DT125R ARCHIVE

Bit of an update. The Dep arrived cant beleive how light it is. The finished bike should be a lot lighter with all the un needed junk taken off it. The old standard exspansion ways a ton. Losing the old clocks and the 2 stroke oil system should all add up nicely.

Waiting on the dash coming because they have ran out of stock looking forward to installing it all.

The engine rebuild is going well apart from a few small problems.

Going to have to think of a way of getting this blind bearing out for the balancer shaft . I tried heating the housing and tapping the casing downward but no luck.

Need to get the clutch bearing out some how.

These cross head screws are really starting to get annoying now. Wouldnt move with a screwdriver but there isnt enough room to get an impact in. I tried to and it just sheared. Going to throw all of them away! Will have to try a stud extractor. Think that was the last one of the entire project ha ha! so typical.

Loads of smashed up alluminium behind the main bearings. The main bearings them selves are totally screwed.

This is how things stand at the moment. The starter motor is getting drilled off the casing tomorrow at work cause the threads are knackered. Hopefully have the cases ready for powdercoating soon.

-- Edited by NEV on Tuesday 5th of February 2013 12:03:44 AM

If thats the case I will give it a crack. Norfes guide on here is amazing for people wanting to do it themselves. I will have to give it a good clean in parafin first though or I will be a dead man lol!

I know mate dont want burning plastic to addd to the aroma of burning filthy chain grease. I am trying to prep them for powdercoating anyway. Don't know if anyone has done inner cases before. Think it will be a nice touch seeing that nearly every feasable part of the bike has been powdercoated already.

Got my engine stuff to the powdercoaters this morning. Risky getting the inner cranks done but the boy is good and I have every faith in him lol. Thats basically every feasable part of the bike powdercoated lol! Lucky I get good rates or I would be broke.

The cylynder head is going to be red along with the powervalve covers. And the cylinder and cranks will be Matt black matching my outer halves.

Started on my vapour install. If you are thinking of buying one of these, I highly recommend you get a bracket of Callum. The mountings that are provided are terrible. With the bracket Callum makes,they will be sitting just where you want them as you will see in the pics.

Bracket in question.

Sitting perfectly. The speddo sensor is going to be tough because my calliper bracket is tiny. Got the indicators on the dash working and the temp scensor in the cooling system sorted out. Will have to buy a fuse for the power install tomorrow.

Got the Vapour all installed. Not the toughest of jobs, does take a bit of fiddiling about. Had a lot of headscratching before callum reminded me of chopping the old plug of my clocks and soldering the vapour on to it.

I was going to try and get it to have left and right indicators to come on each side of the dash by tapping the wires directly into the indicators. Don't know if it would work but maybe worth a try one day as I have a blanked out light as I don't require a 2 stroke warning light.

This was when I just linked up the wires by hand, I also went and got a fuse holder and fuse to be on the safe side that vapour do not provide.

Plumbed into the hoses.

Marking the hole for the sensor. I had to cut some of the plastic off so it would fit.

Just secured with a self tapping screw.

Need to tidy all this up when I get some small cable ties.

Got it so that it lights up when I turn the key. I am actually drawing the power from the wires for the back light of the stock clocks, so no need to go running wires to the battery like trailtech recommend making the install alot more simple.

Just need to glue the magnet to the disc. I will measure the wheel before I do this and lift the front wheel up for a test run before I go glueing stuff! Only yhing I missed out was the RPM sensor but that is simply earthing the wire at the coil earth and wrapping whe red wire around the bottom of the HT lead 5 times.