Suzuki DR500
1981—1983

I have tried to tell DR 500 model history on this page as I know it. This page is still under construction. I would be grateful of any contributions — sales brochures, magazine ads, magazine articles, pictures, specs, facts, corrections etc. Please scan the material in JPEG format (large enough that all the details are visible) and send them to me. Please tell me the source and the publication date if possible. If you send me pictures of your own bike, please follow these instructions.

The Suzuki DR500 was produced from 1981 to 1983 as a high-torque, four-stroke dual-sport motorcycle designed to compete with models like the Yamaha XT500. Introduced in 1981, the DR500 featured an entirely new air-cooled 498cc single-cylinder, four-valve engine (88 mm bore and 82 mm stroke). It utilized Suzuki’s patented TSCC (Twin Swirl Combustion Chamber) design, which split the combustion chamber into two domes with a central spark plug for faster and cleaner fuel burn. Dual counterbalancers were integrated to smooth out engine vibrations. The engine generated between 32.5 to 36 horsepower (different numbers were given in different countries) and strong low-end torque. There was no electric starter. The DR500, with a single-cylinder 498cc motor, was a handful with just a kick-start to get things rolling.

1981 Suzuki year code: X

In USA, 1981 Suzuki DR500 featured distinct white bodywork with red and orange stripes and a signature square headlight. However, in other parts of the world the DR500 red and orange stripes were changed to diufferent shades of blue instead. Also, a slightly different model, DR500S, was sold in some countries. The DR500S had rear mirrors, traditional circular with chrome framing and a grab rail behind the seat (not in every country). The 1981 Suzuki DR500 color options were White and Yellow.

1981 Suzuki DR500S, White with blue stripes

1981 Suzuki DR 500 Overall Length: 2 195 mm (86.4 in) Overall Width: 865 mm (34.1 in) Overall Height: 1 215 mm (47.8 in) Seat Height: 870 mm (34.3 in) Wheelbase: 1 460 mm (57.5 in) Ground Clearance: 290 mm (11.4 in) Dry Weight: 128 kg (282 lbs) Engine: Air-cooled 498 cc single SOHC 4-stroke. 32.5 hp (23.9 kW) @ 6 500 rpm, 37.4 Nm (3.81 kg-m) @ 5 700 rpm Here's even larger picture.

1981 DR500 specifications Overall length: 2 195 mm (86.4 in) Overall width: 865 mm (34.1 in) Overall height: 1 215 mm (47.8 in) Wheelbase: 1 460 mm (57.5 in) Ground clearance: 290 mm (11.4 in) Dry weight: 128 kg (282 lbs) Engine type: Single cylinder four-stroke, SOHC, TSCC (Twin Swirl Combustion Chamber), 4 valves Displacement: 498 cc Bore x stroke: 88.0 mm x 82.0 mm Compression ratio: 8.7:1 Carburetor: Mikuni VM35SS Starter system: Primary kick Ingition type: PEI (Pointless Electronic Ignition) Transmission: 5-speed constant mesh Lubrication system: Wet sump Fuel tank capacity: 9.0 lit (2.4 gal) Engine oil capacity: 1.6 lit (1.7 qt) Suspension Front fork: Oil-damped. Leading axle, 9.1 inch travel Rear swing arm: Aluminum box type. Gas-oil, remote reservoir shocks, 5-load settings. 8-5 inch wheel travel Front brake: Internal expanding Rear brake: Internal expanding, full floating Front tire: 3.00-21-4PR full knobby Rear tire: 5.10-18-4PR full knobby

1982 Suzuki year code: Z

Mechanically the 1982 Suzuki DR500 remained unchaged but received different striping and colors. In some countries you could buy the DR500S model with gold-anodized wheels. In Italy, the 1982 Suzuki DR500S was sold in Black, Yellow, and Red liveries.

1982 Suzuki DR500, White with blue stripes

1982 Suzuki DR 500 Overall Length: 2 200 mm (86.6 in) Overall Width: 870 mm (34.43 in) Overall Height: 1 220 mm (48.0 in) Seat Height: 875 mm (34.4 in) Wheelbase: 1 465 mm (57.7 in) Ground Clearance: 270 mm (10.6 in) Dry Weight: 128 kg (282 lbs) Engine: Air-cooled 498 cc single SOHC 4-stroke. 36 hp (26 kW) @ 6 500 rpm, 42 Nm (4.3 kg-m) @ 5 000 rpm Click on the image for larger format.

