DT125R ARCHIVE

zooankski · DTR Senior Member

1991 DT125r re build

zooankski · DTR Senior Member

I managed to get hold of some before pics. It doesnt look too bad (shame you can't see it close up!

Spent some more time on the bike today. Front and back brake calipers cleaned and painted which was an absolute pain to do!

I have also wire brushed the tank and now need to figure a way of getting all the rust on the inside out. Anyone got any cheap ideas?

I was also looking at the carb and i have noted it has a 130 main jet fitted??? does that sound right as 210 came to mind confuse

NEV · Guru

If the rust is bad inside your tank, there is a sealant you can use for coating the inside, it's called Petseal, you can get it on ebay here look.

http://compare.ebay.co.uk/like/200734783983?var=lv&ltyp=AllFixedPriceItemTypes&var=sbar&cbt=y

fused420 · DTR Senior Member

It might work out cheaper and easier to just get a new tank

eG x LoGiKzZ · Guru

depends how bad the rust is, but ive seen some people fill the tank with a few hand fulls of sand and gravel or a few nuts and bolts then wrap it in a towel and put it in the tumble dryer, look it up tho first if you do try it

zooankski · DTR Senior Member

I might try and tumble it first and see what the result is confuse

garytee · DTR Senior Member

Check out this guy for the tank

http://www.tankcareproducts.co.uk/index.htm

zooankski · DTR Senior Member

Thought i would post a few before pics wink

zooankski · DTR Senior Member

Jobs done to date-

1/ Engine-new piston/rings, water pump seal, re paint and de grease, power valve removed (waiting new servo type), clutch adjusted, new gaskets, fresh oil

2/ brake calipers cleaned and re painted

3/ footpegs, stand and rear brake lever cleaned, repainted and baked at 200 degrees for 1.5 hours (stove enamel)

4/ carb cleaned, and float adjusted, (waiting on new jets)

5/ exhaust cleaned, wire brushed and re painted

6/ frame fully stripped and now at powder coaters together with swing arm

7/ switch gear cleaned and re painted

8/ clocks mounting braket wire brushed and painted

9/ radiator cleaned and re painted

10/ batt tray and air filter housing cleaned

11/ wiring loom cleaned and re wrapped

12/ Tank cleaned externally and wire brushed, given 2 coats of red oxide primer in prep for paint at a later stage

13/ various plastic panels stripped back to base plastic for re paint although will probably buy new

14/ front shocks cleaned and polished and oil / oil seals replaced

Not bad for a couple of weeks with a few hours here and there.

Calum122 · Guru

Looks pretty sweet :D

GADGET · Guru

Yeeeaaaahhhh ,another older dtr love it ,you will not be disappointed,I'm running a 1990 h reg like yours it it can't be touched by any L-plater around lol, keep it coming fella nice one

zooankski · DTR Senior Member

I got the frame and swing arm back from powder oat today-looks fantastic in white and silver. I also got my slinky glide kit for the swing arm bearing replacement but i cannot work it out! The kit has the needle bearings and a couple of bushes although these look nothing like the old ones which appeared to be copper? can anyone enlighten me as i appear to have a couple of these plastic type material bushes already (just got to remember where they came from!)

if you look at the pic on the A J Sutton website i think i need items 3 although the bushes i knocked out of the swingarm looked more like item 21 ?

NathanH · DTR Senior Member

I just purchased a slinky glide but only got two needle rollers and two oil seals? how many parts did you get. If your going to be replacing your suspension linkage bearings/bushes, it just cost me £50 for everything (6 oil seals, 4 bushes and 2 bearings).

zooankski · DTR Senior Member

Started rebuilding today, biggest issue was getting the collars inside the new needle bearings and bushes on the swing arm. Stuck them in the freezer at minus 20 for a couple of hours and pulled them in using a theaded bar eventually.

Pretty pleased with progress although i am waiting on 2 lower bushes for the swig arm (where the dog bones fit) and another load of stainless bolts!

I also got the wiring mostly installed this evening and it is looking good.

My son was after blue plastics but i am thinking it might look pretty cool in all white with some sort of graphics? May be spray the lower for legs white also?

Really chuffed with my mono shock lower rubber inside the spring and the shock over all. What ever used to be there had perished and then vanished so i made one by glueing 3 layers of rubber together and then putting it on a linishing machine to get the tapered shape.

-- Edited by zooankski on Thursday 2nd of August 2012 11:50:27 PM

NEV · Guru

Looking very nice is that Zoo.

zooankski · DTR Senior Member

Swing arm is silver G116, i just want to get on with it and it is soooooo frustrating having to wait for bits. Saying that, my bushes for the dog bone to swing arm link turned up this morning fro Fowlers (very fast delivery!) so i had fun getting that together earlier!

