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Author Topic: 99' DR650 Gearbox failure / repair  (Read 738 times)

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Offline Tallisman

99' DR650 Gearbox failure / repair
« on: December 07, 2012, 04:42:18 pm »
It started after the 2011 Buffalo rally in Mossel Bay (driven from Somerset West), just a hint of a "growl" sound but only in top.  Eventually distinct "growling" after this years Buff - deemed unusable.

Turns out bearing cage on the driven shaft had broken in several places. This caused shafts to separate...

 
 

Offline Tallisman

Re: 99' DR650 Gearbox failure / repair
« Reply #1 on: December 07, 2012, 04:45:52 pm »
I was hoping somebody could tell me this is the master link and how do I get the chain off?
 

Offline Torque Curve

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Re: 99' DR650 Gearbox failure / repair
« Reply #2 on: December 07, 2012, 08:47:09 pm »
You'll need a chain breaker tool. Failing that, you can use a small angle grinder to grind off the chain rivet heads and then punch them out with a pin punch. Best to work on the link that you want to grind when it is on the rear sprocket. Work carefully and slowly so you don't over-heat the links or else you'll cook the O-rings.
“Sometimes it's a little better to travel than to arrive”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
 

Offline Tallisman

Re: 99' DR650 Gearbox failure / repair
« Reply #3 on: December 08, 2012, 11:39:00 am »
Hey thanks Torque Curve. I was thinking of replacing it given what the sproket looked like  ??? Would it still be usable? haven't measured the free length yet but feel and looks good.
 

Offline zetman

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Re: 99' DR650 Gearbox failure / repair
« Reply #4 on: December 13, 2012, 11:28:08 am »
EISH jou engine is die 4de een wat ek van weet wat ontplof het skreeu as jy spares soek ek het n paar ratte en shafts oor van my ou engine ek stel voor jy vervang die sprockets en ketting saam skreeu as jy hulp nodig het :ricky:
« Last Edit: December 13, 2012, 11:38:09 am by zetman »
Hou die Tyres op die Grondpad...
 

Offline lecap

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Re: 99' DR650 Gearbox failure / repair
« Reply #5 on: January 02, 2013, 01:07:07 pm »
Could you please stop this DR gearbox witchhunt now?

There is NO pattern suggesting a design flaw.

A collapsing countershaft bearing is caused by riding with an overtightened chain = operator error also not a design problem.
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Offline Berty77

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Re: 99' DR650 Gearbox failure / repair
« Reply #6 on: January 02, 2013, 02:32:00 pm »
Blixm! That rear sprocket is Fubar! REPLACE PRONTO!!!
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dis mos die lewe!
 

Offline Tallisman

Re: 99' DR650 Gearbox failure / repair
« Reply #7 on: January 12, 2013, 01:22:08 pm »
Could you please stop this DR gearbox witchhunt now?

There is NO pattern suggesting a design flaw.

A collapsing countershaft bearing is caused by riding with an overtightened chain = operator error also not a design problem.

@Lecap
It was actually the drivenshaft bearing on the other side of the the output sproket.  Chain tension all good since I've had it - 2 years.  However what started out as a small 'rumble' was in hindsight there since I bought it.

I not sure if youreceive my lastest PM, indicating I would like to order a bashplate?  I'm in Gordons Bay - Western Cape.