DR650 gearbox whine

**XF650** · 19th October 2010, 20:09

Great to hear from another Freewind owner Miles & I appreciate your comments.
What had me more concerned than the actual "whine" was the swarf in the oil (small that it was), plus the fact that 3rd gear failure's often resulted in motor lock-up.
Check out Nordie's thread here: http://www.advrider.com/forums/showthread.php?t=424132
Have yet to dismantle gear cluster & measure tolerances etc. Only regret so far is that I mentioned oil, a bit premature perhaps.

**XF650** · 19th October 2010, 20:24

Originally Posted by NordieBoy

3rd does look to be in good condition

4th however is really cool...

You can have my 4th gear if ya want it.
Do you know if it was both 3rd gears that had an update / part # change? Or was it just your favorite one?

**miles1** · 19th October 2010, 20:48

In NZ i use a semi Syn 10/40 of what ever brand is the best deal but in africa unfortunatly there is not much option but to use whatever. The 20 40 oil i changed in Egypt was a real problem in Austria at -10 (no supprise) When i started it up to warm it up and change the oil it blew out the counter shaft seal and the engine sounded like a jack hammer. After heating the engine up with a heater, changing the oil with 10 40 and pushing the counter shaft seal back in the problem was sorted. Sometimes the pieces of metal that come out with an oil change are a little worrying but the KTM was a real shocker with big chunks always coming out. even with this the KTM seemed to be no problem.
I really thought of rebuilding the gearbox before africa but I think these motors are bomb proof, so i decided i will ride it to the grave and push it to the dump when finished. I am sure by then the bike wont be worth a dozen tui let alone fixing. Man these are great bikes.

All good, Cheers Miles

**Transalper** · 19th October 2010, 21:18

My DR650 coasted to a stop when the 3rd gear cog split.
Engine locked up and 3rd was still selected but the bike just coasted on quietly to a stop with the rear free wheeling.

We considered opening up Js DR for a look but so far have just left it on the assumption/hope that we who had sudden failures were just an unlucky few out of many thousands.

**Squiggles** · 19th October 2010, 21:27

Originally Posted by XF650

within tolerance but still makes me question the oil I'v been using.

What oil? (For the curious)

**XF650** · 19th October 2010, 22:06

Originally Posted by Squiggles

What oil? (For the curious)

All I'll say is it's a popular motor bike specific semi-synthetic 10W40. The wear surprised me considering regular oil & filter changes. But yet to ascertain if it's all from the mechanical issues (some obviously is) & or from lubrication issues. My question will be, would there be less wear if I had used full synthetic?

**Squiggles** · 19th October 2010, 23:55

Originally Posted by XF650

All I'll say is it's a popular motor bike specific semi-synthetic 10W40. The wear surprised me considering regular oil & filter changes. But yet to ascertain if it's all from the mechanical issues (some obviously is) & or from lubrication issues. My question will be, would there be less wear if I had used full synthetic?

Always used Motul in my bikes to date, but has never felt quite right in the DR

**NordieBoy** · 20th October 2010, 06:35

Originally Posted by XF650

All I'll say is it's a popular motor bike specific semi-synthetic 10W40. The wear surprised me considering regular oil & filter changes. But yet to ascertain if it's all from the mechanical issues (some obviously is) & or from lubrication issues. My question will be, would there be less wear if I had used full synthetic?

Are your NSU screws still there?
Do you spend more time in 4th?

Bit of crap caught in a tooth of the driven gear and eventually wearing all the teeth of the drive gear?

If it was oil then all the cogs would be showing similar wear?
Ryans 3rd was noisy but I seem to recall it was in good condition wear wise when it was checked. Just badly machined.

**cooneyr** · 20th October 2010, 20:57

Originally Posted by NordieBoy

.......Ryans 3rd was noisy but I seem to recall it was in good condition wear wise when it was checked. Just badly machined.

We've been having an off line chat but yep - good condition just badly cut.

**Waihou Thumper** · 20th October 2010, 21:36

Originally Posted by cooneyr

We've been having an off line chat but yep - good condition just badly cut.

Oh, wrong mount....sorry... hehe

**Monstaman** · 21st October 2010, 07:59

Heya Struan

My 2004 DR only has 15000 km, I bought her at about 9 or 10k.

My 3rd is growley compared to the others but it still changes smooth, feels smooth etc so I am not going to bother until something does go pop ... if at all.

Oil changes have netted nothing whatsoever even with the nordieboyfluxcapacitorsuperdupamegamagnet, no fro or chunks of metal either.

Still can't find sixth gear tho....