Feel free to add your own knowledge of the bikes in the comment box below. This page will display the basic specifications of the bikes.
For more information, visit the discussion board.
Specs for Suzuki 370 single:
Engine and transmission
Displacement: 370.00 ccm (22.58 cubic inches)
Engine type: Single cylinder
Stroke: 4
Power: 27.00 HP (19.7 kW)) @ 7500 RPM
Compression: 8.9:1
Bore x stroke: 85.0 x 65.2 mm (3.3 x 2.6 inches)
Valves per cylinder: 2
Fuel control: OHC
Cooling system: Air
Gearbox: 5-speed
Final drive: Chain
Speed and acceleration
Top speed: 129.0 km/h (80.2 mph)
Specs for Suzuki 400 single:
Engine and transmission
Displacement: 396.00 ccm (24.16 cubic inches)
Engine type: Single cylinder
Stroke: 4
Power: 27.00 HP (19.7 kW)) @ 7500 RPM
Compression: 9.3:1
Bore x stroke: 88.0 x 65.2 mm (3.5 x 2.6 inches)
Valves per cylinder: 2
Fuel control: OHC
Cooling system: Air
Gearbox: 5-speed
Final drive: Chain
Speed and acceleration
Top speed: 128.0 km/h (79.5 mph)
Specs for Suzuki 500 single:
Engine and transmission
Displacement: 498.00 ccm (30.39 cubic inches)
Engine type: Single cylinder
Stroke: 4
Power: 27.00 HP (19.7 kW)) @ 6500 RPM
Compression: 8.7:1
Bore x stroke: 88.0 x 82.0 mm (3.5 x 3.2 inches)
Valves per cylinder: 4
Fuel control: OHC
Cooling system: Air
Gearbox: 5-speed
Final drive: Chain
Speed and acceleration
Top speed: 136.0 km/h (84.5 mph)
I am ‘restoring a 1981 dr400, I need a rectifier for it any ideas?
It won’t look as good as yours by the way!
By: Simon on April 14, 2008
at 4:09 pm
Hi Simon.
If you join up to the forum, you will get alot of help on issues such as that.
Rectifier’s can be found here: http://www.norbsa02.freeuk.com/goffyelectrex.htm.
I found this here: http://dr400.freeforums.org/regulator-and-recitifier-t91.html?highlight=rectifier
I think you would have to do some work to fit one of them though.
Theres alot of info on them at the moment though, so join up and do a search. Whos knows what you mite discover
Thanks
Matt
By: Matt on April 14, 2008
at 4:26 pm
I am restoring a DR500 1981, am looking for a kick-start, gear lever,front forks and yokes. if you know of anyone who can help me please let me know.
thanks
By: ray on July 24, 2008
at 3:53 pm
Hi guys new here, From New Zealand.
I have just picked up a DR 400 S I need to rebuild the front shocks, does any one know of an online manual that I can get the required Information from, or does any one have a Work shop manual that they can scan the relivant pages to Email me, Thanks Pete
By: Pete on July 27, 2008
at 8:35 am
hay im from nz too just wondering if you found any info / manuals on your DR400 ?
By: phil on December 12, 2009
at 5:39 am
hi guys please can any one tell the tappet clearances for inlet and exhaust can not find book for this bike so please help long suffering rattley engine,thanks martin
By: martin on July 29, 2008
at 10:54 pm
0.8mm set COLD when engine at TDC [take engine generator cover off and line up {turning clockwise} T mark on rotor with nipple at 9pm on crankcase face].
After loosening lock nut, gently tighten screw till just touching valve stem: then slacken screw by 1/8 of a turn and, holding the screw in position, tighten lock nut. This equals 0.8mm according to the Suzuki manual.
If any vertical movement is felt , redo as the clearance is too great.
All the above is nicked from the manual; me, I set the valves so I can just feel movement when the piston is near the top, but I use a copy of the Protec street and track cam and aftermarket Ford valve springs
By: cloggy on August 5, 2008
at 5:58 pm
Pete, your forks are mid late 70s motocross items.
Any old guy who worked on motocross stuff back in the day can fix them.
Ray, I think the 400 and possibly the 370 use the same kickstart.
The forks are the same as the USA dirt specific 400 I think and are nicked from the 77 ish RMs
Stuff comes up on UK ebay fairly often but less so in USA
By: cloggy on August 5, 2008
at 9:20 pm
Im in the middle of a SP370 restoration. Just discovered my fuel tank has a small amount of rust in one corner and there a tiny pin hole. Anyone know here I can get a replacement fuel tank or get it fixed?
