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Old 04-28-2010, 03:37 PM   #151
blackcap
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Quote:
Originally Posted by eakins
i'm guessing older bikes with higher mileage (the the DR dropped outta the Euro lineup awhile ago) and possibly run at higher bahn speeds.
wouldnt higher bahn speeds mean more 5th gear abuse?
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Old 04-28-2010, 11:51 PM   #152
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Quote:
Originally Posted by blackcap
wouldnt higher bahn speeds mean more 5th gear abuse?
3rd drive gear is involved in 3rd, 4th and 5th gears.

My personal theory is that it's more low-rev tractoring than speed that's the issue.
Higher revs is smoother on the gears than low rev power pulses.
But that's just guessing.

It could also be a problem with the 3rd gear selector fork.
If it goes then 3rd can wander...
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Old 04-28-2010, 11:55 PM   #153
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That would explain why many of the DR650s blowing up are being used in desert trips.
Philth does desert all the time and he's had 2 DR650s blow up from what ive heard.
Sand puts a hell of a load on the trans
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Old 04-29-2010, 06:40 AM   #154
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Could cush hub damper wear be a factor? Any decrease in damping would result in an increase in hammering the transmission.

I don't have a DR but I know the cush hub damper in my KLR does wear and needs to be replaced periodically (20k miles).
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Old 04-29-2010, 02:43 PM   #155
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Quote:
Originally Posted by ADVJake
That would explain why many of the DR650s blowing up are being used in desert trips.
Philth does desert all the time and he's had 2 DR650s blow up from what ive heard.
Sand puts a hell of a load on the trans
i had 5th go soon after crossing the simpson
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Old 04-29-2010, 11:04 PM   #156
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interesting thought.
that part is often overlooked.

Quote:
Originally Posted by Echo1
Could cush hub damper wear be a factor? Any decrease in damping would result in an increase in hammering the transmission.

I don't have a DR but I know the cush hub damper in my KLR does wear and needs to be replaced periodically (20k miles).
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Old 04-29-2010, 11:05 PM   #157
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so stay in 2nd in sand?

Quote:
Originally Posted by ADVJake
That would explain why many of the DR650s blowing up are being used in desert trips.
Philth does desert all the time and he's had 2 DR650s blow up from what ive heard.
Sand puts a hell of a load on the trans
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Old 05-01-2010, 07:30 AM   #158
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Old 05-01-2010, 10:01 AM   #159
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Quote:
Originally Posted by edf
First 2008 reported HERE

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I'll be watching this one close. I was heading out to the Suzuki/Honda dealer this afternoon with checkbook in hand for a new 2009 and was heavily leaning toward the Suzuki.......
I think I'll just wait and see how this plays out. If this turns out to be a low miles '08 then '09 is probably the same (i.e. no new gear really, just a part# change)
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Old 05-01-2010, 10:44 AM   #160
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The bike was probably dropped, bent a shift fork and ended up losing the trans.
Do an Advrider member search for ninja97 and relax and buy the DR...

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Old 05-01-2010, 10:20 PM   #161
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Quote:
Originally Posted by savage99
I'll be watching this one close. I was heading out to the Suzuki/Honda dealer this afternoon with checkbook in hand for a new 2009 and was heavily leaning toward the Suzuki.......
I think I'll just wait and see how this plays out. If this turns out to be a low miles '08 then '09 is probably the same (i.e. no new gear really, just a part# change)
If it turns out it has less than 20,000km on the clock then it's more likely a statistical anomaly.
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Old 05-19-2010, 03:30 PM   #162
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Quote:
Originally Posted by blackcap
kind of thought this might be of interest to everyone here. these photos are of a 2003 DR with 68,000km. the engine strip down was inspired by 5th gear so i decided 3rd would get replaced while it was in pieces. the gear on the left is the 2003 part, the one on the right the updated one. dimensionally they are identical.
My parts finally arrived this morning, only four weeks after they were ordered. Apparently air traffic problems in Europe caused air-freight problems between Japan and NZ. Go figure.

Hopefully I'll have th 650 back on the road for the weekend.

Anyhoo, unpacked the parts at the shop this morning, and one of the guys there suggested that the alignment of the internal splines seems to have changed. Some hasty photochopping suggests that might be right:
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Old 05-19-2010, 04:29 PM   #163
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now would other gears be affected also and be designed/reindexed?

Quote:
Originally Posted by miniroot
My parts finally arrived this morning, only four weeks after they were ordered. Apparently air traffic problems in Europe caused air-freight problems between Japan and NZ. Go figure.

Hopefully I'll have th 650 back on the road for the weekend.

Anyhoo, unpacked the parts at the shop this morning, and one of the guys there suggested that the alignment of the internal splines seems to have changed. Some hasty photochopping suggests that might be right:
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Alaska
AZ map COBDR AZBDR IDBDR South East map
http://www.advrider.com/forums/showthread.php?t=598717
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http://www.advrider.com/forums/showthread.php?t=956350
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Old 05-19-2010, 09:28 PM   #164
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I just picked up a new 09 Dr650, damn, I can't believe this thread.

How bad is this? Lot of folks have these bikes and don't come in here. Lot of other bikes we don't know about.

I had an 04 for a couple years and the only thing the guys talked about back then was that lower gasket leak, that problem was Disneyland compared to this thing.

FROCK!!!!! YIKES!!!!

I need a beer and i'm going to bed on this one...gheeeeeez.
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Old 05-19-2010, 09:40 PM   #165
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Just a thought, wild guess on my part.

I wonder if Suzuki out sourced transmission parts to be made from some third world country.

The reason I say or think this. I don't remember the older DR's ever having this problem.

SO what year bikes on average do we have this issue with? Can we narrow this down to bikes built after a spacific year maybe?

Maybe Toyota is making the third gear? I'm sure FOX and MSNBC will be doing reports on this mess. I'm waiting for the e mail to surface that proves Suzuki is hiding something from all of us.
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