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Author Topic: 1981 Suzuki DR500  (Read 3919 times)

Offline Ross.

  • Posts: 146
  • over there.....
    • Wrench'n Ride'n
1981 Suzuki DR500
« on: Dec 30, 2016, 07:03:50 »
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.





My W'nR'n blog....http://rossmz.blogspot.com/

#japstyle Rusty the Yammie Scorpio (now sold) -
http://www.dotheton.com/forum/index.php?topic=72970.0

Bender (now sold) - http://www.dotheton.com/forum/index.php?topic=70756.0

Suzuki DR500 Tracker (now sold) -http://www.dotheton.com/forum/index.php?topic=72517.0

"Pistoncino" the Gilera 106Speciale Strada  http://www.dotheton.com/forum/index.php?topic=71526

Offline Ross.

  • Posts: 146
  • over there.....
    • Wrench'n Ride'n
Re: 1981 Suzuki DR500
« Reply #1 on: Jan 08, 2017, 02:17:23 »
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.



Took just me to slide it out.



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

My W'nR'n blog....http://rossmz.blogspot.com/

#japstyle Rusty the Yammie Scorpio (now sold) -
http://www.dotheton.com/forum/index.php?topic=72970.0

Bender (now sold) - http://www.dotheton.com/forum/index.php?topic=70756.0

Suzuki DR500 Tracker (now sold) -http://www.dotheton.com/forum/index.php?topic=72517.0

"Pistoncino" the Gilera 106Speciale Strada  http://www.dotheton.com/forum/index.php?topic=71526

Offline Ross.

  • Posts: 146
  • over there.....
    • Wrench'n Ride'n
Re: 1981 Suzuki DR500
« Reply #2 on: Jan 13, 2017, 22:52:02 »
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.





My W'nR'n blog....http://rossmz.blogspot.com/

#japstyle Rusty the Yammie Scorpio (now sold) -
http://www.dotheton.com/forum/index.php?topic=72970.0

Bender (now sold) - http://www.dotheton.com/forum/index.php?topic=70756.0

Suzuki DR500 Tracker (now sold) -http://www.dotheton.com/forum/index.php?topic=72517.0

"Pistoncino" the Gilera 106Speciale Strada  http://www.dotheton.com/forum/index.php?topic=71526

Offline Ross.

  • Posts: 146
  • over there.....
    • Wrench'n Ride'n
Re: 1981 Suzuki DR500
« Reply #3 on: Jan 16, 2017, 05:16:55 »
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.



My W'nR'n blog....http://rossmz.blogspot.com/

#japstyle Rusty the Yammie Scorpio (now sold) -
http://www.dotheton.com/forum/index.php?topic=72970.0

Bender (now sold) - http://www.dotheton.com/forum/index.php?topic=70756.0

Suzuki DR500 Tracker (now sold) -http://www.dotheton.com/forum/index.php?topic=72517.0

"Pistoncino" the Gilera 106Speciale Strada  http://www.dotheton.com/forum/index.php?topic=71526

Offline Ross.

  • Posts: 146
  • over there.....
    • Wrench'n Ride'n
Re: 1981 Suzuki DR500
« Reply #4 on: Jan 18, 2017, 23:30:47 »
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.









My W'nR'n blog....http://rossmz.blogspot.com/

#japstyle Rusty the Yammie Scorpio (now sold) -
http://www.dotheton.com/forum/index.php?topic=72970.0

Bender (now sold) - http://www.dotheton.com/forum/index.php?topic=70756.0

Suzuki DR500 Tracker (now sold) -http://www.dotheton.com/forum/index.php?topic=72517.0

"Pistoncino" the Gilera 106Speciale Strada  http://www.dotheton.com/forum/index.php?topic=71526

Offline coyote13

  • Posts: 1197
Re: 1981 Suzuki DR500
« Reply #5 on: Jan 19, 2017, 13:30:53 »
Brilliant, I'm in
Half the fun's in the get there...

Offline Ross.

  • Posts: 146
  • over there.....
    • Wrench'n Ride'n
Re: 1981 Suzuki DR500
« Reply #6 on: Jan 21, 2017, 02:18:02 »
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.

My W'nR'n blog....http://rossmz.blogspot.com/

#japstyle Rusty the Yammie Scorpio (now sold) -
http://www.dotheton.com/forum/index.php?topic=72970.0

Bender (now sold) - http://www.dotheton.com/forum/index.php?topic=70756.0

Suzuki DR500 Tracker (now sold) -http://www.dotheton.com/forum/index.php?topic=72517.0

"Pistoncino" the Gilera 106Speciale Strada  http://www.dotheton.com/forum/index.php?topic=71526

Offline doc_rot

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  • Posts: 1124
  • Oh the usual... I bowl, I drive around...
Re: 1981 Suzuki DR500
« Reply #7 on: Jan 21, 2017, 02:45:09 »
What are those wheels off of? its tripping me out with that bigger rear wheel and fat front tire but I like it.

