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Old 09-28-2010, 03:05 AM   #226
996DL
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Joined: Aug 2006
Location: too far from the Rockies...
Oddometer: 2,107
For a man of so few posts, you more than make up for the lack of quantity, with substance.
Hats off to you lecap !

996DL
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Old 09-29-2010, 02:01 AM   #227
lecap
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Location: The fairest Cape (South Africa)
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Quote:
Originally Posted by NordieBoy
The only selector fork broken was the one on the 3rd drive gear that shattered. Chicken or egg. Difficult to tell...

My 3rd gear was in 4 pieces which would indicate shattering?



I'm going to drop it and a new gear in to my bro's work (make race gearboxes for Manx Nortons) sometime and see what the boss says.
The fracture in the 1'o clock position of your pic shows some possibly interesting detail.
Can you take some pictures that show the surfaces of the fractures please? Take more or less perpendicular to the fracture surface and try to get good contrast showing the surface structure.

996DL: I've got some 5000 posts to my name on our local South African forum. www.wilddogs.za.net Little time to hang around here
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Old 09-29-2010, 05:35 AM   #228
exoff-roadgoat
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Location: W.Meechigan
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I'm sure its very isolated but after reading these gearbox/blowup posts, I'm glad I bought a later model DR.
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Old 09-29-2010, 08:12 AM   #229
NJ-Brett
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I have a 1998, seems no one has blown one of those?

Later model means newer to me, which are the ones that can go?

Brett




Quote:
Originally Posted by exoff-roadgoat
I'm sure its very isolated but after reading these gearbox/blowup posts, I'm glad I bought a later model DR.
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Old 09-29-2010, 12:27 PM   #230
exoff-roadgoat
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Quote:
Originally Posted by NJ-Brett
I have a 1998, seems no one has blown one of those?

Later model means newer to me, which are the ones that can go?

Brett
I'm not sure which years to tell you the truth. It probably comes down to who beats them the worse. My baby is going to be babied. Whatever.
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Old 09-29-2010, 01:00 PM   #231
996DL
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Quote:
Originally Posted by exoff-roadgoat
It probably comes down to who beats them the worse.


Wring their neck like an RMZ with turn signals and run automotive duration oil change intervals and I wouldn't expect to win any accumulated mileage contests, with damn near any thumper/bike in general.

Mine's a roadie and pampered as well, waited years to finally bring one into the stable.

996DL

996DL screwed with this post 09-29-2010 at 03:38 PM
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Old 09-29-2010, 02:07 PM   #232
Flatulator
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Quote:
Originally Posted by exoff-roadgoat
I'm not sure which years to tell you the truth. It probably comes down to who beats them the worse. My baby is going to be babied.
You're not sure ?

... click back one page on this thread and read the details of the list of people who posted DR650 3rd gr blowups
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Old 09-29-2010, 02:48 PM   #233
NordieBoy OP
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Location: Kiwiland
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Quote:
Originally Posted by exoff-roadgoat
I'm not sure which years to tell you the truth. It probably comes down to who beats them the worse. My baby is going to be babied. Whatever.
1997 53000, 100000km
1999 40,000km
2001 23000, 25000, 29000, 55000, 60000km
2002 ???km
2003 15000km
2004 13000, 37000km
2005 16000km
2006 10200, 21000km
2007 17000, 33800km
2009 37000km

Just about all the low mileage ones (<30000km) are from Oz.
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Old 09-29-2010, 02:49 PM   #234
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
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
RobTheButch (AU) 2007 17,000km
Ganjora (??) 2009 36,857km (looks like 3rd but to be confirmed)
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Old 09-29-2010, 05:42 PM   #235
exoff-roadgoat
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Back in the day, everyone who beat the shit out of their bikes had tranny trouble, with the exception of my Bultacos. That said, off roading IS alot more fun when you DO beat the shit out of them.
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Old 09-30-2010, 12:35 AM   #236
lecap
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Quote:
Originally Posted by NordieBoy
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
RobTheButch (AU) 2007 17,000km
Ganjora (SA) 2009 36,857km (Fifth disintegrated)
Fixed
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Old 09-30-2010, 01:08 AM   #237
Ganjora
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Location: Johannesburg, South Africa
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hey NordieBoy

am from SA (South Africa).

sent my pics etc to sazook sa, their technical manager has asked for more info on the bike as well as the complete shopping list for repair - maybe a happy ending after all....
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Old 09-30-2010, 01:41 AM   #238
Ganjora
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Ghastly pics of the damage.













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Old 09-30-2010, 07:43 AM   #239
diesel critter
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Location: wheatbelt western australia
Oddometer: 33
gday.

Just finished reading this thread from beginning to end and offer my deapest sympathy to all those who have suffered the tragic loss of thier beloved dr. fortunately for me, mine has not spat the dummy quiet yet. Thought I might throw my 2 cents worth in. Im not a gearbox expert or a gearbox virgin, and havent had the pleasure of being that up close and personal with the dr's private parts, but from what Ive seen thus far:
*3rd gear is the hardest working gear in the dr box so it makes sense it will be the first to die.
*From the difference between the older gear and the newer gear with the slightly different indexing/timing, it seam suzuki tried to either add a bit of extra meat in a more appropriate place or change the timing of the dog relevant to other internals.

From my experience with diffs and gearboxes in other mechanical mutants (things with more that 2 wheels), gears tend to fail for the following reasons:
*incorrect meshing/clearances,
*trying to select two gears at the same time,
* or something was there that shouldnt have been.

More often that not its not the gear that fails, but the support bearing, which causes the gears to be miss aligned, thus unevenly stressed and nasty crunching sounds are the result. So please, during rebuilds, check the bearings and the hole that the bearings fit in for any play, and those of you who still have the remain of your failed loved ones, check the bearings and casing for any wear or evidence the bearings have spun in the case.

However in these cases, im wondering about the amount of room between the selection gears (2nd and 3rd) and the selection forks and mechanism. In particular if the selection forks are bent or worn and third is engaging before second is disengaged, or if third is not fully engaging. One of our greiving brothers even admitted to having dropped his beloved so hard it stripped splins on the gear shift lever. Perhaps we should all check the end play in our gear levers. And perhaps put gear lever bash plates on.

I really cant think of more to add to this, as it is a bit of a mystery. Perhaps it is just a case of s**t happens. However the more imfo we have on these events and the more thinking and examining we do, perhaps we shall find a solution, and can all happily fang full on without dreading the third gear menopause.

hope all my dribbling helps.
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Old 09-30-2010, 08:03 AM   #240
NJ-Brett
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Location: Southern New Jersey
Oddometer: 6,221
Well, I have one of the coveted 1998 year bikes that never blow 3rd gear!

I wont loose sleep about it, and always beat the crap out of everything I ever owned, if it blows up, I get all those spare parts!

I would not want to buy a new one, spending $7000.00 or whatever they cost, and have it happen a year later tho!

Brett
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