Nice bike ,Ya I had to have my sp bored to 95mm and had it decked so compression should be up ,the little bas**** scratched the jug up pretty good and then only put half the bolt back in , but thanks to you I might have it going this weekend is there a place to post video's or can I put it in this post don't want to make anybody mad I still need a lot of help

Probably be best to post the videos on youtube and link them here I guess.
Cheers

i'm honestly not trying to be rude, but this site is for thumpers, not for fat cat lots o cash no style lazy ass harley hells angels wanna be's. there are lots of sites out there for pig owners and their cross country trips to the local coffee shop. if your bike does not get muddy as hell, it belongs some place else.

Boy it's so funny how jealous some people get when you show a pic of a HARLEY it's not a pig it's not a hog IT"S AMERICAN STEEL  if you read the thread im rebuilding a SP600 and was looking for advice and not to be jugged by how I live my life I fought for this country and I will do what I wont in it
  Why did you jump in any way now I wont get any help by the way Im not no wanna be you are.
Thanks alot Richard

sorry dude, this thread is for JAP CRAP,  NOT "American Steel" as you call it, although, i have to say that any harley i owned since 94 was chock full o off shore metal so you are fooling yourself if you think harley is what it once was. my only point was that i didn't want this thread to go to the fat Boy owners and loose the fact that it was about SUZUKI DR 600 650's. I duly apologize that I have upset your sensibilities regarding your "american muscle". Lets keep it to the thumpers eh?

DUDE it was just 2 pics and two guys that have more than one bike ,who said anything about turning the thread I'M TRYING to get a thumper going why cant you see that . Come on Richard let it go anybody with me.Your ruining the thread !

I didn't come here to argue with some one over harley's (I also had a KTM 2 stroke pic ), I came here to get help with rebuilding my 1985 SUZUKI SP600 . I have gotten some help Thanks Matt if the moderator thinks Ive stepped out of line and have been pushing Harley's just erase my post I wont have a problem with that at all . I think It is just ONE Richard here offended for some unknown reason Just remember it's a Red and White word hahaha

Jeffrocc,

I am having a hard time seeing what your problem is.

I offered Larkin assistance with the rebuild of his SP/DR600 as I have a workshop manual in my possession.
He sent me a pm for some spec's, which I duly sent. (and am more than happy to do the same for you.)

I then noticed in a later post he also rode a Harley. I thought it was a coincidence that, despite being on opposite sides of the planet, we had the same type of machines.
I thought that posting a pic of my Harley was a perfectly appropriate thing to do, to show we had a similar interest, maybe even creating a "bond" of sorts with a fellow rider on the opposite side of the Earth.
Obviously, you disagree........and thats fine, each to your own.

The main problem I have is that in the digital world, it's very easy to mouth off at people, re, "fat cat lots o cash no style lazy ass Harley hells angels wanna be's.", and not get a punch on the nose like in the analog world.

You don't know me, and you don't know the other fellow, so might I suggest you
relax a little, have a beer, and let it go.

Cheers

I finally got to take the beast out for a weekend of riding! Started easily all day long and didn't miss a beat. Though I was following a couple of newer 425s, 600s and two stroke 200s they only left me in their dust because I haven't been on dirt for ten years [and I feel ten years older too]. Only three issues need fixing, front tyre needs to be a knobby not diamond pattern, gearing is way too tall for bush [120km/h easily in fourth] and the rocker cover still leaks oil. Does anyone know if the rocker cover has a gasket originally or just uses silicon gasket to seal?

Hi,
There's no gasket on the rocker cover.
Best to take it off, clean the surfaces and reassemble with Three-bond.
Cheers
Matt

mattro11 said:

Also, there are 2 seals where the de-comp shafts are, check those, as I had to replace one on DakDak recently.

Cheers

Thought i'd add in here.

I want to motard my DR600. If anyone has any info or pics and any ideas, please post

I saw this on bikepics.com and like the look of the front end.



Apparently its from an R1. Has anybody done anything like this, or know any matches that i could look at?

What exhausts have people put on theres? I currently have a badly rusted can with baffle rings at the end, what have people found that match and is a good swap.

