Project Ground Pounder -1981 Suzuki DR500

I don't normally like hard tail / choppers but this is crazy, I love it. Thanks for posting, really enjoying seeing it develop

Popeye SXM said:

I don't normally like hard tail / choppers but this is crazy, I love it. Thanks for posting, really enjoying seeing it develop

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Haha thanks man! I normally don’t either but between peer pressure (all the cool kids are doing it) and curiosity, I figure the best remedy is to build my own interpretation of one. Thanks for following along!

I cant imagine where peer pressure could be coming from.

Slowly but surely. Yesterday I was able to mount and plug in the CDI. Big fat blue spark! That got me excited because I know now this thing will definitely run. Awesome to see from such a junk pile bike that it started out as. Today I knocked some more to-do’s off of the list. First I pulled the muffler and welded in a 45° section of stainless tubing to tuck the muffler in closer to the frame. It’s just right now:







Next I picked up a brake arm with what was originally a cable actuator for a rear brake from a DR370 off of eBay. The splined portion fit the frame boss perfectly. I built a bracket and extended the actuator and got the master cylinder from a KX250 mounted. I specifically wanted this one because it doesn’t have an external reservoir so it cleans things up:







And finally I popped on a new RK chain and was able to weld up my chain tensioner using a skateboard wheel. I didn’t want the bottom of the chain flapping and hitting the frame at speed:





Finally I stripped and cleaned my donor FCR39 carburetor. Stripped off all of the TPS sensor junk and plugged the holes that it left. It fits the frame perfectly using the pancake filter that I picked up. It’s all coming together:

It looks so much better with that pipe tucked in there.

Hurco550 said:

It looks so much better with that pipe tucked in there.

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Thanks man, the more I stared at it the more it bugged me. Needed fixed for sure.

This is the epitome of insanity! I love it!!!

Yep. Glad you did that ti the pipe. It was not right before. I liked the choice of cone etc but the angle was bad. Much better tucked in like that now.

Thanks guys! Couple of overall shots to highlight the end of the day’s work.

I dig the tank as is but I keep seeing blue metal flake on it.

canyoncarver said:

I dig the tank as is but I keep seeing blue metal flake on it.

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Haha, I have to run this tank as is, it was meant to be. Luckily the frame uses the stock tank mount locations for the TS tank now, so maybe I’ll pick up another one and paint it up and then I can play dress up.

How does the motor like that carb?

pidjones said:

How does the motor like that carb?

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It’s a killer on there. Running the same combo in my dual sport with the same motor and it’s a screamer.

My high school sweetheart was a screamer. She made having sex while the parents were near a bit difficult.

irk miller said:

My high school sweetheart was a screamer. She made having sex while the parents were near a bit difficult.

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At least she wasn’t a squirter. Makes cleanup a problem.

that pancake air filter will not do that bike justice at higher rpm

they are ok for twin and smaller installs but that thumper can go rich at higher rpm

just from how close the cover is to the inlet

check it out on a dyno before getting stuck on it

cxman said:

that pancake air filter will not do that bike justice at higher rpm

they are ok for twin and smaller installs but that thumper can go rich at higher rpm

just from how close the cover is to the inlet

check it out on a dyno before getting stuck on it

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Yeah may warrant some experimentation on filters and jetting for sure once it all gets running. It’s somewhat theoretical at this point.

put a uni filter on it to start

get your jetting in range ish then do the filter playing

Love this bike! Just looking at it is an education - the crazy front end, the snaking exhaust, the restraint on leaving the tank battered and original...this thing is just the coolest ride. Kudos man, this bike's a riot.