Suzuki Dr 800 Problems

The Suzuki DR 800, affectionately nicknamed the "DR Big," is a legendary adventure bike known for its distinctive styling, powerful single-cylinder engine, and go-anywhere capability. However, like any motorcycle, especially one with a production run spanning several decades, the DR 800 isn't without its quirks and potential problems. Understanding these issues is crucial for prospective buyers and current owners alike, allowing them to keep their Bigs running strong for years to come.

Is the DR Big Really That Big of a Problem? Common Issues to Watch Out For

While the DR 800 enjoys a loyal following due to its ruggedness and character, certain issues pop up more frequently than others. Knowing about these beforehand can save you time, money, and frustration down the road.

The Dreaded Cam Chain Tensioner: This is arguably the most notorious issue plaguing the DR 800. The automatic cam chain tensioner is known to fail, leading to a loose cam chain and potentially serious engine damage. Replacing it with a manual cam chain tensioner is a highly recommended preventative measure. This allows you to manually adjust the tension, ensuring the cam chain remains properly tightened.
Electrical Gremlins: Older bikes, in general, are prone to electrical issues, and the DR 800 is no exception. Common culprits include:
- Wiring Harness Issues: The wiring harness can become brittle and cracked over time, leading to shorts and intermittent problems. Inspecting the harness, especially in high-stress areas like around the steering head, is essential.
- Charging System Problems: The regulator/rectifier and stator are known to fail. Symptoms include a weak battery, difficulty starting, and dimming lights. Testing these components regularly is a good idea.
- Ignition Coil Failures: The ignition coil can also fail, leading to a no-spark condition or a weak spark.
Fuel System Foibles: The DR 800 uses a carburetor, which, while reliable in principle, can suffer from various issues:
- Carburetor Clogging: Dirt and debris can clog the jets and passages in the carburetor, leading to poor performance, rough idling, and difficulty starting. Regular cleaning and maintenance are crucial.
- Diaphragm Issues: The diaphragm in the carburetor can become cracked or damaged, affecting fuel delivery and performance.
- Fuel Petcock Problems: The fuel petcock can leak or become clogged, restricting fuel flow to the carburetor.
Oil Leaks: Oil leaks are a common issue on older engines, and the DR 800 is no different. Common leak points include:
- Valve Cover Gasket: The valve cover gasket can become brittle and leak oil.
- Base Gasket: The base gasket between the cylinder and the engine case can also leak.
- Oil Seals: Oil seals around the crankshaft and camshaft can dry out and leak.
Exhaust System Cracks: The exhaust header pipes are prone to cracking, especially around the welds. This can lead to exhaust leaks and reduced performance. Regularly inspect the exhaust system for cracks and repair them promptly.

Diving Deeper: Specific Problem Areas and Solutions

Let's take a closer look at some of the most common DR 800 problems and explore potential solutions in more detail.

The Cam Chain Tensioner Nightmare:

As mentioned earlier, the automatic cam chain tensioner is a major weak point. The stock tensioner relies on a spring-loaded mechanism that can fail, allowing the cam chain to become loose. This can lead to:

Increased Engine Noise: A rattling or slapping noise from the engine is a common symptom.
Poor Engine Performance: A loose cam chain can affect valve timing, leading to reduced power and poor fuel economy.
Engine Damage: If left unchecked, a loose cam chain can jump teeth on the camshaft sprockets, causing serious engine damage, including bent valves and piston damage.

The Solution: Replace the automatic tensioner with a manual cam chain tensioner. Several aftermarket options are available. Installing a manual tensioner allows you to adjust the cam chain tension manually, ensuring it remains properly tightened. Regularly checking and adjusting the tension is crucial.

Tackling Those Tricky Electrical Issues:

Electrical problems can be frustrating to diagnose and repair. Here are some tips for troubleshooting common electrical issues on the DR 800:

Start with the Basics: Check the battery voltage and connections. Ensure the battery is fully charged and the connections are clean and tight.
Inspect the Wiring Harness: Look for any signs of damage, such as cracked insulation, frayed wires, or corroded connectors. Pay close attention to areas where the harness is subjected to stress, such as around the steering head.
Test the Charging System: Use a multimeter to test the output of the stator and the regulator/rectifier. Refer to the service manual for the correct testing procedures.
Check the Ignition System: Test the ignition coil for proper resistance. Check the spark plug for signs of wear or fouling.
Use a Wiring Diagram: A wiring diagram is essential for tracing circuits and identifying potential problems.

