hey fellas, thought id post up my DT 125 rebuild project. some of you probably seen it on BCF.
it's a 1990 DT and shortly after buying it dropped a crank seal and started to knock. doesnt look too bad in the picture, but its tatty, someone sprayed it with everything in the bike.. overspray everywhere!
What iv done so far
Bought full powervalve kit powdercoated frame: (Ral 2009 KTM orange) Full engine rebuild: (crank conrod kit, true up, full engine bearing replacment (every bearing that is), full seal replacment, +2mm rebore and new piston + all new gaskets.
Colour scheme: KTM orange powdercoated frame, high gloss black swingarm, Gloss black engine with silver cylinder head, gloss black plastics/fuel tank (with maybe some orange lines in it or something) and hopefully orange handlebars/hubs and calipers.
Here it goes
Striping engine
Engine removed from frame, now you can see how tatty the frame is!
Crank cases and barrel sandblasted, they come up a treat!
Back to the frame
I started sanding the frame, but ended up leaving it for shotblast.
Rebuild of the engine started, i have had a crank rebuild and true-up and all new bearings.
Nice and cold!
Gears installed into the cases, the gears were in good nick and all tolerances were checked with a vernier.
Barrel and new piston, had it rebored + 2mm by PJ motorcycles in wolverhampton, would reccomend them!
Cases fitted together, looking sexy!i ran through all the gears just to make sure everything was working as it should.
Transmission refitting, i may need a clutch plate set yet, i need to check them.
Here is the engine nearly finished, sprayed in simoniz engine enamel, i think this was the best colour choice given the colour scheme of the bike. turned out better than i though.
-- Edited by MartZ0r on Sunday 24th of October 2010 08:29:29 PM
Right, i have a few more things to post up that i have resprayed and tarted up. i am picking the frame and swing arm up from powdercoaters on tuesday, so i will post the other bits then.
i have got a powervalve servo and PV shaft also to go onto the bike, i also need to sort the jetting out because of the performance changes.
i still have a lot to do such as powdercoating the forks and spring etc. hopefully i can feed your guys addictions with more updates this side of christmas.
-- Edited by MartZ0r on Sunday 24th of October 2010 08:34:18 PM
i dont remember individual prices exactly but i had a gasket set, crank rebuild + tree up inc parts, piston and rebore and 2 blind bearings removed for £160.
started assembling and fitting some parts i have sprayed up.
Radiator resprayed
before
after
Fitted the radiator and oil tank
i have some of the syspension linkages etc to clean up still, im not going to powder coat the linkage i am going to find something thats fairly durable seen as it wont really be seen. for the shocker i think i am going to get a sleeve for it.
i really want to fit the engine, problem is i need to get a genuine head gasket, i only have a cheapo gasket on there atm.
I didnt even bother painting my suspension linkage as it's never seen and gets battered by all the crud. I'd use some stone chip paint normally used for cars
i thought of stone chip too, i know it doesnt really need it but i havy a tendancy to go over the top. bugs me if i leave things of if something aint "right" takes me a liong time to finish things sometimes because of my OCD haha.
Before you go much further, pay out for a genuine head gasket - not worth the effort. Other than that, looking good, nice progress will be an interesting end result
Takes me back to when i did my frame and got it back from the coaters.Love the buzz of it all clean and shiny Dont forget your chain gaurd on your swingarm where it goes into the frame,your chain will really scratch it up. Built all my back end and up and had to take it apart again as i forgot to refit the f*cker.
sorry for the very lack of updates again, once again the project was pushed a side for other things.
i have still been working on the project very slowly, it is almost complete now.
Sorry for the crap pics, i will take some better ones with my other camera.
Rear wheel cleaned up and painted.
The engine is in, complete and the bikes a rolling frame now and best of all, it is a runner as of y'day. dropped some pre-mix 2s/petrol in it to get it started and it fired right up. oil pump is running but i pre-mixed it just for the first run. i must admit, all that hard work on the engine was worth it, it sounds so good and clean!
ignore the green pipes, they are being changed to orange :)
i also have a tiny radiator leak i need to sort out.
i also have another adition to the collection, i got it cheap on ebay, a few people have probably seen it on there. Bought for £122, non runner without papers. i have managed to get the information on the bike and can apply for the loggys. Completly clean 1988 bike with 5 prev Owners. it sparks but is a non runner due to the fact the piston has shot.
-- Edited by MartZ0r on Monday 30th of May 2011 08:33:07 AM
-- Edited by MartZ0r on Monday 30th of May 2011 08:35:33 AM
the handlebars are fitted now and the throttle etc.
im having a little running troubble. i got an original downpipe on now, tookm the big one off due to leaks.
struggling to keep it running off the choke. iv cleaned it out a few times, runs good on the choke, turn it off and it runs good for a bit then start's to bog down. there's hesitation in the throttle response with the choke off.
it's the flat slide type mukini carb, air screw is 1 1/2 turns out. 210 main jet. it's VERY smokey!!
it can benefit from a new filter, so i am going to get a fresh filter and go from there.
the bad running is down to the carb i had to replace my old is actually of a DTX, and the jetting is different. tomorrow i will be taking the jets out my old carb.
i have done so more bits and bobs to it, fitted the rear chain guards, clocks are fitted now too . i need to buy a chain split link tool because i need to take a fair few links out.
going to start prepping the tank for spraying this week
order list still:
* YPVS Housing and plastic pulley, got the cables and cover already. * Seal Savers * LED Indicators * Black Plastics or plasic primer and paint the old ones.
i am going to keep the front light and uprate the bulb in it or something, what you guys think?
