DR650 3rd gear blowups

NordieBoy · 01-16-2009, 12:45 AM

Compiling a list for posterity and interest...

NordieBoy 2001 60,000km
Transalper 2001 55,000km
Rosscoact 2004 13,000km
Mardy 1997 53,000km
TH 1999 40,000km
RubberCow80 2001 25,000km (2nd gear?)

ADVJake · 01-16-2009, 12:51 AM

good on you mate
maybe something to submit to Suzuki. the DR is long due for an update...

13,000kms is nothing, im surprised he still owns a Suzuki

Aussie Trev · 01-16-2009, 02:26 AM

Are there any tell tales noises or shifting abnormalities beforehand? Or is it just 'BANG'?

Max Kool · 01-16-2009, 04:25 AM

Are these prone to failure? Hmmm. I've had two of them (both 1996). Sold the first with 10.000 miles on it, and the second with 30.000. Both were problemless.

Dirtgrain · 01-16-2009, 07:37 AM

What damage to the motor occurred in those scenarios? Or is it the transmission that got destroyed? Why do you think third gear is significant?

To be more objective, maybe tally blowups that occurred in other gears, as well.

Foot dragger · 01-16-2009, 09:40 AM

Honda XR 600s have blown third when run hard since their inception,I dont think Honda ever address'd it. 4 DRs out of how many out there? hard to call it a trend but maybe more will chime in.

NordieBoy · 01-16-2009, 12:15 PM

DR650 3rd gear blowups...

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

I'd probably put the 2nd gear ones as Aussies tanked up on fourecks being confused about this "counting" thing.

I'm starting to think it's 3rd gear itself. The design of it with the thickness of the metal and the selector grooves and the more you use 3rd gear under load. All the low mileage ones are Aussie with quite possibly heavy 3rd gear sand use.

NordieBoy · 01-16-2009, 12:19 PM

Quote:

Originally Posted by DRTrev

Are there any tell tales noises or shifting abnormalities beforehand? Or is it just 'BANG'?

Low revs going up a slight hill and it was a drawn out cruuuuuunnnnch. I thought the chain had come off to start with.

No warning at all.

NordieBoy · 01-16-2009, 12:23 PM

Quote:

Originally Posted by Dirtgrain

What damage to the motor occurred in those scenarios? Or is it the transmission that got destroyed? Why do you think third gear is significant?

Looks like the engine gets totally destroyed - gears/cases/bottom end/conrod/piston...

3rd gear is right in line with the big end.

I think it's the shape of 3rd gear. Where the dogs are in relation to the teeth and the selector groove weakening it as well.

AWM · 01-16-2009, 05:13 PM

Man that sucks!!!

Are ya gonna rebuild it??Or shitcan it?

AWM · 01-16-2009, 05:32 PM

Quote:

Originally Posted by edf

How come all these bikes are in Kilometers, did you convert from miles or were they all outside the U.S?

I think its proof that Ausies hate thrid gear!

They must just put it in thrid and stay there,damn guys up shift.

RiDR · 01-16-2009, 05:34 PM

Quote:

Originally Posted by awm

I think its proof that Ausies hate thrid gear!

They must just put it in thrid and stay there,damn guys up shift.

How come all these bikes are in Kilometers, did you convert from miles or were they all outside the U.S?

Edit: HTF did that happen?

AWM · 01-16-2009, 05:35 PM

Hunh!!
I guess i was too quick to bust balls.

NordieBoy · 01-18-2009, 01:13 AM

Anyone who had a blowup...
Did one of the selector forks have both arms broken off?

Just wondering 'cause if they broke whilst in 2nd gear 3rd may have tried to mesh at the same time...

snpl · 01-18-2009, 02:14 PM

I have a '96 model with 135.000km on it. 2nd gear was moving to neutral as rpm's got higher.Shifting lever was also vibrating between 2nd and neutral.I dont know if my gear problem has something to do with yours but since i disassembled the engine to find what is wrong I will post below what i have found.

01-16-2009, 12:45 AM	#1
NordieBoy ^OP Armature speller Joined: Dec 2006 Location: Kiwiland Oddometer: 6,781	DR650 3rd gear blowups Compiling a list for posterity and interest... NordieBoy 2001 60,000km Transalper 2001 55,000km Rosscoact 2004 13,000km Mardy 1997 53,000km TH 1999 40,000km RubberCow80 2001 25,000km (2nd gear?)

