DT125R ARCHIVE

coastie123 · DTR Senior Member

1999 DTR Project - hopefully 3 months....

coastie123 · DTR Senior Member

Right guys and Girls, Heres my project thread..

It will be Picture heavy as and when i get chance to upload and actually do some work on the bike!

All my images are on Photobucket so i will apologies now for any size problems

How it Started

i bought a 1986 vfr750 for when i passed my test, then swapped it for a 1993 RF600 and now as i still havent passed my test i decided to swap it for a 1999 DT125 on a T plate... You may have seen it on ebay.. I contacted the bloke asking if he wanted to swap and he said yes...

I asked him to deliver it and by the weekend he delivered it, i started it up and sounded ok but not fantastic..

I ended up biting the bullet and swapping as i thought the RF will be sitting in the garage for at least 6 months until i pass my test.. I thought after a while it was a bike mistake until i joined this forum..

I still thought that i wouldnt be able to completely strip it down and rebuild it as i wouldnt have time or the skills.. anyway enought of the talk for a minute and enjoy the pics so far...

Heres the bike and the working Area

I then started stripping the plastics and seat etc.. you all get the picture...

Anyway after asking My good Mate Ben up the road who is very good with bikes and a big fan of TZR's and old school MT50's with H100 engines etc etc we managed to get the engine out and alot of the parts off..

I'm know stuck until the end of the month (payday) until the frame gets taken off to the sandblasters and powdercoaters and i can get some more bits..

I do have a small task to keep me busy until then - one of the Racers is stuck in the headstock and i can't get it out and also the shock adjuster thingy me bobby there is a bolt seized.. I've tried for 4 hours today with the "TZR man" and we can get it out so the next option will be to cut it with a grinder etc and buy a new one (Hint Hint DeeTeeMX)..

Ive also now manage to grind the weld from the kickstart - well actually grind the kickstart off the shaft as some numpty welded it on so thats also on my list to buy...

Heres the frame and swing arm as it stands.

My colour options for the frame are either black or Yammie Blue and the swingarm will either be black or Silver..

I will propably still to all black or black/silver which is more stock colour and it's better than the gold swingarm and forks which are there at the moment..

Please feel free to comment but please do not criticise, this is my first ever bike project and my first ever Engine re-build - obviously all help will be gratefully be received (Hint NEV seeing as your only down the road!)..

I do have more pics to upload but feel free to view my pics which are in my Signature below.. Sorry for the boring posts!!

Enjoy

coastie123 · DTR Senior Member

Thanks nev I couldn't believe it when I had a notification that I had won them and let's say they were cheap!!!!!! Wire brush wheels ordered off eBay, just got to get the parts for the engine... As you've just done yours, what parts will I need for top and bottom rebuild??? I'm sending the barrel off to be rebored which will come back with a new piston kit for the right size bore so it's just a new conrod kit, crank bearings, seals, gasket, oil, coolant, brake fluid, gasket paste.... Oh and the crank balanced?? This is my 1st bike build so I'm still not 100% sure what I need so any advice will gratefully be received!!! My other half isn't to happy with me warming up the cases in the oven but doesn't mind the bearings going in the freezer!!! If someone could List exactly what parts I'm going to need would be of great help... Saves me going to the local bike place to get the list especially when I won't be buying them from there!!!

-- Edited by coastie123 on Tuesday 24th of January 2012 01:07:17 PM

NEV · Guru

If you put into perspective what they have to do for the £150 you're forking out for the shotblasting and powdercoating, say 15-20 mins shotblasting the frame, 10 mins on the swing arm, then 15 - 20 mins spraying on the powdercoat, then banging into the oven to bake it, and then you think whats going to go into sorting your engine out for £200, I'd deffo say £200 is value for money, when you price up all the parts and the labour together. I think I paid £130 to Cornish motorcycles,for them to gas flow, port, skim head, re-bore etc, and I supplied the piston, and gaskets, then they rebuilt and set up the top end, plus also there was the petrol for a 60 mile round trip twice, so yes providing your chap knows whats what, then yes £200 is very good. £50 for the re-wire's a fair price too, providing its for the terminals, shrink tubing and outer wrap, cable ties etc, I reckon you can add another £50 if you needed the wires too.

