DR650 Gearbox Issues

[NordieBoy]

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

Miniroot (NZ) 2007 39,200km

Helicopter (NZ) 2002 ???km

Klay (US) 2001 29,000km

RobTheButch (AU) 2007 17,000km

Ganjora (??) 2009 36,857km

shdashley (AU) 2006 17,500km

Scary fish (AU) 2010 21,000km

MrHilux (AU) 2007 7,000km

cva4259 (US) 2010 22,500km

ChromeSux (US) 2003 13,000km

Willson (FR) 2007 40,000km

Chupas (US) 2009 34,000km

[ProCycle]

I own 2 of these ticking time-bombs (Leftover 2009's purchased in 2011), and now this bullshit.

I'm REALLY not happy about having 2 grenades in the garage.

I thought you were running straight down to the dealer to trade them in on something good.

Since you know they are going to blow up any minute now I'll be happy to buy both of them cheap ?

I for one am tired of reading your whining about something that didn't even happen to you and won't ever affect 99.95% ofDR650 owners. Get rid of your bikes and get over it.

[jussenuf]

"ticking time bombs"

No worry mon, astroid going crash into earth anytime soon

Art

[pacaver]

My clutch cable broke this summer shortly after I passed the 50,000 mile mark. Fortunately I was only about 4 miles from home so I brutalized the tranny by riding home clutchless. I made it and replaced the cable. It shifts a little notchier from 1st through 3rd, but is fine otherwise. I'm now at 55,000 miles and intend to ride her into the ground, then get another. Whenever you buy a bike there's a risk something will break or wear out, that's life. If something like that is a cause for worry, purchase an extended warranty.

[jussenuf]

To make this thread more informative a lot more information needs to be added. If every transmission has the same use history, then you can say it is Suzuki.

Art

[002]

Hi

You can add in another bike to the list.

2002 DR650 with 18,459km. 14t front sprocket, Staintune Exhaust and jet kit to suit.

This bike was in very good condition, with no indication that anything was wrong. I fired it up, cruised down the road for about 1km, then eased it up to about 110kmh, and it just self destructed.

I bought it with about 10,000km, and spent most of the time on bitumen, with a few blasts on the gravel. I will confess that I did ride it relatively hard, but it was regularly serviced and well looked after.

[NordieBoy]

Weird, but those km's do indicate you're from Oz...

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

Miniroot (NZ) 2007 39,200km

Helicopter (NZ) 2002 ???km

Klay (US) 2001 29,000km

RobTheButch (AU) 2007 17,000km

Ganjora (??) 2009 36,857km

shdashley (AU) 2006 17,500km

Scary fish (AU) 2010 21,000km

MrHilux (AU) 2007 7,000km

cva4259 (US) 2010 22,500km

ChromeSux (US) 2003 13,000km

Willson (FR) 2007 40,000km

Chupas (US) 2009 34,000km

002 (AU) 2002 18,500km

[allaroundaus]

I have sent emails with a bunch of details on the ADV thread on this issue. Post number 499 and 500

Cheers.

[NordieBoy]

Oh yeah.....

Ricor Racing Shocks are about to start the process of machining billet 4130 DR650 3rd gears. We've emailed Moore and Nova with no reply. Best case scenario would be if we could just buy a pair of gears and be 'rest assured'. The OEM DR650 gears are made from sintered / powder metal which is used extensively in mass production shock absorbers.

Unless we hear that someone is going to provide billet 3rd gears for DR650s' date=' the next step is for Ricor to order the OEM gears this weekend. Next step is the measure/ copy and CNC machine everything except the teeth. We will find a USA gear machine shop to machine the teeth. The OEM gears will be destructive strength tested to determine the amount of torque it takes to make them to fail/ explode. The new billet gears will also be 'sacrificed' to measure the increased strength. Then they will be tested in our DR650 project bike for noise, etc.

This will be a non profit effort and any advrider inmate who wants to buy a pair will be able to get a set from Ricor Racing. We won't know the price until we know how many customers we have and the gear mfg cost. After the initial production run hopefully another company will handle the mfg and retailing of the parts.[/quote']

Edited March 30, 2012 by NordieBoy

[ndthl]

1997 model, 65000km, 3rd gear significant whine.all others than 1st very rough. Bearings gone I'm told, hardening on 3rd gone explains whine.

In Australia.

[Eazy-E]

Any chance you can post a clip of the 3rd gear whine. My 2012 does this in 2nd and 3rd gear at lower rpm cruising. Sounds a bit like a dull whistle to describe the noise and is somewhat annoying. If I get the revs up higher I don't notice it. Have a 2012 model with 3500kms on the clock. Heading off in a couple weeks to do a 15000km trip tackling some pretty harsh terrain in outback oz. Wouldn't want any engine trouble out there.

Edited December 24, 2012 by Eazy-E

[ndthl]

I'll see what I can do.