DR650 3rd gear blowups

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

  1. NordieBoy

    NordieBoy Armature speller

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    NordieBoy (NZ) 2001 60,000km
    Transalper (NZ) 2001 55,000km
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    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
    #81
  2. senoj

    senoj senoj 54 but now 55

    Joined:
    Feb 15, 2009
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    Location:
    The east side if the island
    Hi Mate
    I'm rebuilding a mates and have ordered the later 2006 3rd gear part number as a precautionary measure.

    Can you please give me your reference as I checked the USA Babbits Online parts listing and the same gears by part number are listed from 2006 to 2009 for all the gears. Their site does show the 3rd gear update in 2006 but nothing new in gears from there to current.

    If you have identified an even later update I am keen to use that part.

    Cheers.


    #82
  3. NordieBoy

    NordieBoy Armature speller

    Joined:
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    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 (TBC)
    #83
  4. DRjoe

    DRjoe Long timer

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    confirmed

    this
    [​IMG]

    did this
    [​IMG]
    #84
  5. dirtbikeslob

    dirtbikeslob Been here awhile

    Joined:
    May 4, 2007
    Oddometer:
    300
    Location:
    dunedin new zealand
    bugger.:cry
    #85
  6. trailrider383

    trailrider383 867-5309

    Joined:
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    3,779
    Location:
    NP, ID
    Four out of 15 are US bikes. 27 %. The rest are Australia and New Zealand. :dood What are you guys doing to those poor DR's?
    #86
  7. Pike Bishop

    Pike Bishop Pull Down the Ponzi.

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    Your Back Yard
    That's just fugly.

    Reminds me of a 1969 Pontiac GTO with a small block 400 I had where the timing chain went, and then, because the motor was 10.75:1 compression, a piston hit an opened valve...and then the collar of the harmonic balancer broke up and went down into the crank and hunks of that got caught between a piston and cylinder wall and broke a piston and scored the shit out of a cylinder wall...FUGLY is the only word to describe it.

    I'm sorry to hear about your loss, DRJoe...did it lock up the rear wheel? :eek1
    #87
  8. Pike Bishop

    Pike Bishop Pull Down the Ponzi.

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    Your Back Yard
    Nordieboy - FWIW, 3rd gear on my 2009 DR650 has whined since I picked it up with 1 mile on the clock at the dealer...in fact, as a new rider, I have come to occasionally use the "whine" to know what gear I'm in... :lol3
    #88
  9. RiDR

    RiDR The Himalayan what?

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    Location:
    45.55397,-78.59676
    weird :huh my 09 has never whined... but I've also blipped the throttle on every single downshift since mile 1.
    #89
  10. rallyhound

    rallyhound Macho stud guy

    Joined:
    Jan 4, 2007
    Oddometer:
    873
    Location:
    Cambridge MN in the woods
    FWIW-- my 03 now has 15,000 miles on it and 3rd gear has made more noise than the other gears since it was new.


    wondering if I should swap it out or take my chances?
    #90
  11. NordieBoy

    NordieBoy Armature speller

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    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.
    #91
  12. DRjoe

    DRjoe Long timer

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    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.
    #92
  13. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
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    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
    #93
  14. Klay

    Klay dreaming adventurer

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    right here on my thermarest

    2001 model. (sorry for the delay in response) I've since put 11,000 miles on the rebuilt motor.
    #94
  15. galusham

    galusham MotoMark

    Joined:
    Apr 8, 2009
    Oddometer:
    20
    Location:
    VA
    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.
    #95
  16. galusham

    galusham MotoMark

    Joined:
    Apr 8, 2009
    Oddometer:
    20
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    VA
    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.
    <DL><DD>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. </DD><DD>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. </DD><DD>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. </DD><DD>The 3rd gear cog is under load in 3rd, 4th and 5th gears and is the hardest working of the cogs. </DD><DD>If you are going to have the cases apart for any reason, for peace of mind it would pay to replace this $70US part. </DD></DL>
    #96
  17. NordieBoy

    NordieBoy Armature speller

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    :evil :wink:
    #97
  18. AdvRonski

    AdvRonski They call me......Ronski

    Joined:
    Feb 4, 2007
    Oddometer:
    823
    Location:
    Finally made it to Fruita!
    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!
    #98
  19. shrubber

    shrubber Adventurer

    Joined:
    Jan 22, 2010
    Oddometer:
    59
    Sweet, I need that. But what are you talking about? :lol3
    #99
  20. Jammin

    Jammin Living on a DR

    Joined:
    Jan 22, 2006
    Oddometer:
    1,563
    Location:
    New Delhi - new 'home' for post RTW
    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.


    [​IMG]
    Removing the engine from the frame. Pushed up from the bottom as she was slid out the side.

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

    [​IMG]
    Old piston being replaced. 1998 stock with 26K miles, not bad.

    [​IMG]
    The 50 mm rotor puller

    [​IMG]
    The engine sitting level with bolted supports

    [​IMG]
    Special tool made to release the ring-nut from pipe section

    [​IMG]
    Ring-nut socket in place

    [​IMG]
    Puller plate with threads to match the DR (also used for SV650 motor)

    [​IMG]
    The cases being split.

    [​IMG]
    Gus, twisting the threaded rod to split the cases.

    [​IMG]
    And Voila! beautiful internal engine components.

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

    [​IMG]
    Cases put back together. Parts and new gaskets installed.

    [​IMG]
    Putting the clutch basket on

    [​IMG]
    Cam and chain installed

    [​IMG]
    One sweet rebuilt DR650 engine :super

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

    [​IMG]
    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 :wings


    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 :lol2 )