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Old 01-16-2009, 12:45 AM   #1
NordieBoy OP
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Location: Kiwiland
Oddometer: 7,074
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?)
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Old 01-16-2009, 12:51 AM   #2
ADVJake
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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
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Old 01-16-2009, 02:26 AM   #3
Aussie Trev
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Are there any tell tales noises or shifting abnormalities beforehand? Or is it just 'BANG'?
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Old 01-16-2009, 04:25 AM   #4
Max Kool
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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.
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Old 01-16-2009, 07:37 AM   #5
Dirtgrain
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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.
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Old 01-16-2009, 09:40 AM   #6
Foot dragger
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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.
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Old 01-16-2009, 12:15 PM   #7
NordieBoy OP
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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.
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Old 01-16-2009, 12:19 PM   #8
NordieBoy OP
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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.
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Old 01-16-2009, 12:23 PM   #9
NordieBoy OP
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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.
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Old 01-16-2009, 05:13 PM   #10
AWM
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Man that sucks!!!

Are ya gonna rebuild it??Or shitcan it?
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Old 01-16-2009, 05:32 PM   #11
AWM
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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.
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Old 01-16-2009, 05:34 PM   #12
RiDR
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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?
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Old 01-16-2009, 05:35 PM   #13
AWM
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Hunh!!
I guess i was too quick to bust balls.
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Old 01-18-2009, 01:13 AM   #14
NordieBoy OP
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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...
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Old 01-18-2009, 02:14 PM   #15
snpl
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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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