Getting to know the elusive DR600 - all what suzuki wont tell you at the dealership

[No Idea]

Spent too long with this bike for the knowledge gained to be wasted. So…

Bike is a pig to start they are all a bit different but look up starting dr600 on you tube. im not covering as well documented.

Unusual bike. Long suspension. Knobblies yet top speed of 100 mph. the gear ranges are narrow meaning to make it go you have little choice of gear

Lots of rake doesn’t want to high side. Works well with counter steering turn bars left at right turn to lean bike then steer as normal

Small turning circle.

 

Wont wheelie you off back just goes

That said… this is a trial bike and will be abused.

[No Idea]

It’s a road legal bike so if bought as such should have  a numberplate.

 

Home work assuming you have its number at home before going to see it,

Its speedo is usually in kms

Check mileage go es up between mots at

https://www.gov.uk/check-mot-history?_ga=2.73319184.2024387619.1579742241-33210135.1557400970

 

make a record of its vin no at facebooks vin to reg before see ing it costs five pound assuming its uk based.

 

On seeing…

Check vin no if it agrees with reg its less likely stolen

This is a trial bike its likely to be abused

People start them on the side stand and crack it or knock it off check for damage

It needs welding if damaged.

If jumped or crashed the front tube will show it by being creased.

 

this is to my mind – unrepairable. The bike may not track right

you  might not believe the clock but bike is essentially a 200,000 mile bike if looked after the clock will go back to 0 in its lifetime without help

they are worth stealing because they are quick on rough ground

[No Idea]

servicing

not much different to servicing anything else

except the head bolts they need regular torquing down each full service

and the head gasket needs instant gasket probably coz the bolts stretch and it leaks

this was the first suzie I owned that didn’t require a man running along behind collecting all  the bit that shook off. only the chain  guard fell off.

The manual is in the info of dr600 facebook – worth joining

https://www.facebook.com/groups/1665364800396264

 

the bike top down front to back

index

1. front mudguard  2. front tyre  3. front wheel  4. fork plastics

5. front brake  6. forks   7. light cowl / plastics   8. headlight  

9. screen  10. steering bearings  11. oil cooler  12. bars

13.  fuel tube  14. decompressor seals  15. cam  16. head

17. bore  18. clutch 19. magneto  20. sump drain

21. air filter  22. fuel system  23. fork bearings  24. Exhaust pipe

25. seat  26. Battery  27. Rectifier  28. Gear lever

29. Chain /sprocket  30. Chain guard  31. Swing arm protector 32. Indictors

33. Reg plate post  34. Bones  35. Rear mudguard  36. Steel guard reinforcement

37. Rear wheel  38. Spokes  39. Tyre black  40.pads  41. Rack / bag 42. Decals

[No Idea]

1. front mudguard

too high wheel throws mud in your face

modify thermal

plastic from ebay

stick on with two sided carpet tape

 

[No Idea]

2. front tyre

says100 100 21 has 90 100 21 its available from black circles I dont self fit wheel anodized and im clumsy

universal  tyre never lost traction does wear – cupping

3. front wheel

spares and bearings from ebay

spokes  available main dealer

no problems with speedo drive cable ebay

forks out of alignment suspect bent axle accident damage secondhand breakers ebay

 

4. fork plastics

if missing suspect crash

unavailable

[No Idea]

5. front brake

pads available ebay

pipes available braided buy by length -  unions

caliper kit available ebay chrome pistons

brake oil standard

tapered threaded pin holds pads bends cant see just will not bleed if bent no feel

if brake sticks on put a master cylinder on caliper end and jack out return blockage then clean reassemble and bleed

disks available ebay use locktite

6. forks

gaiters hide seal leakage need a cross head screwdriver

check chrome cracking indicates bent forks secondhand on ebay mine bent chrome didn’t crack

fork seals ebay

[No Idea]

7. light cowl / plastics not available

repair using 2 inch glass tape and epoxy resin for boats

available ebay

m6 bolts at sides if connectors break

watch you don’t trap indicator wiring

 

8. headlight h4

if all lights blown look at resonator gsf 600 ebay needs filing to fit wiring conector box does no longer fit look at battery swells up ebay

 

9. screen short throat risk if higher

 

[No Idea]

10. steering bearings

ebay bottom set top main dealer if not taper rollers

bike on a stand remove frontwheel pullforks to free yokes

11. oil cooler

in line with front wheel but I haven’t broke it. No knowledge

[No Idea]

12. bars

are straightnable if you know how. Couldn’t find replacement

speedo extra ebay bagged to waterproof electric feed from rear light if no display then no lights on

clutch cable buy from main dealer ebay 1.6mm thick original 3mm

soul be decompressor lever 

aftermarket bark busters knuckle guards available good ones plug in end of bar

mitts don’t come back on levers as bark busters protect need gloves as well in  case of fall

 

13.  fuel tube

this has got to let in air and not let fuel out in a crsh

tried aftermarket with one way valve cut air supply unsuccessful

 

14. decompressor seals main dealer if leaks suspect head bolts

 

cable main dealer

rocker box if leaks oil suspect head bolts

possible to gap tapet clearance when cams on rocks runs bad if you can start

m6 threads suspect use torque wrench figures are with dry bolts no gasket if stripping fit helecioils before aluminum thread strips