Fuel System Fiddling: Carburetor Care

Keeping the carburetor clean and properly tuned is essential for optimal performance. Here's how to address common carburetor issues:

Regular Cleaning: Disassemble the carburetor and clean all the jets, passages, and components with carburetor cleaner. Use compressed air to blow out any debris.
Check the Diaphragm: Inspect the diaphragm for cracks or damage. Replace it if necessary.
Adjust the Idle Speed and Mixture: Use the idle speed screw and the mixture screw to adjust the idle speed and mixture for smooth idling and optimal performance. Refer to the service manual for the correct settings.
Inspect the Fuel Petcock: Check the fuel petcock for leaks or clogs. Clean or replace it as needed.
Consider an Aftermarket Carburetor: Some owners opt to replace the stock carburetor with an aftermarket option, such as a Mikuni TM40, for improved performance and reliability.

Oiling the Wheels (Without the Leaks): Addressing Oil Leaks

Oil leaks can be messy and can indicate underlying problems. Here's how to address common oil leaks on the DR 800:

Identify the Source: Clean the engine thoroughly and then run it to identify the source of the leak.
Replace Gaskets and Seals: Replace any leaking gaskets or seals. Use high-quality aftermarket gaskets and seals.
Tighten Bolts: Ensure all the bolts are properly tightened. Refer to the service manual for the correct torque specifications.
Check for Damage: Inspect the engine case for any cracks or damage that could be causing the leak.

Exhausting Options: Repairing Exhaust Cracks

Cracked exhaust header pipes can lead to exhaust leaks and reduced performance. Here's how to address this issue:

Welding: Small cracks can often be repaired by welding.
Replacement: If the cracks are severe or the exhaust system is heavily corroded, it may be necessary to replace the entire exhaust system.

Preventative Maintenance: The Key to a Happy DR Big

The best way to avoid problems with your DR 800 is to perform regular preventative maintenance. This includes:

Regular Oil Changes: Change the oil and filter every 3,000 miles or six months, whichever comes first.
Air Filter Cleaning: Clean or replace the air filter regularly.
Chain Maintenance: Keep the chain clean, lubricated, and properly adjusted.
Brake Maintenance: Inspect the brake pads and rotors regularly and replace them as needed.
Tire Maintenance: Check the tire pressure regularly and inspect the tires for wear and damage.
Valve Adjustments: Check and adjust the valve clearances regularly.
Carburetor Cleaning: Clean the carburetor regularly.
Cam Chain Tensioner Inspection: Regularly inspect and adjust the cam chain tensioner (if you have a manual tensioner).
Electrical System Inspection: Inspect the wiring harness and electrical components regularly.

Finding Parts and Resources

Finding parts for the DR 800 can sometimes be challenging, especially for older models. Here are some resources to help you find the parts you need:

Suzuki Dealers: Suzuki dealers can still supply some parts for the DR 800.
Aftermarket Parts Suppliers: Many aftermarket parts suppliers specialize in parts for older motorcycles.
Online Forums and Communities: Online forums and communities dedicated to the DR 800 are a great resource for finding parts and information.
eBay: eBay can be a good source for used and NOS (new old stock) parts.

Frequently Asked Questions

Why is my DR 800 hard to start? Common causes include a dirty carburetor, a weak battery, or a faulty ignition coil.
What is the best way to deal with the cam chain tensioner issue? Replacing the automatic tensioner with a manual one is the most reliable long-term solution.
Where can I find parts for my DR 800? Suzuki dealers, aftermarket parts suppliers, online forums, and eBay are good sources.
How often should I change the oil on my DR 800? Every 3,000 miles or six months, whichever comes first.
Is the DR 800 a reliable bike? With proper maintenance and attention to known issues, the DR 800 can be a very reliable adventure bike.

Final Thoughts

The Suzuki DR 800, despite its potential problems, remains a beloved motorcycle for its unique character and off-road capabilities. By understanding the common issues and performing regular preventative maintenance, you can keep your DR Big running strong and enjoy many years of adventure riding. Consider investing in a manual cam chain tensioner for peace of mind.