1982 Suzuki DR 500 S Overall Length: 2 200 mm (86.6 in) Overall Width: 870 mm (34.43 in) Overall Height: 1 220 mm (48.0 in) Seat Height: 875 mm (34.4 in) Wheelbase: 1 465 mm (57.7 in) Ground Clearance: 270 mm (10.6 in) Dry Weight: 128 kg (282 lbs) Engine: Air-cooled 498 cc single SOHC 4-stroke. 36 hp (26 kW) @ 6 500 rpm, 42 Nm (4.3 kg-m) @ 5 000 rpm Click on the image for larger format.

1982 Suzuki DR500S Specifications (Finland)
Overall length:
Overall width:
Overall height:
Seat height:	870 mm (34.3 in)
Wheelbase:	1465 mm (57.7 in) +-15 mm
Ground clearance:	270 mm (10.6 in.)
Dry mass (weight):	128 kg (282 lbs.)
Engine:	Air-cooled single cylinder 4-stroke, TSCC
Valve system :	SOHC, 4 valves per cylinder
Maximum power output:	36.5 hp (27 kW)/ 6.500 rpm
Maximum torque:	43 Nm (4,4 kpm)/ 5.700 rpm
Bore:	88.0 mm (3.465 in)
Stroke:	82.0 mm (3.228 in)
Piston displacement:	498 cc
Compression ratio:	8.9 :1
Carburetor :	Mikuni 35SS slingshot
Air cleaner type:	Polyurethan foam element
Generator:	6V 50W
Battery:	None
Ignition:	Suzuki PEI pointless
Head light:	15/15 W
Starter system:	Primary kick
Lubrication system:	Wet sump
Clutch type:	Wet multi-plate
Transmission type:	5-speed constant mesh
Gearshift pattern:	1-down, 5-up
Primary drive ratio:	2.39: 1
Gear ratios
1st gear:	2.42: 1
2nd gear:	1.63: 1
3rd gear:	1.63: 1
4th gear:	1.00: 1
5th gear:	0.83: 1
6th gear:	22/23
Final drive ratio:	3.36: 1
Final drive:	0-ring chain
Front suspension:	Telescopic Showa 36mm, oil damped
Rear suspension:	Swinging arm , adjustable spring preload, gas/oil damped, adjustable compression damping
Front suspension stroke:	230 mm (9.1 in.)
Rear suspension travel:	220 mm (8.7 in.)
Front brake:	Drum brake, 150mm diameter
Rear brake:	Drum brake, 150mm diameter
Front tire size:	3.00-21
Rear tire size:	5.10-18 (4.60-18 in Japan)
Fuel tank capacity incl. reserve:	9 liter (2.4 US gal.)
Reserve:	2 liter (0.5 US gal.)
Recommended retail price in Finland:	17,200 FIM (November 1982)

1983 Suzuki year code: D

1983 was the final year of production for the Suzuki DR500. A notable high point in motorsport history occurred when rider Marc Joineau piloted a DR500 to a impressive 3rd place finish in the 1983 Paris-Dakar Rally. Suzuki started the DR dual-sport line in 1978 with the DR370, followed by the DR400S (1980–1981), which was a bored-out version of the smaller engine.

1983 Suzuki DR500, as shown in a USA sales brochure

1985 Suzuki year code: F

For some reason, there was a DR500 model available in Austria (the European country, not Australia) a couple of years later. The model, sold exclusively in Austria between 1985 and 1989, was simply a DR600 with the displacement reduced to 500cc (exactly 499.7 cc). The displacement was decreased from 600 to 500cc by shortening the stroke 13 mm from 85 to 72 mm. The bore (94 mm) and the compression (8.5:1) remained unchanged. The 500 and 600cc models used the same carburetor, a Mikuni VM 38 SS. Reducing the cylinder capacity made the DR500 engine 5 hp less powerful, with 39 hp peak power at 7,000 rpm compared to the DR600's 44 hp at 6,500 rpm. The 500 and the 600 versions of the bike looked the same, apart from the big '500' number on the side of the seat. I don't know why such a model was made for the Austrian market. If you do, please tell us!

More: Suzuki DR500 brochures

More: Suzuki DR models

More: All Suzuki models

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