 

15. cam not available

cam chain needs little maintenance 50,000  not stretched

careful of cam bearings cant replace

[No Idea]

16. head

if valve seats fall out machine shop hasn’t happened to me

valves main dealer if damaged

head gasket is sealed with hylomar or equivalent kit ebay

not one but two spark plugs in one cylinder

17. bore did 80,000 kms no damage replaced expecting…

barrel second hand ebay

piston oversize rings needed sizing ebay

head bolts stretch retighten each main service important

big end small end original no slack at 80.000kms  

timing chain not needed but fitted ebay

haven’t parted halves

 

use torque wrench figures dry

[No Idea]

18. clutch

can lay bike on side oil does not run out when clutch removed

doesn’t need uprated springs tried them

replace plates if overheated or under thickness mine wasn’t

replace plates if synthetic oil used ebay doesn’t need first thin plate

dosent need extra plate

clutch basket is critical not wear grooves but rubbers irreplaceable got lucky ebay

clutch cable main dealer not thin ebay ones

refitting decompressor a pain haven’t found alternative

make sure spacers are fitted torque the bolts

[No Idea]

19. magneto

rewind new ones not available

two windings

one runs bike one fires engine

20. sump drain check on buying for seepage 

can be helicoled new bolt ebay

 

21. air filter

clean and dip in engine oil engine is set to run with this much restriction

low hp

watch drain in bottom of airbox case if too active torque head bolts

[No Idea]

22. fuel system

tank ok no experience of lining this model

tapseals washers not available mine too stiff leak a little

carb

flat slide wears out sound like camchain rattle

no parts available thickened with epoxy two pack not good

no stop valve available pipe under carb stops leak

replaced with new carb ebay Holland beware unseen import tax

cables will reach need re setting under bar

[No Idea]

23. fork bearings

available ebay seals separate purchase

same with rear suspension parts

only two bolts remove fork spring assy after chain removal

new spacers not available machine shop?

[No Idea]

24. Exhaust pipe

Illegal to sell unstamped british standard one illegal to buy use

Not illegal to make

3ft 4 inch exhaust pipe one foot 2 inch pipe 2 foot perforated stainless 2 inch pipe plate foot square 3mm thick all ebay chicken short welds ground redone until flat important detail ebay decibel killer ebay to cut noise and make back pressure not to noisy didn’t buy exhaust pipe.

[No Idea]

25. Seat

Seat cover ebay local upholserers

I bought a secondhand so didn’t damage original ebay

 

Cut half foam to lower seat height reupholstered

26. Battery

Ebay

27. Rectifier 600 gsf ebay file to fit

28. Gear lever

Bend to miss casings after crash haven’t snapped one bending straight yet

Put gear lever in vice put hacksaw blade through slot to tighten it on shaft

Avoid welding it on as repair split case

Kick starter no problems with this or gearbox hear second gear is weak csml? has spares

[No Idea]

29. Chain /sprocket ebay

Sealed roller ring clean off oil when servicing as collects sand and wears

30. Chain guard the bolt bends and comes loose torque

31. Swing arm protector

Makes bike judder if worn out

Bolted on through swing arm chain hits bolt when badly worn main dealer

32. Indicators ebay

Led lights need a different flasher unit ebay haven’t got it right warned too dim on sunny day does nt save anything magneto  makes 80 volts rectifier throws excess away.

33. Reg plate post mine hasn’t one no plate light passed all mots don’t know why

Reg plate on mudguard with light standard halfords bulb 12 volt

[No Idea]

34. Bones ebay

Shorten to lower bike is filed holes if too short

35. Rear mudguard

Haven’t replaced if damaged repair with 2 inch glass tape and epoxy

If bones shortened too much wheel hits guard and cuts holes in it 

36. Steel guard reinforcement painted it haven’t replaced

37. Rear wheel

38. Spokes main dealer

39. Tyre black circles universal good grip bad wear tubed no punctures

Havent fitted rim locks

Rims anodized haven’t replaced need rim protector to repair /replace tyre available ebay

[No Idea]

40. Later pads ebay Early bike unknown

Disk ebay loctite bolts

Haven’t broken rear brake lever assy pads ebay and slave cyl kit and disc

Rack / bag

41. Ebay

42. Decals facebook mateo muratore Italian postal have some of these

43. security easy to take useful to thieves. Bike lock is weak ebay ignition easy to bypass only thing is difficult to start . bore a hole through swing arm steel fit pipe (liner) . use notched spare axle   pin as wheel stop secure with cargo lock bay weld to 10mm security chain. Cant get at with angle grinder. Or crops.

44. side stand. When bike is lowered is too long cut in half remove 4 inches weld in m12 nuts add more nuts to length fit m12 studding

[turboguzzi]

nice wrap up!

some questions:

1. Are you still riding it after the accident?

2. If yes, how does it go after all the tender loving care lavished on it?

3. Are you aware that the bottom bearing is upside down in this pic? Is that how you actually mounted it? If yes, your steering would be very weird. Take down the fork and mount it properly.