DR650 3rd gear blowups

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

  1. DR Donk

    DR Donk Been here awhile

    Joined:
    Jul 30, 2009
    Oddometer:
    470
    Location:
    Western Michigan
    :eek1 Oh, no! I have an '02 DR650 with 38,000 on it with no problems and now I'm going to be nervous about this happening!!!!!!!!!!!
    #61
  2. lastmanout

    lastmanout Been here awhile

    Joined:
    Dec 30, 2005
    Oddometer:
    210
    Location:
    NW PA,USA
    I would not worry about it. If you must, then split your cases and inspect # 3 shift fork - mine was worn to half the original thickness- and replace the shift fork. Also inspect/ replace gearset for third gear set and neighboring gear if dogs show damage. I was impressed with the clean metalwork of the Suzuki engine. It is a quality machine.
    #62
    Benduro likes this.
  3. mike1952

    mike1952 Long timer

    Joined:
    Jan 27, 2008
    Oddometer:
    1,114
    Location:
    north of ann arbor michigan
    In the southern hemispere the Coreolis effect is opposite the northern hemisphere. The tendency to rotate the opposite direction is probably what causes the gear to go. It was clearly designed to be a northern Hemisphere bike. Someone should make an adapter to make the bike safe to operate south of the equator. BMWs come standard with unihemispherical gears.
    #63
  4. rallyhound

    rallyhound Macho stud guy

    Joined:
    Jan 4, 2007
    Oddometer:
    873
    Location:
    Cambridge MN in the woods
    .




    I thought it was because them Aussies are drunk all the time and shift with their heels. .

    I stand corrected
    #64
  5. Klay

    Klay dreaming adventurer

    Joined:
    Nov 19, 2005
    Oddometer:
    105,784
    Location:
    right here on my thermarest
    That's exactly what happened to mine at 18,000 miles. I believe it's a pretty rare failure. I'm not really worried about it with the new engine.
    #65
  6. bluebye

    bluebye Skin it back

    Joined:
    Mar 23, 2004
    Oddometer:
    1,445
    Location:
    'neckville is where you hang your hat, Rolling
    [​IMG]
    [​IMG]p://i143.photobucket.com/albums/r130/wsldxe/blownupSir3.jpg[/IMG
    [​IMG]
    #66
  7. bluebye

    bluebye Skin it back

    Joined:
    Mar 23, 2004
    Oddometer:
    1,445
    Location:
    'neckville is where you hang your hat, Rolling
    [​IMG]
    [​IMG]
    [​IMG]
    Beware, it took everthing but the head.
    #67
  8. Reposado1800

    Reposado1800 Juicy J fan!

    Joined:
    Dec 8, 2006
    Oddometer:
    5,815
    Location:
    5th and Main
    Time for a donor motor.
    #68
  9. bluebye

    bluebye Skin it back

    Joined:
    Mar 23, 2004
    Oddometer:
    1,445
    Location:
    'neckville is where you hang your hat, Rolling
    I'm looking. Bleedin' salvage yard wants $1600 for a 2005 motor!
    #69
  10. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
    Oddometer:
    7,172
    Location:
    Kiwiland
    That'll polish out.

    At least you end up with a spare head, stator, clutch, starter, carb...
    #70
  11. JVL

    JVL b00nie

    Joined:
    Jun 13, 2009
    Oddometer:
    32
    Location:
    Clarksville,TN

    damn, i just traded my klx for an '05 dr650 w/15k miles. i was starting to get worried until i read the above......... i'll sleep much better now although my stomach still hurts from laughing. :rofl
    #71
  12. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
    Oddometer:
    7,172
    Location:
    Kiwiland
    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
    #72
  13. DRjoe

    DRjoe Long timer

    Joined:
    Sep 6, 2007
    Oddometer:
    6,357
    Location:
    Sunshine coast qld
    you forgot mine 97 100'000k's but it was just one tooth on the third gear the bike still ran for a few thousand k's going "clunk clunk clunk clunk" i thought it just gave the bike a bit more character.
    #73
  14. Mr. Guy

    Mr. Guy Ubernoob

    Joined:
    Feb 5, 2008
    Oddometer:
    151
    Do you think the DR trans. is any more likely to fail than another brand or model? Or is the DR more reliable then others?

    It doesn't seem to me to be a big failure rate.

    Of course, it sucks big time if it's yours.

    Guy
    #74
  15. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
    Oddometer:
    7,172
    Location:
    Kiwiland
    I think the 3rd gear is a bad design.

    Lugging/clutchless shifts in 4th/5th may have some influence.

    The way it's used in 3rd-4th-5th and the diameter of the gear means there's not much meat there for strength and if it drops a tooth the chances it'll hit the crank are very high.

    It's not a high failure rate but it's always the 3rd drive gear and is usually catastrophic.

    They changed the part number in '08 for the cog...
    #75
  16. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
    Oddometer:
    5,457
    Location:
    On a RTW ride - currently touring the U.S.
    Nordie,

    I also checked the microfiches and can confirm that the part was changed in 08. Interestingly enough a bunch of other transmissions parts have been gradually updated since 96 as well.

    When we have the first 08s blow up, maybe it's time to look at having a replacement made. It's always the drive gear that breaks, right?

    Does anybody have an idea how much a single gear like this could cost if you make a batch of 50 or so out of better material?



    By the way, you forgot to add my buddy Klay to the list (hi Klay! :D), see post # 65.

    #76
  17. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
    Oddometer:
    7,172
    Location:
    Kiwiland
    18,000 miles - What year?
    #77
  18. Jammin

    Jammin Living on a DR

    Joined:
    Jan 22, 2006
    Oddometer:
    1,563
    Location:
    New Delhi - new 'home' for post RTW
    So, to replace this as a preventative measure, only the 3rd Drive Gear (#3 below) needs to be upgraded to P/N 24231-12D21, right?

    Does anything else need to be replaced? Haven't gone into the cases yet, but maybe this weekend.

    Should the shifter forks (25211-37401 & 25221-37401) also be replaced?

    [​IMG]
    #78
  19. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
    Oddometer:
    7,172
    Location:
    Kiwiland
    I'd do the shifter forks as well as mine was in 2nd gear when 3rd went...

    When I do mine it'll be 3rd gear, shifter forks, base gasket, high comp piston.
    #79
  20. Jammin

    Jammin Living on a DR

    Joined:
    Jan 22, 2006
    Oddometer:
    1,563
    Location:
    New Delhi - new 'home' for post RTW
    All 3 shifter forks (including 25231-14A01) or just the two mentioned above?


    Here's a nice high res image of Coyote_X's damaged 3rd gear: :huh

    [​IMG]
    #80