01-16-2009, 12:51 AM	#2
ADVJake i like stuff Joined: Aug 2004 Location: Sydney, Australia Oddometer: 4,319	good on you mate maybe something to submit to Suzuki. the DR is long due for an update... 13,000kms is nothing, im surprised he still owns a Suzuki __________________ "And some guy said, let there be filtering, and we filtered and we saw that it was good, and hours became minutes..."

01-16-2009, 02:26 AM	#3
Aussie Trev aka DRTrev Joined: Nov 2007 Location: Gawler, South Australia Oddometer: 3,612	Are there any tell tales noises or shifting abnormalities beforehand? Or is it just 'BANG'? __________________ TJ 2011 Triumph Tiger 800XC 2010 XT660Z Tenere 2007 DRZ400E 1982 PE175Z

01-16-2009, 04:25 AM	#4
Max Kool Xtankteam™ Joined: Jan 2004 Location: Windmillonia Oddometer: 3,206	Are these prone to failure? Hmmm. I've had two of them (both 1996). Sold the first with 10.000 miles on it, and the second with 30.000. Both were problemless. __________________ Click here for an auxiliary sidetank for the BMW Xchallenge . Click here for a recalibrated speedo ring for the BMW G650X series .

01-16-2009, 07:37 AM	#5
Dirtgrain Gnarly Adventurer Joined: Apr 2005 Location: Ypsilanti, MI Oddometer: 309	What damage to the motor occurred in those scenarios? Or is it the transmission that got destroyed? Why do you think third gear is significant? To be more objective, maybe tally blowups that occurred in other gears, as well. __________________ Don't laugh at my mule: http://new.wavlist.com/movies/176/afd-mule.wav

01-16-2009, 09:40 AM	#6
Foot dragger beat up ex flat tracker Joined: Dec 2006 Location: chico,just below rag dump(nor-cal) Oddometer: 6,760	Honda XR 600s have blown third when run hard since their inception,I dont think Honda ever address'd it. 4 DRs out of how many out there? hard to call it a trend but maybe more will chime in. __________________ 2003 DR 650.(1976 Montesa 250 Enduro-nice!) - - 1990 MASI TEAM-3V.- 1976 Motobecane, Super-Mirage.- Kona, HumuHumuNukuNukuApua'a. Single Speed ThRaShEr BiKe. 1968 360 Greeves challenger MXer. 1999 Triumph Trophy 1200. 2011 KTM530 EXC. 2012 KONA Hei Hei Deluxe (ongoing bike issues) -2009 KTM 200XC-W.

01-16-2009, 12:15 PM	#7
NordieBoy ^OP Armature speller Joined: Dec 2006 Location: Kiwiland Oddometer: 6,781	DR650 3rd gear blowups... 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 I'd probably put the 2nd gear ones as Aussies tanked up on fourecks being confused about this "counting" thing. I'm starting to think it's 3rd gear itself. The design of it with the thickness of the metal and the selector grooves and the more you use 3rd gear under load. All the low mileage ones are Aussie with quite possibly heavy 3rd gear sand use.

01-16-2009, 05:13 PM	#10
AWM Beard Bros Racing Joined: Mar 2007 Location: Your Mom's house Oddometer: 10,159	Man that sucks!!! Are ya gonna rebuild it??Or shitcan it? __________________ "Hes not called the Angry White Man for nothing,much more fitting then the,Unicorn Clouds and Happy Trees Man".... UpST8 "If you french fry when you shoulda pizza'd,your gona have a bad time".

01-16-2009, 05:35 PM	#13
AWM Beard Bros Racing Joined: Mar 2007 Location: Your Mom's house Oddometer: 10,159	Hunh!! I guess i was too quick to bust balls. __________________ "Hes not called the Angry White Man for nothing,much more fitting then the,Unicorn Clouds and Happy Trees Man".... UpST8 "If you french fry when you shoulda pizza'd,your gona have a bad time".

01-18-2009, 01:13 AM	#14
NordieBoy ^OP Armature speller Joined: Dec 2006 Location: Kiwiland Oddometer: 6,781	Anyone who had a blowup... Did one of the selector forks have both arms broken off? Just wondering 'cause if they broke whilst in 2nd gear 3rd may have tried to mesh at the same time...

01-18-2009, 02:14 PM	#15
snpl n00b Joined: Sep 2007 Oddometer: 8	I have a '96 model with 135.000km on it. 2nd gear was moving to neutral as rpm's got higher.Shifting lever was also vibrating between 2nd and neutral.I dont know if my gear problem has something to do with yours but since i disassembled the engine to find what is wrong I will post below what i have found.

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