Btw is 1st choice quoting the £150? the reason I ask is they charged me £80 for the frame and £30 for the swing arm, fair enough it was last May when they did mine, but still a fair big price hike. They'll do a cracking job, but its the two week turnaround that got up my nose, and another thing, if you have a tank cutter, cut some circles out of some plywood,and a couple of long bolts or 6mm threaded bar, so as to block off the head race stem, and swing arm bush tubes, as you don't want them powdercoating inside, as they wont block off for you.

-- Edited by NEV on Tuesday 24th of January 2012 05:11:13 PM

NEV · Guru

I reckon if you were to get it to him stripped down and ready, so all he had to do was rebuild it all back together,after the re-bore £50-£60 quid ball park.

I mean it's totally your call, but sometimes piece of mind can cost a few bob extra.

-- Edited by NEV on Tuesday 24th of January 2012 05:42:33 PM

NEV · Guru

Wow Coastie, you've done well with all those parts mate, you'll have a turn around of about 2 weeks at 1st Choice, so you'd better get yersen busy with a parafin bath(baby bath £2 recycling centre) and wire wheel/cup on a drill, and get cleaning your parts ready for building back up, purchase tons of different size cable ties too, found them to really usefull, especially for your wiring,looking forward to this coming together, always nice to see an old DT given a new lease of life, save all your chinese/indian takeaway plastic containers with lids too, for keeping all nuts/bolts/fittings together.

NEV · Guru

Oh aye another thing, keep all your receipts for the renovation, as for when it comes to insuring it, you're going to need an Agreed Value Policy, because if you don't and your bike gets buggered / stolen they'll only pay out on the book price, and you're going to spend what I think you're going to spend on it, you'd be well out of pocket.
I had to go with Carole Nash for mine, as my old insurers didn't do AVP, They just needed all my receipts, and 4 photos of the bike when done, front, rear, and both side views.

coastie123 · DTR Senior Member

right guys... after spending the last 3 hours browsing the net etc.. i've made the decisions!!

I will be sending my barrel to a guy on ebay who will re-bore, send a piston set, crank bearings, conrod kit, small end, full gasketset to fit the re-bore, and all oil seals including water pump seal £193.. here is the guy i will be using
http://www.ebay.co.uk/itm/280746462717?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

these are the reed petals i will be buying.

http://www.ebay.co.uk/itm/Yamaha-DTR125-DT125R-DTR-125-TZR125-TZR-125-Hy-Tech-Racing-Reeds-Petals-/140677099658?pt=UK_Motorcycle_Parts&hash=item20c102308a

I will be buying tapered headstock bearings etc - will this one fit?
http://www.ebay.co.uk/itm/YAMAHA-DT125-R-89-98-Headstock-Bearings-Japan-/150601909420?pt=UK_Motorcycle_Parts&hash=item231092c4ac

heres my spark plug
http://www.ebay.co.uk/itm/YAMAHA-DT125R-1988-NGK-IRIDIUM-spark-plugs-/350513557736?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item519c3c70e8

and probably 2 packs of these
http://www.ebay.co.uk/itm/560-pcs-STAINLESS-ALLEN-BOLT-PACK-EXTRAS-BARGAIN-20-/310300790728?pt=UK_Motorcycle_Parts&hash=item483f5e4fc8

and 200 of each size cable ties!!
http://www.ebay.co.uk/itm/Cable-Ties-Good-Quality-Free-Delivery-Varies-Size-and-Colours-/250907572680?pt=UK_Packaging_Materials&var=&hash=item80119ece30

I think that will be it for a minute!!

the next thing is for the colour of the bike etc..

I've decided black frame and black swingarm.... I do like the look of the blue but im now toying with a black/orange panelling or black/yellow but dont want it looking hideous and also dont want to copy everyone on here - although i do like your bike NEV!!

I can get unlimited amounts of "Rescue Orange" Paint in a spray or Tin The clue is in the picture at the end and i will be using this bike to attend......!!

Anymore tips or advice?? i've got my work cut out now and my other half is pulling her hair out!!

