Suzuki Dr 600 Problems

The Suzuki DR600, a stalwart of the 1980s and early 90s dual-sport scene, is renowned for its robust engine and go-anywhere capability. However, like any motorcycle of its age, the DR600 is not without its quirks and potential pitfalls. Understanding these issues can help owners maintain their bikes, troubleshoot problems effectively, and ultimately keep these classic machines running strong for years to come.

The Beast's Achilles Heel: Starting Issues

Perhaps the most common complaint surrounding the DR600 revolves around its starting procedure, particularly when cold. This isn't usually a sign of a broken bike, but rather a characteristic of its carburetion and ignition system. The DR600 uses a dual-carburetor setup, with one carb responsible for low-speed running and the other kicking in at higher RPMs. Getting the mixture right, especially when cold, can be tricky.

What makes cold starting so difficult? The DR600 relies on a manual choke to enrich the fuel mixture for cold starts. However, over-choking can easily flood the engine, making it even harder to start. Furthermore, the aging ignition system can sometimes struggle to provide a strong enough spark, especially if the battery is weak or the spark plug is fouled.

Tips and tricks for conquering the cold start:

Fresh Fuel is Key: Old or stale fuel can significantly hinder starting. Always use fresh, high-quality gasoline. Consider adding a fuel stabilizer if the bike will be stored for extended periods.
Battery Health Matters: A weak battery can struggle to turn the engine over fast enough for a reliable start. Ensure the battery is fully charged and in good condition. Consider upgrading to a modern AGM battery for improved performance and longevity.
Master the Choke: Experiment to find the sweet spot for the choke. Start with the choke fully engaged, then gradually reduce it as the engine warms up. Listen to the engine – if it sounds like it's struggling or coughing, reduce the choke.
The Magic Decompression Lever: The DR600 has a manual decompression lever that makes starting easier by reducing compression. Use it! Pull the lever, kick the engine over a few times to clear any excess fuel, then release the lever and kick again with authority.
Check the Spark Plug: A fouled or worn spark plug can make starting nearly impossible. Remove the plug and inspect it. If it's black, oily, or damaged, replace it. Ensure the spark plug gap is set correctly.
Carburetor Cleaning: A dirty carburetor can cause all sorts of starting and running problems. If you're struggling with starting, consider cleaning the carburetors thoroughly. Pay close attention to the jets and passages.
Valve Adjustment: Incorrect valve clearances can also contribute to starting difficulties. Check and adjust the valve clearances according to the manufacturer's specifications.

The Carburetor Conundrum: More Than Just Cold Starts

While starting is the most common complaint, the DR600's dual-carburetor setup can also lead to other running issues. Synchronization between the two carburetors is crucial for smooth operation. If they're out of sync, the engine may run rough, hesitate during acceleration, or suffer from poor fuel economy.

Symptoms of carburetor problems:

Rough idling: The engine idles unevenly or stalls frequently.
Hesitation during acceleration: The engine stumbles or hesitates when you open the throttle.
Poor fuel economy: The bike is using more fuel than it should.
Black smoke from the exhaust: Indicates a rich fuel mixture.
Popping or backfiring: Indicates a lean fuel mixture.

Troubleshooting carburetor issues:

Check for air leaks: Air leaks can disrupt the fuel mixture and cause running problems. Inspect the intake manifolds and carburetor boots for cracks or leaks.
Clean the carburetors: As mentioned earlier, a thorough cleaning is essential.
Synchronize the carburetors: Carburetor synchronization ensures that both carburetors are delivering the correct amount of fuel at the same time. This requires special tools and knowledge, so it may be best left to a professional.
Check the float levels: Incorrect float levels can cause the carburetors to flood or starve the engine of fuel.

Electrical Gremlins: The Price of Age

Like all older motorcycles, the DR600 can suffer from electrical problems. Wiring can become brittle and corroded over time, leading to intermittent faults. Connectors can also become loose or corroded, causing voltage drops and other issues.

Common electrical problems:

Dim headlights: Indicates a weak battery, corroded connections, or a faulty charging system.
Intermittent starting problems: May be caused by a faulty starter relay, corroded connections, or a weak battery.
Blown fuses: Indicates a short circuit in the wiring.
Charging system problems: The battery is not being charged properly, leading to a dead battery.