Cheers
Adam

I have a 89 dr 600. I have only seen one more, and i've lookd. There is one more in my town but i beleive it is out of comision. This bike kicks ass. The only machine i know that will do 100 mph on knobby tires. (or close to it) Does anyone else have trouble locating parts??? I think it's time for an overhaul?

Finally got my SP600 running man what a beast to start is there any way to make it electric start from a newer year DR

What model is the SP? If 84-86 etc, the decompression cables should help you out. I only weigh 60kg and can kick mine over without jumping up onto the footpegs. It's just a matter of first letting the auto decompression get you to the top of the stroke, then a couple of quick flicks on the manual decomp to get past top dead centre [ the hard to push part ]. After that it just slides through to a nice thump thump thump noise. I did notice the engines don't seem to have changed much in nearly 20 years so a newer kick start cover and internals, motor and wiring might do the trick. Best to wait and see if someone has done it before though.

By the way, she's almost registered now, just gotta pay the RTA the money. Front rim has a bit of a flat spot so I'll have to straighten or replace it for those long rides. Yee-haa!

It is a 1985 , have kicked all day long with the decomp on but found out from matt's post I need seals for mine so maybe that is the problem were do I get the seals would the stealer still have them . I dont even have the small pull handle on mine so I dont even know what it is supposed to look like pics a couple pages back needs a lot of work but it runs now and that is a start.

Which seals? Valve stem seals I guess? Suzuki genuine probably the only place to get 'em. I have seen wheel and steering bearings on ebay and I got fork seals from there. Haven't seen much else aftermarket though. I'm sure they still have spares available genuine.
The manual decompression lever is next to the clutch lever, cable runs down to the front right hand side of the rocker cover where there should be a spring loaded lever. You could probably rig up a BMX brake lever and cable to do this. Without it, I'd have no hope of kicking over the bike. Looks like in the photo your tank has a few dingles. I'm about to work on mine as the steering stops have been ground off and bark buster brackets have smashed into the tank. If you get yours straightened out before me, let us know how, just to give me some pointers eh?!

I'm talking about the actual shafts that go into the head and push on the valves for the seals or what ever holds them in,on my bike you can pull them right out if you wont to or they can vibrate out ,my tank doesn't have any dents just really bad paint haha . If you can could you post a pic of the routing of the cable for the decomp having trouble picturing it but I'm missing a lot of it.

Here are some pics I hope will help.

Manual decompression cable goes from here to the left handlebar.
The only seal here is for camshaft, easy to fix leak with gasket glue.

The only seal here is for the auto decompression lever. If this or the manual one on the other side leak, do what I did, remove the rubber seal and the spring inside it [if it has one], then make up a new spring out of some wire like a keyring piece of steel. Make it fit snug around the rubber and test it on the shaft to see if it seals nicely. If so, whack gasket glue around it , fit it back in and oil leak fixed. Mind you, this may be a temporary or dodgy fix but mine has done okay for over 100km now, no sign of seeping at all. It's all about getting pressure on the surface of the rubber and steel.
If the seal you're talking about is inside the rocker cover, it's most likely valve seals. There is a website somewhere that lists Suzuki part numbers and diagrams. Might take a bit of searching but you can find it. I did.
Cheers. EDIT - I can't get the pictures bigger, software [alcohol] related issues so if you need more clarity [claret] then let me know. BTW I have started boggin up my tank with putty, getting close to original shape now. just need the colour.

larkin35 said:

Those seals are still available from Suzuki.  I fitted a pair to my DR600 a couple of weeks ago and my local dealer ordered them up no problem.  The part number for the 600 ones is 09282-10014 and I'm fairly sure it'll be the same for your SP500.  the shafts shoudnt vibrate out, have you got all the cam cover bolts in? 2 of the bolts hold he shafts in, they have a "waist" on the shafts that the bolt will sit against, stopping them falling out.
I actually tried to get some pattern seals from my local bearing shop & he said they were made of a non standard material, he could get normal urethane ones, but they are only designed for temps upto 100 C, so get the genuine ones.  I think I paid about £10 UK for the pair.