DR 800 BIG 1997

In this document is just listed all the maintenances and repairs done to the bike.

10.7.1997 registered under temporary licence: R-813 at Espoo, Finland

Zero kms!
First engine oil: Motul 15W-50
-Sparks: NGK DPR9EA-9
-Tyres:
front: Bridgestone TrailWing G-41, 90/90-21
rear : G-42, 130/80-17


"1,000 kms maintenance"
995 kms
14.7.97
Suwalki, Poland
- Engine oil changed: Motul 15W-50
- Oil filter changed
- Valve clearances checked: 1040 km, ok.

"6,000 kms maintenance"
5967 kms
25.7.97
Istanbul, Turkey
- Engine oil changed: Castrol GPS 15W-50
- Oil filter changed
- Valve clearances checked: 9511 km:
left exhaust: 0.25 -> 0.20
right exhaust: 0.20 ok
intake valves: 0.10 ok

8130 kms
Repairs (after the accident in South Lebanon):
Additional oil radiator was tried to repair with 'chemical metal'

"12,000 kms maintenance"
11736 kms
2.9.97
Athens, Greece
- Engine oil changed: Castrol GTX3
- Oil filter changed
- Air filter cleaned
- Valve clearances checked: ok
- Cam chain tension checked
- Sparks changed: NGK DPR9EA-9
- Tachometer light bulb changed

Repairs (after the accident in South Lebanon):
- Throttle knob installed
- The broken clutch lever was changed
- Additional oil radiator (modification) welded with aluminium


All the work done at Sfakianakis s.a., Suzuki importer, Athens!! :)
FOR FREE as a sponsorship!!!

Maintenance
14264 kms
16.9.97
Bassano del Grappa, Italy
- Engine oil changed: Motul 15W-50
- Oil filter changed

"18,000 kms maintenance"
18340 kms
7.10.97
Madrid, Spain
- Engine oil changed: Castrol GP
- Oil filter changed
- Air filter changed
- Valve clearances checked: ok
- Cam chain tension checked

Work done at Moto Mecanica, Madrid

"24,000 kms maintenance"
23459 kms
7.11.97
Agadir, Morocco
- Engine oil changed: Motul 4100 15W-50
- Oil filter changed

- Valve clearances checked: ok
- Later in Nouadhibou, Mauritania: 25239 kms:
- Sparks changed: NGK DPR9EA-9
- Drive chain washed with gasoline, before desert.

15.11.97
- Fuel filter changed

3.12.97
28472 km Bamako, Mali
- Air filter changed (really dusty!!!)
- Air intake holes of the air filter treated with thick grease because
of dust
- Drive chain washed with gasoline and lubricated, after desert.

"30,000 kms maintenance"
29983 kms
14.12.97
Sevare, Mali
- Engine oil changed: Motul 4100 15W-50, plus
Total 7000 15W-50
- Oil filter changed
- Valve clearances checked: ok

- Rear brake pads changed: 31505. They were totally worn out:
dust between brake pads & the disk wears the pads quickly out.
- Throttles: diaphragms and jets rinsed with plenty of
fuel from the red Sahel dusts. 16.1.98, Accra, 32945 km


"36,000 kms maintenance"
36069 kms
12.3.98
Accra, Ghana
- Engine oil changed: Shell Helix 20W-50
(Oil change for just before shipping)

"36,000 kms maintenance", continued
36145 kms
17.4.98
Durban, South Africa
- Engine oil changed: Penzoil 20W-50
- Oil filter changed
- Sparks changed: NGK DPR9EA-9
- Valve clearances checked: ok
- Engine bottom metallic oil 'filter' checked
- Front brake pads checked
- Front sprocket checked

"36,000 kms maintenance", continued
36911
18.4.98
Manzini, Swaziland
- Air filter changed

"42,000 kms maintenance"
41859 kms
4.5.98
Maun, Botswana
- Engine oil changed: Shell Helix 20W-50
- Oil filter changed
- Valve clearances checked:
- left ex. 0.25 -> 0.15
- right ex. 0.25 -> 0.15
- left in. 0.15 -> 0.10
- right in. 0.10 ok
- Power wiring of GPS repaired
- Moving parts of choke lubricated


Starting problems:
43802 kms
11.5.98
Walvis Bay, Namibia
- Checked valve clearances:
- left in. 0.05 -> 0.10

Maintenance

45898 kms
19.5.98
Cape Town, South Africa
- throttles: diaphragms and jets rinsed with plenty of
fuel from the white Namib desert dusts.