What i really need is my supply of M6 stainless bolts so i can replace everything!

-- Edited by zooankski on Friday 3rd of August 2012 02:42:35 PM

the only way is YAMAHA DTR · Guru

biggrin what colours the swing arm? gun metal grey?

looking good, hard to stop to wait for parts,

the only way is YAMAHA DTR · Guru

sweet, i need some m6 allen bolts for my new engine, i replaced every bolt nut and washer on my bike. dont forget threadlock and put grease on threads depending on use

FunkeyMunkeyDavid · Guru

coming along very well that! love seeing dt's being rebuilt to showroom condition again smile

zooankski · DTR Senior Member

Hope to get her started tomorrow once i have re fitted the wheels so will be taking a load more pics! Any tips on a first start up? i was going to bleed the pump but run it on premix too for the first few starts (smokey but better than lean!)
Fingers crossed and i will keep you posted!

zooankski · DTR Senior Member

Got the wheels back on, topped up 2 stroke tank, added coolant and rigged up a funnel for fuel. Pre mixed a bit and poured it in. Ignition on and choke up, kicked it over and it will fire up but die after a few seconds. Choke off and it dies strait away.

Sounds like a lack of fuel but i am just not sure? Only thing missing is the air filter which i am waiting on although i expected it to at least run with it off.

I have checked the float heigh and adjusted it so the fuel in the drain pipe is level with the top of the float bowl but still no joy.

Posted a quick video to show what is going on. Any suggestions for me to look at?

I have removed the carb again and am going to give it a good blow through. Son was gutted but i told him that these things happen and at least it did fire up although only quickly, and that someone on here would have an idea of what is going on!

http://www.youtube.com/watch?v=Yqsn02uWwLI&feature=youtu.be

http://www.youtube.com/watch?v=oMk1N38NcLE&feature=youtu.be

-- Edited by zooankski on Monday 20th of August 2012 03:34:56 PM

-- Edited by zooankski on Monday 20th of August 2012 03:35:44 PM

-- Edited by zooankski on Monday 20th of August 2012 03:50:35 PM

-- Edited by zooankski on Monday 20th of August 2012 03:50:54 PM

-- Edited by zooankski on Monday 20th of August 2012 03:56:54 PM

-- Edited by zooankski on Monday 20th of August 2012 04:13:45 PM

GADGET · Guru

I would say blocked pilot jet ,...but before you go taking it apart again try tapping the carb a few times with a the handle of a screwdriver etc ,and then try starting it as th floats get stuck an can cause this to happen for a while till they settle in

zooankski · DTR Senior Member

Blew through the jets and VOILA! it is going and will idle well. next step is putting it back together properly!

GADGET · Guru

Nice to hear dude

,but tell ur son about tappin th carb coz it can get stuck open aswel,saves him gettin stuk somewhere,with fuel pizzing out

the only way is YAMAHA DTR · Guru

get photobucket mush wink

zooankski · DTR Senior Member

Will do!

zooankski · DTR Senior Member

MDK · DTR Legend

looking nice .... how did you spray the spokes on wheels take them out or just mask all rim off ?

zooankski · DTR Senior Member

The spoke nuts were not going to budge so rather than re lacing the wheel ( my son just wants it on the road! ) I rubbed them all down and masked off which took forever! Then 4 coats of hammerite smooth spray paint. They look good from about a foot away. I will either re lace or buy better condition wheels when the budget allows. Only bits we need now are a cylinder and head for the spare engine and some handle bar grips I think! Plastic and tank are still to be sprayed but wanted it running before we go spending out more of MY cash! Lol.

zooankski · DTR Senior Member

sounds the same with the cover fitted mate. I had it running and thought i would make sure the clutch worked so pulled the lever and put it in first. Bike stalled instantly and jutted forward so the clutch is not disengaging the drive from the gearbox. I tried tightening the cable as far as it would go and no joy (new cable too). the feel of the lever is as i would expect it though so no idea what is going on. The noise was not apparent last week when i started it up from memory so what would be the symptoms of the clutch lock nut coming off?
I have not taken it apart although it may have been previously. All i do know is the plates seemed free when the cover was off as i remember running my figer over them and there being slight movement.

-- Edited by zooankski on Tuesday 28th of August 2012 07:39:49 PM

-- Edited by zooankski on Tuesday 28th of August 2012 07:45:15 PM