Suzuki DR800 1988-1997 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Suzuki Model: DR800 Generation Production Years: 1988-1997 Codes Engine Codes: DR800 (various internal codes based on year and market) 👋 Introduction Market Position Market Segment:...

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Type: Motorcycle

Vendor:

Sku: 433623

Tags: 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 DR Series DR800 Motorcycle Motorcycles Suzuki

Product variants

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DR800

Generation

Production Years:

1988-1997

Codes

Engine Codes:

DR800 (various internal codes based on year and market)

👋 Introduction

Market Position

Market Segment:

Large-displacement dual-sport motorcycle, known for its long-distance touring and off-road capability.

Competitive Analysis

Key Competitors:

Honda Africa Twin (early models), Yamaha Ténéré, BMW R80GS/R100GS.

Key Features

Motorcycle Characteristics:

Torquey large-bore single-cylinder engine, long-travel suspension, robust build for adventure touring, comfortable riding position.

Manual Utility

Target Audience:

DIY mechanics, home mechanics, professional technicians, owners seeking to maintain or repair their DR800.

📋 Manual Details

Coverage Areas

Vehicle Models Covered:

Suzuki DR800 (all variants for 1988-1997)

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, cylinder head, piston, crankshaft, camshaft, valve train, lubrication system, cooling system, fuel system (carburetor specifics), ignition system.

Drivetrain Systems:

Clutch, transmission (gearbox), final drive (chain and sprocket maintenance).

Chassis Systems:

Frame, front suspension (forks, steering stem), rear suspension (shock absorber, swingarm), wheels, tires, braking system (front and rear brake systems).

Electrical Systems:

Battery, charging system (stator, rectifier/regulator), starting system (starter motor, starter clutch), lighting system, ignition system components, wiring diagrams, fuses.

Bodywork And Trim:

Fairings, fuel tank, seat, fenders, exhaust system.

Procedures Included

Maintenance:

Periodic maintenance schedules, oil changes, filter replacements, lubrication points, chain adjustment, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Systematic fault diagnosis for engine performance, electrical issues, braking problems, and other common concerns.

Repair And Overhaul:

Detailed step-by-step procedures for disassembly, inspection, repair, and reassembly of all major components and systems.

Adjustments:

Carburetor synchronization and adjustment, valve clearance adjustment, brake lever and pedal free play, clutch cable adjustment, suspension adjustments.

Technical Depth

Depth Of Information:

Comprehensive; covers everything from routine maintenance to complete engine and transmission rebuilds. Includes specifications, tolerances, and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

Yes, all pages are printable.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

Software Requirements

Reader Software:

Adobe Reader

Compatibility

Operating Systems:

Windows, Mac, Linux OS

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, air-cooled, single-cylinder

Displacement:

779 cc (approximately)

Bore X Stroke:

Not specified in product info, but typically around 94.0 mm x 113.0 mm for this model.

Performance

Horsepower:

Approximately 50 HP (varies by market and tuning).

Torque:

Approximately 6.0 kg-m (varies by market and tuning).

Fuel System

Carburetor Configuration:

Dual Mikuni carburetors (e.g., VM36)

Fuel Capacity:

Typically 20-22 liters (approx. 5.3-5.8 US gallons).

Lubrication

Oil Type Recommendation:

Suzuki recommends specific grade motorcycle oil (e.g., 10W-40 or 20W-50 depending on climate) meeting API SE, SF, SG or higher.

Ignition

Ignition System:

Electronic ignition (CDI).

🔧 Transmission

Standard

Transmission Type:

5-speed manual constant mesh

Features

Clutch Type:

Wet multi-plate

Final Drive:

Chain drive

📐 Dimensions

Exterior

Overall Length:

Not explicitly stated in product data, but typical for large dual-sports.

Overall Width:

Not explicitly stated in product data.

Overall Height:

Not explicitly stated in product data.

Weights

Dry Weight:

Approximately 185 kg (408 lbs).

Wet Weight:

Approximately 205 kg (452 lbs).

🛡️ Safety Features

Ratings

Safety Features Integration:

Manual emphasizes proper maintenance and use of correct tools/procedures for safe operation. No electronic safety aids like ABS expected on these models.

Active Features

Active Safety Systems:

Effective braking system (disc brakes front and rear), responsive handling.

Passive Features

Passive Safety Features:

Robust frame construction, rider protection through motorcycle design.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (This is a mechanically focused motorcycle from the late 80s/early 90s, no integrated infotainment systems).

Driver Assistance

Driver Assistance Systems:

N/A (Basic motorcycle without electronic rider aids).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 4,000-6,000 km (2,500-3,700 miles) or annually. Check manual for exact intervals.

Valve Clearance Interval:

Typically every 10,000-15,000 km (6,200-9,300 miles). Manual provides precise intervals and procedures.

Fluid Specifications

Engine Oil Grade:

Refer to manual for specific viscosity (e.g., 10W-40, 20W-50) and API classification. Suzuki recommends genuine or equivalent oils.

Brake Fluid Type:

DOT 3 or DOT 4 recommended for hydraulic brake systems.

Coolant Type:

Not liquid-cooled; utilizes air cooling primarily.

Known Issues

Common Wear Items:

Cam chain tensioner (potential for noise), clutch wear, suspension seals, carburetor diaphragms.

Electrical Gremlins:

Age-related issues with wiring insulation, rectifier/regulator failures, starter solenoid issues.

📚 Vehicle History

Brand Heritage

Suzuki Offroad Legacy:

Suzuki has a long and successful history in off-road and dual-sport motorcycles, including the legendary DR series.

Model Evolution

Dr Series Development:

The DR800 (also known as DR750S initially) was Suzuki's answer to the growing demand for large-capacity adventure bikes, featuring one of the largest single-cylinder engines in production at its time.

Production

Manufacturing Location:

Primarily Japan.

🏆 Awards & Recognition

Recognitions

Model Specific Awards:

While specific awards for the DR800 are not commonly cited, the DR series is widely recognized for its reliability and capability in the adventure touring segment, paving the way for future models.