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Old 02-26-2010, 02:46 AM   #106
NordieBoy OP
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Good luck with it.

Sounds like 4th gear itself but get 3rd replaced as well just in case...
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Old 03-08-2010, 12:15 AM   #107
LukasM
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Thank you very much for the write-up Jay! I will eventually do mine so this will help a bunch.

Hope you are having a great trip!
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Old 03-28-2010, 06:31 AM   #108
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just split the case on my 96 because it was starting to jump out of 2nd gear - 28,000 miles. 3rd driven gear had several teeth that had portions of their contact surface starting to spall off. not sure if this is related to the catastophic failure or not.

I just wanted to inform group of my mistake so you guys don't make it also.

as I was pulling 2nd drive gear off of the transmission input (driving) shaft, I put the gear puller push rod on what I thought was the end of the shaft.

on my 96, the driving shaft has been bored to supply oil to the bearing journals of two gears and the clutch. what I thought was the left end of the shaft is actually a plug (with a drilled out oil port) pressed into the internal bore of the driving shaft. as I applied load on the gear puller to remove 2nd drive gear, the oil port plug pushed further into the shaft rather than the 2nd drive gear sliding off of the shaft.

as soon as I noticed that the plug had moved and that the gear did not, I stopped and determined that the plug had shifted within the driving shaft.

Hoping that the bore of the driving shaft had an internal ledge that the plug would seat against, I lighted tapped the plug and it continued to travel deeper into the bored out driving shaft. I stopped tapping when the plug traveled into the shaft far enough to block the first oil journal outlet hole.

I assume this could have been catastaphic if I would have assembled it and then the plug would have continued to move until an oil journal feed was blocked and siezure would have occured. Ended up making an adapter out of a 3/8" bolt head to center and set on top of the shaft end that allowed me to pull the 2nd driving gear without pushing against the plug inside the shaft.

If you are going to pull the 2nd driving gear off of the transmission driving shaft - make / use an adapter to prevent pushing against the plug inside the left end of the driving shaft.

Bike Bandit lists the driving shaft as +/- $125. I will order a new one when the local shop opens on Monday.
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Old 03-28-2010, 01:11 PM   #109
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Good stuff to know.

Thanks.
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Old 04-20-2010, 05:59 AM   #110
miniroot
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Boy, do I wish I didn't qualify to join this jolly little club! Shifting from 4th down to 3rd, on the ride home tonight. Low load, low speed. Crunch, rattle, no power. Wheel locked up just as I got to the kerb. Could have been worse

Haven't opened it up. Probably take it along to my local workshop and have them do the autopsy. But it all sounds very familiar.

And I'd just had a bloody awesome weekend's riding, too.

:/
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Old 04-20-2010, 06:23 AM   #111
FloridaSteve
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Really sorry to hear of your troubles. This is starting to really suck... So what's the count?
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Old 04-20-2010, 07:11 AM   #112
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Looking for a DR650 carb

Any of you modder's got a stock carb to sell?
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Old 04-20-2010, 01:29 PM   #113
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Quote:
Originally Posted by MLB
Any of you modder's got a stock carb to sell?
Depends where in the world you are.
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Old 04-20-2010, 01:30 PM   #114
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Quote:
Originally Posted by FloridaSteve
Really sorry to hear of your troubles. This is starting to really suck... So what's the count?
19 confirmed so far.
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Old 04-20-2010, 01:31 PM   #115
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Quote:
Originally Posted by miniroot
Boy, do I wish I didn't qualify to join this jolly little club! Shifting from 4th down to 3rd, on the ride home tonight. Low load, low speed. Crunch, rattle, no power. Wheel locked up just as I got to the kerb. Could have been worse

Haven't opened it up. Probably take it along to my local workshop and have them do the autopsy. But it all sounds very familiar.

And I'd just had a bloody awesome weekend's riding, too.

:/
Bugger :(

What year/mileage?
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Old 04-20-2010, 01:36 PM   #116
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Quote:
Originally Posted by NordieBoy
19 confirmed so far.
I'll let you know the results of the autopsy.

I may have helped it along a little -- stacked the bike a few weeks back hard enough to strip the splines off the inside of the gear lever. Spent two weeks waiting for a replacement lever from Japan.

In retrospect, that downtime could have been usefully used to perform a leisurely inspection of the 'box.

Ah, well.

Quote:
Originally Posted by NordieBoy
Bugger :(

What year/mileage?
2007, 39200km. Like I said though, I'm half expecting to find that I've borked one of the selector forks when I dropped it, and it hung in just long enough.
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Old 04-20-2010, 02:13 PM   #117
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Quote:
Originally Posted by miniroot
2007, 39200km. Like I said though, I'm half expecting to find that I've borked one of the selector forks when I dropped it, and it hung in just long enough.
The selector fork on 3rd will have blown apart but as to wether it was before or after...
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Old 04-21-2010, 03:06 PM   #118
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Quote:
Originally Posted by NordieBoy
The selector fork on 3rd will have blown apart but as to wether it was before or after...
Called in to the workshop on my way to work this morning. They haven't finished stripping it down, but they've got far enough to show a few things. The gear shift shaft is slightly bent. Hard to see on the picture, but the two gears closest to the centre-line of the case have disintegrated.
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Old 04-22-2010, 01:47 PM   #119
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Yep. That's 3rd alright.

On mine only 3rd and it's selector fork disintegrated.
But it destroyed the rest of the engine :(
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Old 04-22-2010, 04:11 PM   #120
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Quote:
Originally Posted by NordieBoy
Yep. That's 3rd alright.

On mine only 3rd and it's selector fork disintegrated.
But it destroyed the rest of the engine :(
If I remember this morning's conversation correctly, the parts list is:

3rd gear input
3rd gear counter
input shaft
selector fork
gasket set

They also confirmed that my drop a month back looks to have tweaked the selector shaft slightly, but not enough to cause a leak at the seal. I'm in two minds whether to replace it. I might, just because of the stress the splines took when I broke the lever.
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