Offline Ross.

  • Posts: 146
  • over there.....
    • Wrench'n Ride'n
Re: 1981 Suzuki DR500
« Reply #8 on: Jan 21, 2017, 04:26:38 »
What are those wheels off of? its tripping me out with that bigger rear wheel and fat front tire but I like it.

First model Suzuki RG250WD

My W'nR'n blog....http://rossmz.blogspot.com/

#japstyle Rusty the Yammie Scorpio (now sold) -
http://www.dotheton.com/forum/index.php?topic=72970.0

Bender (now sold) - http://www.dotheton.com/forum/index.php?topic=70756.0

Suzuki DR500 Tracker (now sold) -http://www.dotheton.com/forum/index.php?topic=72517.0

"Pistoncino" the Gilera 106Speciale Strada  http://www.dotheton.com/forum/index.php?topic=71526

Offline JadusMotorcycleParts

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Re: 1981 Suzuki DR500
« Reply #9 on: Jan 29, 2017, 07:30:51 »
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?

Offline Ross.

  • Posts: 146
  • over there.....
    • Wrench'n Ride'n
Re: 1981 Suzuki DR500
« Reply #10 on: Jan 30, 2017, 06:34:50 »
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.
My W'nR'n blog....http://rossmz.blogspot.com/

#japstyle Rusty the Yammie Scorpio (now sold) -
http://www.dotheton.com/forum/index.php?topic=72970.0

Bender (now sold) - http://www.dotheton.com/forum/index.php?topic=70756.0

Suzuki DR500 Tracker (now sold) -http://www.dotheton.com/forum/index.php?topic=72517.0

"Pistoncino" the Gilera 106Speciale Strada  http://www.dotheton.com/forum/index.php?topic=71526

Offline irk miller

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Re: 1981 Suzuki DR500
« Reply #11 on: Jan 30, 2017, 08:56:15 »
I'm a fan, Ross.

Offline Kanticoy

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Re: 1981 Suzuki DR500
« Reply #12 on: Jan 30, 2017, 09:09:09 »
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.

I get not knowing, but I can't for the life of me understand not trying. It's only metal it can be fixed. Man up and risk a mistake in exchange for a lesson.
'

Offline JustinLonghorn

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Re: 1981 Suzuki DR500
« Reply #13 on: Jan 30, 2017, 10:15:20 »
I'm on board.
I'm going to eat your brains and gain your knowledge.

Into The Sunset, CB750 build

TT500 the Animal

Offline Eleganten

  • Posts: 116
Re: 1981 Suzuki DR500
« Reply #14 on: Jan 30, 2017, 18:58:17 »
Nice! Going to be interesting to ride it in sunlight with that tank thou!


Sent from my iPhone using Tapatalk

Offline Ross.

  • Posts: 146
  • over there.....
    • Wrench'n Ride'n
Re: 1981 Suzuki DR500
« Reply #15 on: Jan 31, 2017, 03:20:31 »
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
My W'nR'n blog....http://rossmz.blogspot.com/

#japstyle Rusty the Yammie Scorpio (now sold) -
http://www.dotheton.com/forum/index.php?topic=72970.0

Bender (now sold) - http://www.dotheton.com/forum/index.php?topic=70756.0

Suzuki DR500 Tracker (now sold) -http://www.dotheton.com/forum/index.php?topic=72517.0

"Pistoncino" the Gilera 106Speciale Strada  http://www.dotheton.com/forum/index.php?topic=71526

Offline Ross.

  • Posts: 146
  • over there.....
    • Wrench'n Ride'n
Re: 1981 Suzuki DR500
« Reply #16 on: Feb 09, 2017, 06:22:07 »
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.

My W'nR'n blog....http://rossmz.blogspot.com/

#japstyle Rusty the Yammie Scorpio (now sold) -
http://www.dotheton.com/forum/index.php?topic=72970.0

Bender (now sold) - http://www.dotheton.com/forum/index.php?topic=70756.0

Suzuki DR500 Tracker (now sold) -http://www.dotheton.com/forum/index.php?topic=72517.0

"Pistoncino" the Gilera 106Speciale Strada  http://www.dotheton.com/forum/index.php?topic=71526