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
. 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.