Troubleshooting electrical problems:

Inspect the wiring: Look for frayed wires, corroded connections, and loose connectors.
Clean the connections: Clean all electrical connections with a wire brush or sandpaper. Apply dielectric grease to prevent corrosion.
Test the battery: Use a voltmeter to check the battery voltage. A fully charged battery should read around 12.6 volts.
Test the charging system: Use a voltmeter to check the charging voltage while the engine is running. The voltage should be between 13.5 and 14.5 volts.
Check the fuses: Replace any blown fuses with the correct amperage rating.

Suspension Woes: Bushings and Springs

The DR600's suspension was adequate for its time, but it may feel dated by modern standards. Over time, the suspension bushings can wear out, leading to sloppy handling. The springs can also sag, reducing ride height and bottoming out easily.

Symptoms of worn suspension:

Sloppy handling: The bike feels unstable or difficult to control.
Excessive bouncing: The suspension bounces excessively after hitting bumps.
Bottoming out: The suspension bottoms out easily, even on small bumps.
Leaking fork seals: Indicates worn fork seals.

Addressing suspension issues:

Replace worn bushings: Replacing the worn bushings can significantly improve handling.
Rebuild the forks: Rebuilding the forks with new seals, oil, and bushings can restore their performance.
Replace the springs: Replacing the springs with heavier-duty springs can improve ride height and prevent bottoming out. Consider progressive springs for a more comfortable ride.
Upgrade the rear shock: Upgrading to a modern aftermarket shock can significantly improve the bike's handling and comfort.

Frame Cracks: A Serious Concern

While the DR600 frame is generally robust, it's susceptible to cracking in certain areas, particularly around the steering head and rear subframe. This is more common on bikes that have been ridden hard off-road or have been involved in accidents.

How to check for frame cracks:

Visually inspect the frame: Carefully inspect the frame for any cracks, especially around the steering head, rear subframe, and engine mounts.
Use a magnifying glass: A magnifying glass can help you spot hairline cracks.
Clean the frame: Cleaning the frame before inspection can make it easier to see cracks.

If you find a crack:

Stop riding the bike immediately: Riding with a cracked frame is extremely dangerous.
Have the frame professionally repaired: A qualified welder can repair the crack.
Reinforce the frame: Consider reinforcing the frame in the affected area to prevent future cracks.

Keeping it Cool: Overheating Issues

The DR600 is an air-cooled engine, which means it relies on airflow to dissipate heat. In hot weather or during slow, technical riding, it can be prone to overheating.

Signs of overheating:

Loss of power: The engine may lose power or run rough.
Pinging or knocking: The engine may ping or knock, especially under load.
Oil leaks: Overheating can cause oil seals to fail, leading to oil leaks.
Steam or smoke from the engine: In severe cases, the engine may produce steam or smoke.

Preventing overheating:

Use high-quality oil: Use a high-quality motorcycle oil that is designed for air-cooled engines.
Keep the engine clean: A clean engine will dissipate heat more effectively.
Avoid prolonged idling: Prolonged idling can cause the engine to overheat.
Consider an oil cooler: An oil cooler can help to reduce oil temperatures and prevent overheating.
Ensure proper jetting: Lean jetting can cause the engine to run hot.

Frequently Asked Questions

Why is my DR600 so hard to start? Starting issues are common. Ensure fresh fuel, a strong battery, and proper choke technique. Carburetor cleaning and valve adjustments might also be necessary.
How often should I change the oil on my DR600? Change the oil every 1,500-2,000 miles, or more frequently if you ride in dusty or off-road conditions. Use a high-quality motorcycle oil designed for air-cooled engines.
Where can I find parts for my DR600? Parts can be found online at motorcycle parts retailers, eBay, and from specialized DR600/Suzuki forums. Some parts may require cross-referencing with other Suzuki models.
What is the best way to clean the carburetors on my DR600? Disassemble the carburetors carefully, clean all parts with carburetor cleaner, and reassemble with new gaskets and O-rings if needed. Pay close attention to the jets and passages.
Is the DR600 a good bike for beginners? While reliable, the DR600's starting quirks and relatively high seat height might make it less suitable for beginners. Smaller displacement dual-sports are often a better choice.

The End of the Road (But Not For Your DR)

Owning a Suzuki DR600 requires a bit of patience and understanding, but the rewards are well worth it. By addressing these common problems proactively and performing regular maintenance, you can keep your DR600 running strong and enjoy its legendary off-road capabilities for years to come.