Thanks
Clive
By: Clive Palmer on August 10, 2008
at 10:25 pm
My SP370 has had the resistor,battery and rectifier replaced, and I cant think of any other lectrical components to replace. My problem is that it is kicking out 17 volts @ 5000 rpm and is blowing all the bulbs and has fried the battery. I dont think that it has been converted to a 12v system as the magneto coils look original. I have checked all the wiring and is as it should be…..Has anybody got any ideas? as winter will be around the corner and I shall need my lights.
By: Steff on August 16, 2008
at 10:47 am
Can anyone tell me if i can use a CDI from an DR 400 on my DR 500. THANKYOU.
By: DEL on August 17, 2008
at 1:52 am
does anyone out there remember the White Brothers moto-cross bike in the 80’s. it was based on a DR 400, motor was tuned and taken out to 420cc, steering angle altered,motor up in frame a smidgeon, footrests highered 3/4″ supertrap exhaust, simon’s fork’s, ohlin shock’s.and their own banana swinging arm. I loved it and want to build one. White Bros have no information, what about you lot?any photo’s etc, I have one feature from an old mag.
By: DEL on August 17, 2008
at 2:04 am
I lost my way around the site but I’m looking for shocks rear, service manual,and I think somthing else. my bike is 1981 sp 500 starts good runs very well untill past mid range then breaks up . I believe I need to adjust spark timing, this started after changing cam chain bacause it was stretched. I did line up crank&cam & turn over 2 revolutions and it all lined up again
By: larry-firestar on September 13, 2008
at 3:01 am
Hi Dell the CDI unit off a DR400 is a different part number to the DR500 so I would assume it will not run properly with it.
Mike
By: mike hattemore on September 14, 2008
at 10:47 am
thank’s mike, Does anyone reading this have a cdi for a Dr 500 and willing to sell. cheers Del
By: DEL on September 17, 2008
at 8:04 pm
Hi, LANCE HERE FROM NEW ZEALAND, I AM REBUILDING A 1979 DR370 AND WANT TO MAKE IT LOOK LIKE A DR400. PARTS I AM LOOKING FOR ARE , TANK, FRONT & REAR GUARDS, SIDE COVERS,FRONT & REAR SPROCKETS ,R/H FOOT REST,REAR SHOCKS AND ANY OTHER PARTS YOU MAY HAVE, HOPE YOU CAN HELP
By: lance on September 28, 2008
at 11:38 pm
Hey,
I am looking for a repair manual for a 1981DR 500 suzuki. If anyone knows where I can get one please let me know.
Thanks
By: Paul Matiash on October 20, 2008
at 2:23 am
I have a DR500 manual I can email it to any one who needs it
By: Ray Crutchley on October 25, 2008
at 7:54 pm
I need to do some carb work on my DR500 and a manual would be a life saver. If you could e-mail me a copy it would be greatly appreciated. thanks
By: Gary Davenport on May 5, 2009
at 12:38 am
i need a 1981 dr 500s manual also would that be a problem?
By: jared petersen on May 17, 2009
at 6:41 am
Is this offer still available? I live on a farm and the manual would be a godsend.
By: Ronnie Jack on July 29, 2009
at 4:44 pm
can you send me a copy of how to time and set valves,it was in parts when i got it ,1981 sp 500 they tell me it is the same as dr500,thank you in advance jim spencer pekin il 61554
By: jim on September 4, 2009
at 5:02 pm
Would it be possible to E-Mail me a copy of the DR500 workshop manual also.
I have tried everywhere to get one.
Thanks and Regars Norm
By: Stormster58 on October 12, 2009
at 9:29 am
Wonderful, will you please email me the manual for my Suzuki DR 500
By: Andre on October 13, 2009
at 8:52 am
Would very much appreciate a copy of the w/shop manual for the DR500 please.
By: Eben Bosman on November 3, 2009
at 8:05 am
Hi, my name i Carl, i´m from Sweden. Would it be possible to E-Mail me a copy of the DR500 workshop manual also.
Thanks
By: Karl Lofberg on November 8, 2009
at 1:09 am
Mate i have just got a dr 500 s and if the offer of the work shop manual is still open i would love one!
By: Ian on November 22, 2009
at 4:07 am
If you could please send the dr 500 manual that would be amazing.
By: Matt M on November 25, 2009
at 5:41 am
IF YOU COULD SEND ME A COPY OF A MANUAL FOR SP500 OR DR5OO, IT WOULD BE AWESOME.
THANKS
By: NEAL on December 17, 2009
at 11:51 pm
I have an original service manual for a 1981 DR500.
I’ll see if I can scan it into computer soon and upload it so everyone can download it.
By: Joshua Vandal on December 18, 2009
at 4:25 am
I have a DR400s but i find it really hard to start. Has anyone got any idea how i can start it? Thanks
By: Mark on November 10, 2008
at 11:10 pm
how well does it run when it starts?
By: Matt on November 10, 2008
at 11:20 pm
Its been so long since it ran i cant really remember. I use to find it hard to start when it was hot but now its colds and dont really want to start. The last time i had it running it ran for a bit then died. any ideas?
