1981 Suzuki DR500

Ross.

over there.....
Some of you may have seen my Transalp Bender in the Specials forum? Engine is on the way out. My true love is 500 singles. So I have acquired this 1981 Suzuki DR500 off a mate.
Engine insides have had a freshen up. New piston fitted.

This is as it stands at the moment. I take delivery in the next few weeks. The tracker seat stays., I would have done this to it if it had not come with that already fitted. It will get a different tank. New rubber. Rego and on the road as quick as i can cause public transport sucks when you do shift work.

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Six hours of driving in total and the DR500 is here.

Lego bike loaded up in the car. Took 2 of us to get it in.

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Took just me to slide it out.

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2 beers down and its ready for rego... I wish...

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Many years ago I used to tig weld and sheetmetal work for a living. Roll forward to now again that trade is paying off. Broken stud in bottom of engine. I know how to get that out. Build up whats left of the stud with weld. Then weld nut on. Then use spanner on nut. Out comes stud. Had to do this to the sump plug bolt as well.

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I am known for doing rat style bikes. This style is not for the DR.
This is a sneak look at were I am going with this. From now on I am keeping the rest of the build under wraps till it is done.

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Mirror tank just about mounted. Made mount for rear of the tank. Bit of bending and welding. Some more design mock ups for how it will look. The apprentice wanted to help. Local wild cockie.

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Productive day. Shift at work and then home to work on the seat unit for the DR. Sanded back and first colour down. Not showing the colour just yet.
Tomorrow will tackle the wiring harness refit. What can go wrong with wires that are colour coded and I am green colour blind.

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What are those wheels off of? its tripping me out with that bigger rear wheel and fat front tire but I like it.
 
This is cool man. Nice progress. I really love the routing of the header on this bike - the cool big loop around the frames down tube then out to the back. Is that stock btw?
 
JadusMotorcycleParts said:
This is cool man. Nice progress. I really love the routing of the header on this bike - the cool big loop around the frames down tube then out to the back. Is that stock btw?

The header from the factory loops to the left. This has had some extra put into it to get it to swing across to the right.
 
Killer! This is the only other DR500 I can recall seeing on DTT other than mine. Here's how mine turned out. Some assembly required.

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Nice! Going to be interesting to ride it in sunlight with that tank thou!


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Cheers all. Love the support. Have paused on the DR while parts arrive etc. Dividing my time between the DR and this http://www.dotheton.com/forum/index.php?topic=71526
 
Went to the local wreckers. Said a mate said they had wrecked an RG250. Owners says yeah 25 years ago. Ask if he had a speedo from it. He says he has two. Gets a drill with a bit of speedo cable in it. Both speedos work. I buy one.

The RG speedo matches the RG front wheel fitted to the DR500. Speed will be show correctly.

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