DR650 3rd gear blowups

[LukasM]

Nordie,

I also checked the microfiches and can confirm that the part was changed in 08. Interestingly enough a bunch of other transmissions parts have been gradually updated since 96 as well.

When we have the first 08s blow up, maybe it's time to look at having a replacement made. It's always the drive gear that breaks, right?

Does anybody have an idea how much a single gear like this could cost if you make a batch of 50 or so out of better material?



By the way, you forgot to add my buddy Klay to the list (hi Klay! ), see post # 65.

Originally Posted by Klay

That's exactly what happened to mine at 18,000 miles. I believe it's a pretty rare failure. I'm not really worried about it with the new engine.

[NordieBoy]

Originally Posted by Klay

That's exactly what happened to mine at 18,000 miles. I believe it's a pretty rare failure. I'm not really worried about it with the new engine.

18,000 miles - What year?

[Jammin]

So, to replace this as a preventative measure, only the 3rd Drive Gear (#3 below) needs to be upgraded to P/N 24231-12D21, right?

Does anything else need to be replaced? Haven't gone into the cases yet, but maybe this weekend.

Should the shifter forks (25211-37401 & 25221-37401) also be replaced?

[NordieBoy]

Originally Posted by Jammin

So, to replace this as a preventative measure, only the 3rd Drive Gear (#3 below) needs to be upgraded to P/N 24231-12D21, right?

Does anything else need to be replaced? Haven't gone into the cases yet, but maybe this weekend.

Should the shifter forks (25211-37401 & 25221-37401) also be replaced?

I'd do the shifter forks as well as mine was in 2nd gear when 3rd went...

When I do mine it'll be 3rd gear, shifter forks, base gasket, high comp piston.

[Jammin]

Originally Posted by NordieBoy

I'd do the shifter forks as well as mine was in 2nd gear when 3rd went...

All 3 shifter forks (including 25231-14A01) or just the two mentioned above?


Here's a nice high res image of Coyote_X's damaged 3rd gear:

[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

[senoj]

Hi Mate
I'm rebuilding a mates and have ordered the later 2006 3rd gear part number as a precautionary measure.

Can you please give me your reference as I checked the USA Babbits Online parts listing and the same gears by part number are listed from 2006 to 2009 for all the gears. Their site does show the 3rd gear update in 2006 but nothing new in gears from there to current.

If you have identified an even later update I am keen to use that part.

Cheers.

Originally Posted by LukasM

Nordie,

I also checked the microfiches and can confirm that the part was changed in 08. Interestingly enough a bunch of other transmissions parts have been gradually updated since 96 as well.

When we have the first 08s blow up, maybe it's time to look at having a replacement made. It's always the drive gear that breaks, right?

Does anybody have an idea how much a single gear like this could cost if you make a batch of 50 or so out of better material?



By the way, you forgot to add my buddy Klay to the list (hi Klay! ), see post # 65.

[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 (TBC)

[DRjoe]

confirmed

this


did this

[dirtbikeslob]

bugger.

[trailrider383]

Four out of 15 are US bikes. 27 %. The rest are Australia and New Zealand. What are you guys doing to those poor DR's?

[Pike Bishop]

Originally Posted by DRjoe

confirmed

this


did this

That's just fugly.

Reminds me of a 1969 Pontiac GTO with a small block 400 I had where the timing chain went, and then, because the motor was 10.75:1 compression, a piston hit an opened valve...and then the collar of the harmonic balancer broke up and went down into the crank and hunks of that got caught between a piston and cylinder wall and broke a piston and scored the shit out of a cylinder wall...FUGLY is the only word to describe it.

I'm sorry to hear about your loss, DRJoe...did it lock up the rear wheel?

[Pike Bishop]

Originally Posted by NordieBoy

96-97 seem to be susceptible to 3rd gear "whine".
I've ridden 3 that have it including mine.

The whine is caused by loosing the hardening?

Nordieboy - FWIW, 3rd gear on my 2009 DR650 has whined since I picked it up with 1 mile on the clock at the dealer...in fact, as a new rider, I have come to occasionally use the "whine" to know what gear I'm in...

[RiDR]

Originally Posted by Pike Bishop

Nordieboy - FWIW, 3rd gear on my 2009 DR650 has whined since I picked it up with 1 mile on the clock at the dealer...in fact, as a new rider, I have come to occasionally use the "whine" to know what gear I'm in...

weird my 09 has never whined... but I've also blipped the throttle on every single downshift since mile 1.

[rallyhound]

FWIW-- my 03 now has 15,000 miles on it and 3rd gear has made more noise than the other gears since it was new.


wondering if I should swap it out or take my chances?