Cheers

Shaun

-- Edited by coastie123 on Tuesday 24th of January 2012 10:25:52 PM

coastie123 · DTR Senior Member

If you go out for a swim at somepoint I'm Sure you both will!!! I may need some help at somepoint with the spraying (hint hint)!! I don't know wether to have orange panels and black detail or black with orange detailing.... Hmmmm decisions!!! The only problem with orange and black detailing is its gonna look like a Ktm!!

-- Edited by coastie123 on Tuesday 24th of January 2012 11:13:45 PM

coastie123 · DTR Senior Member

Right...

Been in contact with a guy who does rebores and he can supply all parts for the full engine rebuild, his reply was...

"hi for a piston ,crank bearings, conrod,small end, full gasket, and all oil seals including water pump £173. plus £20 if you need want a rebore. postage is free."

Does this price sound about right?? I'm going to phone about before I say yes but I thought this price wasn't bad..

Any thoughts on the price??

If that's about right for the price then it's goin to cost me (rounded up)

£200 engine build
£150 sand blast and powder coat
£50 rewire

Plus any other bits and pieces I need...

coastie123 · DTR Senior Member

The shot blasting and powder coat I was quoted 110-120+VAT do 150 not
Far wrong..

The price of 200 was for parts and rebore, no labour apart from the rebore, I would have to do everything else!!!

coastie123 · DTR Senior Member

I'm guessing it quite expensive then..

I think I explained it wrong!!!

If I sent him the barrel for a rebore, he would do the rebore and SUPPLY the parts all for 200 then send it back to me with the piston kit, seals, bearings etc and I would have to fit it!!

Looks like I'm gonna have to search eBay for a cheaper parts supplier!!

Do you have any idea the exact parts I will need??

NEV · Guru

On top of what you've just said, a GENUINE yamaha, or Athena head gasket, (you'll need this honing out to size, depending on how much of an over bore you're doing) a pattern made full gasket set will do for the rest of the stuff.
Check the reed petals for any wear, and replace with either standard fibre glass ones if needed, or go for the better performing carbon ones, a fair few choose Boyesons, but to be honest HY-TEK ones are just as good and cheaper to boot, a new plug, personally I go for the iridium one, but again your choice if you want a standard one, which would be a couple of quid cheaper. Another thing to think about if you'll be doing it yourself is to get some new nuts and bolts, again two ways with this, either zinc coated standard bolts and nuts/washers etc,
but again theres a dearer but better option IMO that's to get stainless, either allen bolts, or hex, and stainless washers and nylock stainless nuts. I reckon thats pretty much it really, I dare say if I've missed owt, someone will add to this, but main thing I've found is to read through the manual and see that you've got all the tools you'll need, nowt worse than at 3pm on a Sunday, stuck in the garage unable to finish off something, and finding you haven't got say a torque wrench or something daft like that.
Thats my ten bobs worth anyroad.

stroker · DTR Senior Member

Nice one dude i offered 600 for that bike on eby and didnt get a reply lol nice to see its gone to a good home (:

coastie123 · DTR Senior Member

Cheers stroker.. To be honest none of the work that he said had been done had actually been done..

His text to me said

"Bike runs gr8.its got new brakes,battery,cables,grips,fork seals, fork springs. radiator,seat cover,and been rewired at cost! It has a couple of loose spokes on the front wheel that will need done for mot. Little dent ìn left side of tank and patch just below where tank has been patched .see pics. all good after that"

Apparently it was rewired at liskeard motorcycles if it has then the bloke must have a guide dog!!

It's a ball ache but I'm enjoying working on it!!!

Thanks for the reply nev, will look in to it...

stroker · DTR Senior Member

Yea sounds about right, its like everything i buy lol some people talk out of there ass

When some one says stuff like that always think the oppersit then you cant go wrong, but least your enjoying it

coastie123 · DTR Senior Member

stroker wrote:
Yea sounds about right, its like everything i buy lol some people talk out of there ass

When some one says stuff like that always think the oppersit then you cant go wrong, but least your enjoying it

Thats exactly how i looked at it... I think i paid £450 for the original VFR so i'm not really out of pocket until after the rebuild!!!

NEV · Guru

Ah goo on coastie, can me n lad go out on it sometime? lol
Looks pretty much like you got the rebuild pretty much sussed mate, and neon orange would look the dogs too!!

coastie123 · DTR Senior Member

Just a quick update...

