DR 500 PARTS '81-'83

[WillsRD]

G'day All,
looking for a good stock or aftermarket exhaust system for DR offroader project. I'm in Sydney so postage might be an issue

Everything considered. Any other unwanted parts also condsidered

thanks!

[oldfart]

Made my own  for less than $100-00 using mandrel bends

[WillsRD]

Made my own  for less than $100-00 using mandrel bends

There is a few car exhaust guys around home who might do one, but they would charge an arm and a leg! I'll keep an eye on Ebay and see what comes up. Unfortunately I don't have the facilities at home to make one :'(


Cheers.

[oldfart]

 Will keep an eye out ....Dr 400 header is close but not the same .

[DR]

what's the diff with the DR400 pipe Stew? If it is only minor would it be worth grabbing a 400 pipe if it came along at the right price?

[WillsRD]

Will keep an eye out ....Dr 400 header is close but not the same .

Are the 400 headers smaller diameter? would it be possible to use just the first 40 or 50mm of the original 500 header inserted into the 400 pipe? I just picked up a stock 400 muffler that I should be able to get modified to fit whatever pipe I can eventually get. It looks as though the whole system on my DR is 'homemade' I'll take the whole pipe off Sun weather permitting and have a good look at it. Maybe the engine pipe can be salvaged? Looks absolutely disgusting, just like iron ore

cheers.

[oldfart]

Pipe Id is same ( header )  just the curve that comes out of header and loops around frame ...just a visual thing ,  they do fit .
And yes I have a header FOR FREE ....30mm missing ( port flange and ring )  no make that 2 of

Muffers above swing arm are the same

[WillsRD]

Pipe Id is same ( header )  just the curve that comes out of header and loops around frame ...just a visual thing ,  they do fit .
And yes I have a header FOR FREE ....30mm missing ( port flange and ring )  no make that 2 of

Muffers above swing arm are the same

For free oldfart? where are you?
I dismantled bits of the bike today to repaint some parts, and thought I'd remove the bodgy exhaust and have a better look at it. Bad decision! Turns out the upper exhaust flange drilling in the head is stripped :'( I wondered why there was an oversize nut being used as a spacer on the bolt The head will have to come off now and I'll have to have the hole drilled and helicoiled. I'll drop the rolling chassis down to the mechanic's tomorrow arvo. Interestingly, the exhaust still won't come off with the head in place as there isn't enough room to manoeuvre the complete pipe and muffler out of the frame. It's been welded together 'in situ' by the look of it.
Now I need to wait and see what the thread repair will cost me my cheap offroader mightn't be so cheap after all

Cheers 

[oldfart]

Whoa hold your horses .   Exhaust bolt if drilled too deep will end up in oil gallery. It should be a stud
 When taking head off taking note of copper washers and dome nuts plus rubber bung.
Exhaust system has a slip joint @ first muffler . If it is welded cut at just past 2 nuts( kick lever ) on side pipe and ad a joiner
Mate it won't come out as one       
I live on the Gold Coast  (nothern end ) and will be at "The Nationals"   
Go to  http://www.alpha-sports.com/suzuki_parts.htm     and look up 1981   Dr 500   and use it as a reference

[WillsRD]

Thanks oldfart. I thought it was odd that the lower exhaust flange mount was a stud, and the top was a bolt! I'll take the DR to the mechanics and have it professionally repaired.  I'm a two stroke person and these cams, oil galleries, cam chains and valves scare the bejeezuz outta me!

cheers

[DR500]

This is a link for new system.http://www.musket.co.nz/index.asp.Not sure of the cost.

[oldfart]

4 bangers are easy, It's the 2 smokers that shit me       pretty straight forward and remembering where they go back that catches most people out .
Remind your mechanic not to go any deeper with thread ( put a ball bearing in the hole ) and use it as a stop when drilling new hole for Heli coil   ( remove ball before installing H/C )        that way you shouldn't have to take head off and save a few bucks    

[bigk]

Do these things make reasonable vmx'ers? I have a one owner '81 DR500 with 18,000klms on the clock coming and a mate is thinking about riding it in vmx.
Cheers,
K

[oldfart]

HEAVY with tree climbing grunt .....     Tony  chime in here

[WillsRD]

Thanks oldfart. I'll take the bike down on the trailer so the mechanic can have a look. He said he might be able to fit the Helicoil without removing the engine from the frame. Fingers crossed!

I'll have to cut the pipe where the join should be at the header to get the @#$%^^ thing off, looks like it grew there


cheers