By: Mark on November 16, 2008
at 1:57 pm
Hello, I’m also seeking for a cdi for a dr500?
Anyone who can help me?
Thanks !!
By: Koen on December 12, 2008
at 4:21 pm
hi,
I´m from austria, and I will start to restore my DR500s a 1981.
I am looking for a repair work (factory) manual for it.
Does anyone can send me something like that?
Thanks
By: ross on December 18, 2008
at 5:47 pm
Hi Ross
Join/Check the forum. There are guys on there who i believe can send you copies
Thanks alot
Matt
By: Matt on December 18, 2008
at 9:23 pm
Steff
if only one output wire from the generator is properly connected the other runs over 12 volts.
Del
the White Bros bike had a 36mm mikuni roundslide carb [start with TT500 settings, they are around on various XT/TT sites] It had a White Bros profab made swing arm that closely resembled the aftermarket one for XTs and are very very rare
the piston was a wiseco item, also unobtainable, and the cam was a |White Bros race grind, used with aftermarket springs
You can get a cam and spring set from Megacycle.
The Dirtbike WB bike used 1979RM 38mm forks, the wheels go straight in once you have the yokes bored 2mm. There doesn’t seem to be another piston that fits, maybe a Quad one?
I don’t think they changed the engine position or head angle, I think that was the result of more suspension. If you have the article to prove me wrong I’d love to see it.
Larry
are you sure your cam isn’t one tooth out?
Lance
“Japanese Bike Dismantlers” work out of New Zealand
Mark
Provided your motor is sound and you haven’t got an intake air leak there are two thing that will stop your bike from starting reliably
1 The little jet way underneath and engine side of the carb can fill up with crap, the manual doesn’t show it. My DR was almost impossible to start till I got the carb cleaned, had to pour fuel down the plug thread
2 If it kicks back then the advance retard electronic box may have packed sticking on full advance
By: cloggy on January 2, 2009
at 7:47 pm
thank’s for your response cloggy, yes i still have article on white bros DR crosser. may have changed spec for another year,my article list’s changes made to frame and picture show’s simon’s fork’s fitted. it’s taken me ages to find these so this is the spec i’ll be following.i cant find a banana swinging arm yet but have a 78 RM one till a closer or correct one becomes available. article is from a cycle world mag,see if i can find year of mag dont know how to show mine, mind you if I did you’d all want one! cheer’s Del
By: DEL on January 30, 2009
at 2:11 am
hi again cloggy, I have found the article about white bros suzuki DR 400 crosser. I have to stand corrected regarding title of mag feature appeared in. It was featured in Motocross Action on Feb 1981. Article was written by Dennis Cox and heading was THUMP THUMP Bikes of the four stroke nationals. Unfortunetly the photo is in Black and White but it was enough for me to try and recreate this lovely looking bike,I would love a colour photo, fat chance eh? just have to get on and build mine. cheer’s Del
By: DEL on January 31, 2009
at 3:17 am
cloggy forgot to mention, article states steering angle steepened by one degree,lowered motor in frame one inch, and raised footrest’s by 3/4″ all very slight mod’s but need to be done by me to ensure my bike end’s up as close as, It’s got me hook line and sinker this project so much so that I bought a fully restored RM 400 N from a dealer just to rob it of it’s Simon’s Fork’s, I had looked elsewhere for a long time for some and began to get worried telling myself that a pair would never come along, once I’d convinced myself this was the case I just had to get some,
By: DEL on January 31, 2009
at 3:38 am
At 17 volts it looks as if yor coils have been wired up incorrectly, the max from the one lighting coil shoud be 8-9 volts. when the 2 coils are wired in series it will be double that.
The ingnition coil shoud have finer wires than the lighting coil, if they are identical one has been changed. HTH
By: Bernhard on February 28, 2009
at 4:49 pm
I just bought DirtBikes original article on the DR400
Basically they said the DR370 frame and suspension was pants, so they’d grafted bits of RM frame to make it handle. They said the 400 handled really well, except in tight going, but the suspension was still weak
Somewhere I’ve also got the 2nd of two hop up articles on the DR400 that they did, that was in ‘80
You seem to have a further development Del
I know the head angle is too slack standard but thanks for saying just how much they steepened it. I don’t think there’s much room to steepen it any more before the wheel hits the frame. One mod is to use an 1978.5 RMC swingarm
An engineer charged an hour’s labour to internally sleeve and very slightly broaden the pivot tube, so that standard bearings fit. That may be what you already have. I now have to modify the wheel pivot slots before it will fit.
