Suzuki DR 800 S [1990–2000]: The Legendary "DR Big" Tested

Introduction

The Suzuki DR 800 S, affectionately nicknamed the "DR Big," isn’t just a motorcycle—it’s a statement. Born from Suzuki’s Paris-Dakar rally ambitions in the late 1980s, this air/oil-cooled thumper dominated the dual-sport scene with its audacious 779 cc single-cylinder engine, the largest production single of its era. Designed for riders who craved adventure without compromise, the DR Big straddled the line between desert racer and touring workhorse. From 1990 to 2000, it carved out a cult following, offering a blend of raw simplicity and rugged capability that modern ADV bikes still aspire to match.

I recently spent a week with a meticulously maintained 1996 DR 800 S, and it’s clear why this machine remains a legend. Let’s dissect what makes the DR Big tick—and why it still resonates with riders today.

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Design & Ergonomics

A Rally-Bred Aesthetic

The DR Big’s design screams purpose. Its towering stance, long-travel suspension, and signature "duckbill" front fender (mounted rigidly to the lower fork) were radical in 1990. Early models (1990–1991) featured a colossal 29-liter fuel tank (7.7 US gal), ideal for transcontinental rides but bulky for riders under 180 cm (5’11”). Suzuki addressed this in 1991 with a slimmer 24-liter tank (6.3 US gal), wider knee recesses, and a reshaped seat. The update transformed comfort, though purists mourned the loss of range.

At 890 mm (35 inches), the seat height is intimidating, but the narrow chassis lets most riders plant at least one foot. The riding position is upright, with wide handlebars and mid-set pegs. Long-distance comfort is surprising, though the bench-style seat firms up after 200 km (124 miles).

Weight & Practicality

Dry weight fluctuated between 185 kg (408 lbs) in early models to 209 kg (461 lbs) wet in later years. That heft is noticeable off-road, but on pavement, the DR Big feels planted. The low-slung exhaust (pre-1991) allowed for saddlebags without meltdowns—a thoughtful touch for adventurers. Post-1991 models adopted twin exhausts, boosting style but complicating luggage setups.

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Engine & Performance

The Heart of a Giant

The DR Big’s 779 cc SOHC single is a masterpiece of brute-force engineering. With a 105 mm bore x 90 mm stroke, it produces 50–54 HP (37–40 kW) and 59–62 Nm (43.5–45.7 lb-ft) of torque, depending on the year. Twin Mikuni BST33 carburetors feed the beast, while twin spark plugs and dual balancer shafts tame vibrations—somewhat.

Riding the Pulse

Fire it up, and the DR Big announces itself with a deep, resonant thump. Clutch pull is heavy, but the hydraulic decompression system (to ease starting) works flawlessly. First gear is tractor-low, perfect for crawling over obstacles, while fifth gear cruises comfortably at 110 km/h (68 mph). Push past 5,000 RPM, and vibrations creep into the bars and pegs, reminding you this isn’t a smooth twin.

Acceleration is brisk for a 90s thumper: 0–100 km/h (0–62 mph) in 5.6 seconds and a top speed of 170 km/h (106 mph). The engine thrives on mid-range torque, pulling strongly from 3,000 RPM. Off-road, the throttle response is predictable, though the carburetors can hesitate during abrupt altitude changes—a quirk fixable with aftermarket jets.

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On-Road & Off-Road Handling

Pavement Manners

With 90/90-21 front and 130/80-17 rear tires, the DR Big leans toward loose surfaces, but it’s no slouch on asphalt. The 43 mm telescopic fork (post-1991) and link-type rear suspension soak up bumps admirably, though damping feels undersized for aggressive riding. Braking improved in 1992 with a larger 300 mm front disc, but overall stopping power is average—plan ahead when loaded.

Off-Road Credentials

This isn’t a dirt bike. At 200+ kg (440+ lbs), deep sand and technical trails demand skill and stamina. Yet the DR Big surprises with 230 mm (9.1 inches) of ground clearance and plush suspension travel. The 21-inch front wheel rolls over rocks and ruts confidently, while the torquey engine bulldozes up hills. Keep momentum steady, and it’ll tackle moderate enduro terrain—just don’t expect KTM agility.

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Competition

The DR Big’s rivals were mostly twins, and each had distinct strengths:

| Model | Engine | Power | Weight | Key Differences |
|--------------------|----------------|--------|---------|------------------------------------------|
| Yamaha XTZ 750 Super Tenère | 750 cc twin | 50 HP | 207 kg | Smoother, better touring ergonomics |
| Honda Africa Twin (XRV 750) | 742 cc V-twin | 62 HP | 223 kg | More refined, higher maintenance costs |
| BMW R 80 G/S | 798 cc boxer | 50 HP | 186 kg | Lighter, iconic status, pricier parts |

Why the DR Big Stands Out:
- Simplicity: Air/oil cooling and a single cylinder mean fewer failure points.
- Range: Even the 24-liter tank offers 400+ km (248+ miles) between fill-ups.
- Character: The thumping single delivers a raw, visceral experience twins can’t match.

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Maintenance

The DR Big is famously robust, but neglect is its nemesis. Key tips:

1. Valve Adjustments: Check every 6,000 km (3,728 miles).
2. Intake: 0.05–0.10 mm (0.002–0.004 in)

3. Exhaust: 0.15–0.20 mm (0.006–0.008 in)

4. Oil Changes: Use SAE 10W-40 (2.7 liters with filter). Frequent changes (every 3,000 km/1,864 miles) combat oil shear from the single-cylinder thrash.

5. Carb Tuning: Clean jets annually. Consider a Mikuni TM36 upgrade for altitude compensation.

6. Chain & Sprockets: The 15/47 sprocket combo wears quickly off-road. Replace with DID 520VM2 chains for longevity.

7. Tire Pressures:

8. Road: 1.75 bar front / 2.0 bar rear (25 psi / 29 psi)

9. Off-road: Drop to 1.5 bar / 1.8 bar (22 psi / 26 psi)

10. Spark Plugs: NGK DPR9EA-9 (standard) or DPR9EIX-9 (iridium) gapped to 0.9 mm (0.035 in).

MOTOPARTS.store Recommendations:
- Upgrade to a high-flow air filter for better throttle response.
- Swap stock brake pads for sintered metal variants.
- Install a reinforced skid plate for rocky terrain.

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Conclusion

The Suzuki DR 800 S is a relic of a bolder era—a time when "adventure biking" meant grit over gadgets. Its vibrations, weight, and agricultural charm won’t appeal to everyone, but for riders seeking authenticity, nothing else comes close. Whether you’re retrofitting a rally replica or prepping for a cross-continent trek, the DR Big rewards mechanical sympathy and adventurous spirit in equal measure.

At MOTOPARTS.store, we’re here to keep your DR Big roaring for another decade. From performance upgrades to OEM-spec maintenance kits, we’ve got the parts to fuel your next adventure.

Ride far, ride wild, and let the thump guide you.

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Specifications sheet

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