   #101
NordieBoy OP
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Cool info.

What year is your bike?
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Old 02-19-2010, 05:16 PM   #102
greendude
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Location: Northside Brisbane. australia
Oddometer: 1,132
got an 07 model. 3rd gear has had a whine on decelaration since new. has never got any worse .42000k on it now ,my fingers are crossed.Has anyone thought about poor fuel being a contributing factor in these failures.detonation will put alot of stress on a drivetrain. some of the catspiss that gets sold as petrol in remote places cant help

greendude screwed with this post 02-19-2010 at 05:22 PM
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Old 02-19-2010, 05:21 PM   #103
eakins
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Location: Fort Collins, Colorado
Oddometer: 17,852
jammin,
did you replace the plastic oil pump gear and locktite the NSU switch bolts (i don't see new bolts like most use), while you had it all appart?
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Old 02-19-2010, 07:53 PM   #104
Jammin
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Location: New Delhi - new 'home' for post RTW
Oddometer: 1,528
Quote:
Originally Posted by NordieBoy
Cool info.

What year is your bike?
1998

Quote:
Originally Posted by eakins
jammin,
did you replace the plastic oil pump gear and locktite the NSU switch bolts (i don't see new bolts like most use), while you had it all appart?
Yes to both. The NSU bolts were previously lock-tited, but I didn't replace the bolts. Didn't think about it actually. Oh well, lock-tite's good enough.
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Trip Website: JamminGlobal.com
Current Ride Report: Global South | Past Trips: CDR '09, Alaska '08, Mexico '07 | YouTube Videos
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Old 02-26-2010, 12:19 AM   #105
teza_125
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aussie 06 35,000 k's

bought it off my uncle at 22,000 (he gets a new one every three years and has never had a problem.) it was ridden up until 22,000k mostly on a farm, every day. with some highway trips also. never had a problem until a tiny noise in 3rd at about 30,000 (not sure if it's the whine everyone is talking about. it is pretty hard to hear with a noisy pipe and only occurrs when accellerating, not when you let off or pull the clutch in). just 2 days ago, normal ride and suddenly when i went into 4th it lost alot of power (like being in really low revs) and makes the worst constant clunking noise i have ever heard (in a way it sounds a little like machine gun fire if that makes sense) so i went straight into 5th and it stopped. went back down to 4th and the noise was there again so i went straight home (only about 5 mins away) staying out of 4th and i'm taking it to get checked out tomorrow.
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