The PE 250/400 swingarm fits with no mods at all but the shock mountings are very far forward. It’s also about an inch or two longer. The RMC is exactly the same length as stock. Really the only practical advantage of the RMC is that it is lighter and you can use a readily available 395mm shock length. Once you’ve added more front suspension the standard steel swingarm needs 16.5″ shocks to stop it becoming even more of a barge, I got Falcon to make a decent pair.
Apparently a KLX twinshock swingarm also fits.
There’s lots of info on ozvmx
By: cloggy on March 7, 2009
at 11:16 pm
I am ‘restoring a 1980 dr400, I need a work shop maual any ideas?
PS I live in the UK
By: Mike Pratt on March 17, 2009
at 11:00 am
They turn up regularly on UK Ebay
By: cloggy on June 22, 2009
at 5:45 pm
Hi all,
I have an ‘80 SP400 that was given to me that I have been tinkering with. I purchased another used carb on eBay and made one ‘good’ carb out of parts of the old and new and it seems to run good, but rich. I can’t seem to find where the air/fuel mixture screw is. One carb has a screw in front of slide, on top of carb, the other one doesn’t. Is that it? Also, I am looking to sell this bike, so if there are any takers, let me know. If i get enough out of the parts, I would be willing to part it out.
larry-firestar, I have rear shocks if you want ‘em.
thanks!
By: Wes on March 25, 2009
at 6:17 pm
HI Guys,
I have an english manual for the dr350 covering most models. I also have a German manual for a dr600s 1985. I’ve done lots of repairs to this bike having bought it off ebay. It is a great old single dirt bike and someone has fitted a flat slide tm series mikuni instead of the oem which was a vm38 round slide.
Can any one scribble a few translations from my german manul in a few key areas if I sent it over bittorrent? Cam chain section in particular. Happy to share these manuals
RF
By: Rabbit_FighterF on April 4, 2009
at 8:23 am
I have a 1978 400sp and i tuke the carb in to get clean and stuff now that i put it back on this year the bike has lost a lot of power and speed when i tuke is out for a test run 80km was the fast i got it up to any ideas on how i can fix this.
By: Ryan on August 29, 2009
at 12:01 am
Yes, learn to spell.
By: cloggy on November 8, 2009
at 10:33 pm
And replace the diaphragm if it’s still a listed part. Before that take the carb to a decent bike shop, that actually has a good reputation for engine rebiulds, and ask them to clean the carb.
By: cloggy on November 8, 2009
at 11:18 pm
Hi, anyone still here
just bought a 1980 dr400 and want to upgrade the forks. whats the best easiest way to go.
cheers
Richard
By: richard on September 10, 2009
at 12:50 am
The standard forks are wimpy
In the USA the same frame with 9″ forks and longer shocks. Still not great as they are 36mm. I had 10″ PE175 36mm forks on and sold them as offroad at [not much] speed they wandered around a bit too much for my liking. You can get the whole front end off another bike, say a DR350, but the head stock on the 400 is pretty tall so you may need to get a steerer machined up. I’ve just had that done for a XR600 front end I’ve shoved on another frame. If you can get something with a long enough steerer and compatible bearings pay more for it if you have to, you’ll save in the long run.
The easiest fork is a 78 to 80 38mm RM item but these don’t often turn up. This fork will take the DR front wheel. I got a later 81 and put a tls RM500 brake on it, but a decent machinist will turn you up some sleeves/spacers to fit the smaller spindled DR wheel into the later 4 bolt clamp forks.
If you get 38mm you can have your 36mm yokes bored out 2mm to accept the forks [that's all Suzuki seem to have done] or press the steerer out and press it into the the 38mm matching yokes. The later ones are deeper so the DR steerer only just threads up but mine is race tested.
There is also a 81 on 43mm fork. This has the same wheels as the 81 on 38 but you will need the yokes. You could also get something from say an XT/TT 600. The advantage of getting something from a hefty trailbike is that the springs might be about right. I had to find a heavyweight set for the 38s and it was neither easy or cheap.
By: cloggy on November 8, 2009
at 10:59 pm
I just replaced the clutches (original) in my ‘81 DR500. I put it back together the right way, but the kickstarters all fucked up, don’t know what happened. Didn’t go near the kickstart assy. ???help???
By: Joshua Vandal on December 13, 2009
at 2:57 am
IF YOU COULD SEND ME A COPY OF A MANUAL FOR SP500 OR DR5OO, IT WOULD BE AWESOME.
THANKS
ati
By: ati on December 18, 2009
at 9:07 pm
I am a owner of one DR500S 1982 an I was trying to find a workshop manual for this bike in the internet and I can not find one. if someone who have it could sent it to me trough e-mail I will be appreciate it.
By: Bill on December 19, 2009
at 11:05 am
I have a 1980 DR 400n was wondering if any one knew how the timing marks under the case and on the sprokets went.
By: Derek Smith on December 21, 2009
at 6:16 pm