DR650 3rd gear blowups

Discussion in 'Thumpers' started by NordieBoy, Jan 16, 2009.

  1. NordieBoy

    NordieBoy Armature speller

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    After riding a mates (TH in the list) DR650 that has blown up and been repaired it seems like I was definitely in 2nd gear when it let go.

    Also his bike has a pronounced engine based vibration from about 60kph in 3rd gear (5000 odd rpm?). I think the counterbalancer is out a tooth or 2.
    #21
  2. briangv99

    briangv99 n00b

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    add mine to the list. 21,000km and third let go big time, cases, crankshaft, piston, rod etc are all scrap. Got a complete engine from a wrecker to replace it for $2k
    #22
  3. Teddy

    Teddy Trail Lover

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    I'll just leave this here:

    <object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/FNkZDJyXrbM&hl=en&fs=1"></param><param name="allowFullScreen" value="true"></param><param name="allowscriptaccess" value="always"></param><embed src="http://www.youtube.com/v/FNkZDJyXrbM&hl=en&fs=1" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="425" height="344"></embed></object>
    #23
  4. rivercreep

    rivercreep Banned

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    over 50,000 miles on a 91 and 97 without nary a hiccup!
    Then again, I'll admit my off road pace was geared the same way as the bikes were......somewhat mellow!

    I wish you guys the best!
    ...........only bought my little XT250 since I'm doing more off road now.
    These reports make me even more happy with my decision.
    #24
  5. NordieBoy

    NordieBoy Armature speller

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    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

    Hey Brian. Where are you from and what year is your bike?
    #25
  6. briangv99

    briangv99 n00b

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    G'day Nordie,

    Canberra, Australia. 2006 model. Just came across your pics on TT, mine looked much the same inside, except less damage, I was only about 200 metres from home when it went
    #26
  7. NordieBoy

    NordieBoy Armature speller

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    Yep. Thought it was Aussie type distances.

    Do you remember what gear you were in when it went?
    Could yours have been a 2005 old stock sold as a 2006?
    #27
  8. XRsteve

    XRsteve Been here awhile

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    I'm pretty sure this was just the XR 600s made in the eighties. I believe they fixed it in 1990. I hadn't heard that DRs can do it too. Was this from abuse or lack of maintenance? Or a possible design issue?
    #28
  9. ADVJake

    ADVJake ***** dweller

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    definitely design issue. The DR being such a detuned overbuilt engine should withstand any abuse at the gearbox.
    The regular occurrence of the similar faults is evident here..

    You dont usually see pistons, rings, cylinders or cranks failing on DRs, they all seem to be 2nd or 3rd gear...
    #29
  10. LukasM

    LukasM Long timer

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    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.

    <table id="PartsList" cellspacing="0"><tbody><tr class="whiterow"><td class="li" align="left" valign="top" width="40%">GEAR,3RD DRIVE
    24231-12D21 (replaces 24231-12D20) </td> <td class="li" align="center" valign="top">1</td> <td class="li" align="center" valign="top">$53.39</td></tr></tbody></table>
    #30
  11. ADVJake

    ADVJake ***** dweller

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    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 ?
    #31
  12. LukasM

    LukasM Long timer

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    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
    #32
  13. RedLander

    RedLander Adventurer

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    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!!
    :deal

    Oops, just saw the post, maybe '06/'07. Thanks.
    #33
  14. Eugene

    Eugene -

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    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?
    #34
  15. Yobob

    Yobob Adventurer

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    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?
    #35
  16. RiDR

    RiDR The Himalayan what?

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    engine, carb, drivetrain modifications? any stock bikes in the mix?
    #36
  17. NordieBoy

    NordieBoy Armature speller

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    12 bikes :D
    #37
  18. NordieBoy

    NordieBoy Armature speller

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    At least 1 completely stock engine/carb - TransAlper.
    #38
  19. Yobob

    Yobob Adventurer

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    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.
    #39
  20. NordieBoy

    NordieBoy Armature speller

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    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.
    #40