DR650 gearbox whine

[cooneyr]

Does anybody have any info at all on the 3rd gear whine? DAS have just rang and said that apart from a very slightly rough main bearing (not sure which one) there is absolutely nothing wrong with the gear box. All of the thrust surfaces and bushes etc are "perfect". They have asked if I know anything about this and hence I'm asking if you guys have found any sources of info?

Cheers R

P.S. DAS now have the only DR650 fly wheel puller in Chch after getting one manufactured. Suzuki NZ didn't even have one apparently

[Crisis management]

Short answer, No, I was relying on you. My enquiries up here of the suzuki dealerships were similarly helpful.

I suppose it's buy earplugs and carry on then?

[XF650]

I'm the same, got the 3rd gear whine (Freewind's have DR650 engine) & was anticipating same fix as yours, whatever that is. However looks like you may have saved us a lot of $, if there isn't anything obvious that actually needs fixing.

When running 16th front sprocket my "whine" seems worse than 15 tooth, so it's probably load related? Next ride I will change to 14th sprocket, to see what effect that has.
Then I might try 'Rock Oil' in the gearbox (instead of usual Castrol GPS) to see if that has an effect, or am I wasting money.....

[NordieBoy]

I wonder if everyone with 3rd gear whineering are using bashplates?

[cooneyr]

OK the final verdict (went and saw DAS after work) is that the gears are poorly made in that the teeth dont mesh that well - lets just put it this way the are not precision machined gears! This is not to say that they aren't in good shape i.e. the case hardening etc is good etc. Apparently DAS talked to a couple of guys who know a thing or too about gears and they reckon they are pretty badly made gears but nothing to get excited about in terms of replacing.

Plan of action - put it back together and ride. Doing new rings while in there and giving the head a bit of a going over.

So all of you with DR650 engined bikes and 3rd gear whines who I just saved a lot of money, feel free to chip in a hundy for the cause LOL

Cheers R

[Transalper]

J and I both have a bash plates (1 BnB 1 similar) no whining on our bikes... and I don't reckon I can tell any noise increases with the plates on vs off.
I wear plugs any time I am leaving the city limits.

[XF650]

Would pay to check that your motor has the metal base gasket upgrade, while it's apart.

[cooneyr]

Would pay to check that your motor has the metal base gasket upgrade, while it's apart.

Told the guys about that to the guys without trying to sound like a know it all - doing think I succeeded. Also told them about the neutral sender unit and then proceeded to have a look at the cases and noticed they hadn't removed it (I'd just locktighted it anyway).

What I'm curious about is what model you guys with the whine have. Do you have the micro switch on the carbie or not and do you have or not the US Forestry service approved can?

Cheers R

[Crisis management]

As you know, mine has whined from @ 4000 kms and its an 03 NZ model. I don't have the stock exhaust so can't comment on that but i did have the throttle microswitch.

[XF650]

I have changed front sprocket to 14t & a lot less 3rd gear whine now. Plus able to use 4th gear more instead of 3rd around town etc.
The DAS guys didn't think changing oil type would help - just stick to a good semi or full synthetic.
Bike has more power out of corners & gets to the ton quicker than standard gearing. Suspect economy & tank range might suffer though.

[howiezowie]

My story, same but different ..
Bought a used DRZ 250, no noise noticed with 16000 km (shown)
Noticed a pronounced grind/whine in top (6th) gear. diagnosed by dealer as worn gear hardening.
long story short, motor stripped down, 6th gear and opposing cog stuffed, long wait (2 months +) for parts from Japan, and bill to pay $1500+.
Are there some issues here for Suzuki to face up to ? considering some of the other stories .
H

[simonantz]

I have been reading this with interest, if this was my bike I would try a gearbox additive...like ..motor up.. or moreys...always used them and so far so good!

[cooneyr]

I have been reading this with interest, if this was my bike I would try a gearbox additive...like ..motor up.. or moreys...always used them and so far so good!

In a bike where the gearbox oil is also the clutch and engine oil? Is that really a good idea?

Anyway - got the engine back on sat morning and put it back in late today. Started and ran OK. When I get the shock I'll take it for a ride and report back on the whine.

I drilled the second hole in the carb slide but not sure that is was a good idea. I get a big hiccup when you give it a wrist full - maybe the slide is lifting too fast now? Cant ride it yet but maybe it is just associated with the lack of load but if it isn't then the hole is getting glued up again!

Cheers R

[NordieBoy]

The hole should just make it respond quicker off the bottom.
It'll lift to the same levels just get there more quickly.

I'll send you down my stock needle, nylon spacer and extra spacery thing which let my de-snorkeled bike run nicely.
See if they make a difference from your very worn needle/spacer combo?

Still havn't pulled mine apart to see why it's so rich now...

[cooneyr]

The hole should just make it respond quicker off the bottom.
It'll lift to the same levels just get there more quickly.

I'll send you down my stock needle, nylon spacer and extra spacery thing which let my de-snorkeled bike run nicely.
See if they make a difference from your very worn needle/spacer combo?

Still havn't pulled mine apart to see why it's so rich now...

Thanks for the offer nordie. I think I'll take this discussion to your thread cause it is rather off topic in this one.

Cheers R