Maintenance
45900 kms
20.5.98
Cape Town, South Africa
- changed:
- front sprocket
- drive chain
- rear sprocket
(Those parts were got as a sponsorship from
Suzuki importer: Sfakianakis s.a. Athens, Greece!! :)

Maintenance
46766 kms
31.5.98
Buenos Aires, Argentina
As a preventive maintenance:
- changed clutch discs, 8 pcs.
- changed the right engine cover gasket
Clutch disks were got as a sponsorship from
Suzuki importer: Sfakianakis s.a. Athens, Greece!! :)

46766 kms
1.6.98
Buenos Aires, Argentina
- checked cam chain tension
- changed the left engine cover gasket

Starting problems:
Checked starter engine: ok.

46918 kms
31.7.98
Buenos Aires, Argentina

!!!! Starting problems, and engine running RED HOT !!!!
-checked:
-battery: NOT OK
-cam timing: ok
-sparks: ok
-carburetors: ok
-sealing of valves: NOT OK!!
*** Valve springs (4 pairs) were all dead ***
- also therefore all valve plates were burnt
-throttle position sensor: ok
-CDI unit: NOT OK!!
In acceleration, the ignition timing wasn´t correct.

All work of inspections and repairs was done at Gaston Alonso's
bike workshop, Buenos Aires!!! :)

CORRECTIONS:
- Valve springs changed
- Valve plates finished with paste
- Valve plates' sealing surfaces on cylinder cover repaired
- Valve guide sealings changed (preventive maintenance)
- CDI unit changed
- Battery changed

- Engine oil changed: Motul 15W-50
- Oil filter changed
- Cam chain tension checked
- Air filter changed
- Valve clearances checked and set: IN: 0.10 / EX: 0.20 mm
- Sparks changed: NGK DPR9EA-9

Bike checked from tail lamp to front tire.

"48,000 kms maintenance"
47946 kms
3.8.98
somewhere in North Argentina
- Engine oil changed: Shell Advance SX 4T 20W-50
- Oil filter changed
- Valve clearances checked: ok. IN: 0.10 / EX: 0.25 mm

48860 kms
12.8.98
Maringá, Brazil
- Front brake pads changed

Maintenance
51169 kms
26.8.98
Guarapari, Brazil
- Engine oil changed: Esso Ultra 15W-50

Maintenance
53373 kms
10.9.98
Maringá, Brazil
- Cam chain changed
- Left magneto cover gasket changed
- Engine oil changed: Castrol GPS 20W-50 (mineral oil)
- Oil filter changed
- Front light bulb changed
- Light switch repaired (problem since West Africa)

Maintenance
55262 kms
16.9.98
Buenos Aires, Argentina
- oil plug washer changed
- Engine oil changed: Motul 15W-50

60000 kms maintenance
59976 kms
7.10.98
Calama, Chile
- Engine oil changed: Esso Racing 15W-40
- Oil filter changed
- Air filter changed
- Valve clearances checked: IN: 0.15 / EX: 0.25 mm
- Battery connections cleaned
- Sparks changed: Denso EPR-U9
- Carburetors' needle jets adjusted for higher (> 2000 m) altitudes.

Maintenance
61135 kms
22.10.98
Sucre, Bolivia
- Adjusting of valve clearances: IN: 0.10 / EX: 0.20 mm
- Balancer chain tension checked, NOK
- Engine oil changed: Shell 15W-50
- Changed the broken bolt in the topcase frame. Trembling
on bad roads had broken it.

Maintenance/repair
61189 kms
31.10.98
Sucre, Bolivia
- Balancer chain changed
- Engine oil changed: Esso 10W-40
- Adjusting of valve clearances: IN: 0.10 / EX: 0.20 mm
- Changed the balancer chain tension adjuster´s protector/
chain guide into right position (turned 180 degrees)
**** Repaired ****
- the lug of cam chain
- polished left side cam of the cam chain with finishing paper
(density 400). In the left cam there were minor scrathces.
- changed the two bolts of the longer balancer chain guide

Repairs
61245 km
5.11.98
Sucre, Bolivia
-Left rear signal light's aluminium lug welded
-Both rear signal lights' covers repaired

Maintenance
62682 km
27.11.98
Sucre, Bolivia
-Rear brake pads changed

Maintenance
62562 km
19.11.98
Sucre, Bolivia at Imcruz (Suzuki dealer)
-Engine oil changed: Esso 10W-40
-valve clearances checked: 0.10/0.20 mm
-air filter cleaned from Santa Cruz - Sucre road dusts
-carburetors cleaned from dusts
(plus washing the bike well...)

