Segment:
Dual-sport / Enduro motorcycle
Target Audience:
Owners, enthusiasts, and independent repair shops of the Suzuki DR500S/DR500
Competitors Era:
Competed against models like the Honda XR500R, Yamaha XT500, Kawasaki KLR500
Benefit 1:
Enables significant cost savings on maintenance and repairs
Benefit 2:
Provides clear, step-by-step instructions with visual aids for ease of understanding
Benefit 3:
Empowers owners to perform complex tasks, increasing self-sufficiency
Model Years Covered:
1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989
Trim Levels Covered:
All DR500S and DR500 variants and trim levels
Engine Types Covered:
All DR500 engine configurations
Transmission Types Covered:
All DR500 transmission configurations
Estimated Page Count:
Comprehensive (Exact count not specified, but described as 'Complete' and covering A-Z)
Type:
Workshop Service Repair Manual
Purpose:
DIY repairs, maintenance, and troubleshooting
Format:
Downloadable Digital File (PDF)
Accessibility:
Printable (individual pages, chapters, or entire manual), downloadable to tablet/smartphone
Engine Mechanical:
Engine assembly, disassembly, tuning, valve clearance, piston, rings, crankshaft, bearings, cylinder head, timing chain, lubrication system
Fuel System:
Carburetor overhaul and adjustment, fuel tank, fuel lines, fuel pump (if applicable)
Ignition System:
CDI unit, spark plugs, ignition timing, coils
Transmission And Drivetrain:
Gearbox overhaul, clutch operation and adjustment, final drive (chain and sprockets)
Cooling System:
Air cooling system (fin cleaning, airflow management)
Electrical System:
Wiring diagrams, lighting, battery, charging system (alternator, regulator), starter motor, fuses
Brakes:
Front and rear brake system (discs/drums), brake fluid, master cylinder, calipers, hydraulic lines, bleeding procedures
Suspension And Steering:
Front forks (oil change, seal replacement, damper adjustment), rear shock absorber, swingarm, steering head bearings
Wheels And Tires:
Tire selection, pressure, wheel bearing maintenance, spoke tension (if applicable)
Bodywork And Frame:
Frame inspection, body panel removal and installation, seat, fuel tank mounting
Controls:
Throttle, clutch, and brake lever adjustments, cable maintenance
Maintenance Procedures:
Regular servicing, oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, brake adjustments, air filter cleaning/replacement
Repair Procedures:
Engine rebuilds, carburetor tuning, electrical diagnostics, suspension overhauls, brake caliper rebuilds, wheel bearing replacement, clutch replacement
Troubleshooting:
Step-by-step diagnostic guides for common problems (starting issues, poor performance, electrical faults)
Disassembly And Assembly:
Detailed instructions for taking components apart and putting them back together correctly
Torque Specifications:
Crucial torque values for all critical fasteners to ensure proper assembly and prevent damage
Depth:
Comprehensive, from basic routine maintenance to complete engine and gearbox rebuilds
Diagnostics:
Detailed fault-finding procedures and diagnostic flowcharts
Illustrations:
Step-by-step pictures and diagrams to clarify procedures
Engine Type:
4-stroke, SOHC, Air-cooled
Bore X Stroke:
92.0 mm x 75.0 mm (Typical, refer to manual for precise variants)
Compression Ratio:
Typically 8.4:1 or similar (Refer to manual for exact spec)
Fuel System:
Mikuni VM34SS carburetor (Typical, refer to manual for specific variants)
Horsepower:
Approx. 30-35 HP (Varies by year and market, refer to manual)
Torque:
Specific figures to be found in manual, but designed for low-end torque
Carburetor Details:
Single Mikuni, specifications and tuning detailed in manual
Overall Length:
Varies by model year, refer to manual for precise specifications
Overall Width:
Varies by model year, refer to manual for precise specifications
Overall Height:
Varies by model year, refer to manual for precise specifications
Dry Weight:
Approximately 130-140 kg (Varies by model year, refer to manual)
Fuel Tank Capacity:
Approx. 10-13 Liters (Varies by model year, refer to manual)
Safety Certification:
Meets regulatory standards for its production era (specific certifications not detailed in product info)
Braking System:
Front disc brake, Rear drum brake (Typical, some later models may have disc rear), detailed in manual
Lighting System:
Headlight, taillight, turn signals, brake light, all detailed in electrical section of manual
Oil Change Interval:
Typically every 3,000-5,000 km or annually (Refer to manual for exact interval and engine oil type)
Air Filter Cleaning:
Regular inspection, cleaning/replacement recommended every 3,000-6,000 km or as needed based on riding conditions
Spark Plug Check:
Check and clean/replace spark plug every 5,000-10,000 km
Engine Oil Type:
API SE, SF or SG, SAE 10W-40 or 20W-50 (Consult manual for precise Suzuki recommendations)
Brake Fluid Type:
DOT 3 or DOT 4 (Consult manual for exact specification and replacement interval)
Fork Oil Type:
Specific viscosity (e.g., SAE 10W) and quantity detailed in manual
Carburetor Performance:
Mikuni VM series carburetors can be sensitive to tuning and may require periodic cleaning and adjustment for optimal performance, especially if fuel quality varies.
Suspension Wear:
Original fork seals and rear shock dampening can degrade over time, leading to leaks or a softer ride. Regular maintenance as per the manual is key.
Electrical Connections:
Age can lead to corroded electrical connectors or frayed wires. The manual's wiring diagrams are invaluable for troubleshooting.
