DR650 3rd gear blowups

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

  1. briangv99

    briangv99 n00b

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    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 :wink: . 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 :eek1 . Had a XR600 that spat teeth from 4th gear, but least the gear remained intact and didn't vandalise every part of the engine.
    #41
  2. DRjoe

    DRjoe Long timer

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    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.
    #42
  3. NordieBoy

    NordieBoy Armature speller

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    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...
    #43
  4. RiDR

    RiDR The Himalayan what?

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    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.
    #44
  5. plugeye

    plugeye unforgiven

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    #45
  6. NordieBoy

    NordieBoy Armature speller

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    DJ'd stock carb.

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

    But in NZ half the bikes we get are US spec.
    The '97 I bought to nick the engine from is a US one.
    #46
  7. NordieBoy

    NordieBoy Armature speller

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    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.
    #47
  8. LukasM

    LukasM Long timer

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    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.
    #48
  9. bluebye

    bluebye Skin it back

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    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.
    #49
  10. NordieBoy

    NordieBoy Armature speller

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


    All my pics are here...
    http://www.photostorage.nelson.geek...ybikes/DR650/20090113 Blown engine/index.html
    #50
  11. 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
    bluebye (US) 2004 37,000km
    #51
  12. oldturtle

    oldturtle Been here awhile

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    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.
    #52
  13. Cathalp

    Cathalp Adventurer

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    #53
  14. NordieBoy

    NordieBoy Armature speller

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    XF650 motors.

    Re: That pic of 5th gear. What do the dogs look like on the 3rd cog?
    #54
  15. Cathalp

    Cathalp Adventurer

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    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.
    #55
  16. lastmanout

    lastmanout Been here awhile

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    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:clap . 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.
    #56
  17. neepuk

    neepuk Such a drag...

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    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.
    #57
  18. rivercreep

    rivercreep Banned

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    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.
    #58
  19. NordieBoy

    NordieBoy Armature speller

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    We'd hear about them if the riders are on AdvRider/ThumperTalk/KiwiBiker :D
    #59
  20. LukasM

    LukasM Long timer

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    I read about a few cases on the German DR forum as well.... :cry
    #60