I popped up to a bike repair shop and aske him to remove my flywheel as I don't have a puller.. I explaine I would be willing to buy parts from him and not the bike there etc...

I had to leave the engine with him, he had to modify his puller which he made to get the flywheel off!!!!

I dropped it up there at 9.45 this morning and I'm now waiting for a phonecall to say its done!! The cheeky begger quoted me £270+vat for parts alone, little does he know I'm not going there to get the parts!!!

Anyway It was just an excuse to get the flywheel off!!!

NEV · Guru

Ebay for the flywheel puller, I think I paid around a tenner, handy piece of kit to keep in toolbox.

coastie123 · DTR Senior Member

I did contemplate buying on but seeing as he will do it for nothing I thought I'd get him to do it...

I will be buying one as soon as I get paid!!!

He's a very clever bloke, not CMS Exeter, it's Dave Massam in Colyton

NEV · Guru

Because they aren't directional to set up for the road no, unless you dropped lucky and they are the right height and to the correct setting to the left, which I very much doubt, but good thing is they take about 1/2 hour to swap over after an MOT, not that I'd advocate doing that, "officer"

Or go for the daylight MOT option, I keep hearing about recently.

-- Edited by NEV on Friday 27th of January 2012 10:43:47 PM

NEV · Guru

Aye, and remember it goes back in exactly the same mess, lol take plenty of pics, print stuff off too, handy for next to the bike reference, I got missus to get one of those book files, with the transparent sleeve pages, came in pretty handy for me

-- Edited by NEV on Friday 27th of January 2012 11:00:01 PM

NEV · Guru

Now then, I finished putting the green stripe on my other replacement tank, yesterday,due to the the chap who repaired my bike tipped the tank forward, and it pissed petrol out over the front of the tank, buggering up the paintwork, he said he would respray it, for nowt, using the proper tank paint (two-pack), so after I bought another tank for him to respray while I could still use the bike. and true to his word he resprayed it black, and polished it nice.
So that tank you see on signature pic is going begging after i swap with other one, just needs wirebrushing down, or repair where paint has 'melted' up to you. its a good tank mind

Thats the other tank(new) makes for a nice table feature too, lol

-- Edited by NEV on Friday 27th of January 2012 11:39:54 PM

-- Edited by NEV on Friday 27th of January 2012 11:42:22 PM

coastie123 · DTR Senior Member

right guys just a little update, had a phonecall from my good mate up the road to pop up...

I popped up and he said he had a little present in his garage for me...

Im now the owner of a Husky 250 front end and a digital speedo!!! - USD's FTW!!!

all ive got to do is change over the centre pin and turn the yokes around!!!!

here a pic.. i have more bits but this was in my hand at the time..

NEV · Guru

Got just the thing for that front end mate, couldn't use it for mine as I couldn't get it to sit with the clocks on, it needs a digital clock to sit right, what digital clock you have for it a VAPOUR? or Koso?
Oh aye, and you'd need to re-spray that green panel lifeboat orange too, or strip it back to ally

coastie123 · DTR Senior Member

is it MOT passable??

coastie123 · DTR Senior Member

the only downside is when my pager goes off at stupid o'clock i wont be able to use the bike!!

very interesting though!!

dont know what digital speedo it is yet,, it's not going to be a fantastic one, i bet it's only a push bike one - LOL!!

started stripping the wiring down today to see what i need to do, at the moment it only looks like the jumble of mess that sits behind headlight etc...

coastie123 · DTR Senior Member

thanks for all your help so far... i've now ordered a pack of 24 wire brush set so i've got plenty!!
http://www.ebay.co.uk/itm/Hilka-24pc-Wire-Brush-Display-Box-Power-Drills-/260853178578?pt=UK_Home_Garden_PowerTools_SM&hash=item3cbc0fa0d2

i'm also in talks at the moment for a brand new tank for my bike but it's cheap!!

how do i find the Part number for a genuine tank online, i've searched AJSuttons site but can find the part numbers!!!

My other option is to strip down my old tank but there is filler on it so im not to sure what exact damage is on it unless i strip it down.. if i do do a respray tehn help may be required mate!!!!(Wink Wink)

coastie123 · DTR Senior Member

Pm me!!!!!