NOTE: from now on I made oil changes every 1500 kms or so.
I was told that South American (and also African) engine oils
are not of good quality...
I also added oil many times because of hot conditions. The reason is
big negative pressure in the oil space, due to single cylinder
engine structure. That explains the oil loss.

Maintenance
62819 km
5.1.99
Sucre, Bolivia at Imcruz (Suzuki dealer)
-carburetors removed and cleaned (was lots of dust inside!)
-valve clearances checked: 0.10/0.20 mm
-air filter cleaned
-front sprocket checked (17,000 kms used)
-Maintenance was FREE. Thanks for Imcruz!

Maintenance
64455 km
16.1.99
Abancay, Peru
-Engine oil added 0.5 litres: Esso 10W-40

Maintenance
64601 km
16.1.99
Andahuaylas, Peru
-Engine oil changed: Castrol GTX2 20W-50

Maintenance
65463 km
19.1.99
Lima, Peru
-carburetors' 'high altitude' adjustments restored back
to 'sea level' settings
-front light socket plugged better
-RPM-gauge light bulb connection improved (always problematic)
-Engine oil added 0.3 litres: Castrol GTX2 20W-50
-wires lubricated

"66,000 kms maintenance"
66009 km
20.1.99
Trujillo, Peru
-oil changed: Castrol GTX2 20W-50
-oil filter changed

Maintenance
67433 km
23.1.99
Quito, Ecuador
-carburetors' 'sea level' adjustments changed back to
'high altitude' settings
-valve clearances adjusted: 0.10/0.20 mm
-Engine oil added 0.5 litres: Castrol GTX2 20W-50
-'camping light' installation repaired (a modification
to electrical system)

Maintenance
67714 km
26.1.99
Tulcan, Ecuador
-Engine oil changed: Castrol GTX2 20W-50

Maintenance
68663 km
28.1.99
Medellin, Colombia
-carburetors' 'high altitude' adjustments restored back
to 'sea level' settings

Maintenance
29.1.99
-Engine oil added, oil leak in the O-ring casket of clutch.

Repairs
69018 km
30.1.99
Planeta Rica, Colombia
-changed O-ring to the clutch installation (8 x 13 mm)
-side bag of the right side repaired (crash 28.1. in South Colombia)

Maintenance
69340 km
31.1.99
Cartagena, Colombia
-air filter changed
(3 filters bought from Buenos Aires half a year before!!!)

Maintenance
69936 km
10.2.99
Panama City, Panama
-Balancer chain adjusted
-Magneto cover gasket made & changed
-front sprocket changed

69937 km
11.2.99
Panama City, Panama
-Engine oil changed: Castrol GTX

"72,000 kms maintenance"
71717 km
16.2.99
Choluteca, Honduras
-'Oil seal' (two O-rings) of clutch changed
-Sealing secured with 'gasket maker silicone'
-Engine oil changed: Castrol GTX
-Oil filter changed
Maintenance
72350 km
Antigua, Guatemala
-Brake fluid changed

72,000 kms maintenance, cont'd...
73151 km
22.2.99
Flores, Guatemala
-Sparks changed: NGK DPR9EA-9
-Valve clearances checked: IN: 0.15 (a bit too much)
EX: 0.20 Ok
-Air filter element cleaned with air pressure

Maintenance
73881 km
25.2.99
Cancun, Mexico
-Engine oil changed: Esso Racing 20W-50

Maintenance
76006 km
1.3.99
Tampico, Mexico
-Engine oil changed: Esso Racing 15W-50

Repair
76790 km
11.3.99
Matamoros, Mexico
-Frame of Givi topcase welded. Were three cracks.
-Cable of right side rear signal light repaired.
Hot exhaust fumes had burned the cable.
78,000 kms maintenance
77795 km
20.3.99
Houston-Galveston, USA
-Engine oil changed: Motul "3100" 10W-40

Maintenance/repair
79822 km
6.4.-5.5.99
St. Petersburg, Florida, USA
  • Engine:
  • Front fork oils changed

  • Steering bearings (lower & upper) changed. Lower one was in bad condition.

  • Clutch lever switch removed (= modification)

  • Bolt threads of balancer chain guide repaired: steel thread inserted. 1