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Post Info TOPIC: My DTR 2003 project


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My DTR 2003 project
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First post guys.

bought it from breakers yard, got them down from 1000 to 400 ;)
No engine number, for weight saving... french model, fully working powervalve, full dep system,
unfortunately the front pipes a bit rusty, but hey. 
runs likes a dream but wont idle; last owner clearly didnt do much maintenance, the oil came out in lumps.

Huge thanks to the mother, letting me use her conservatory for  4 months to work on it,
and lending me 700 quid to do it, until i sell my RS to pay her back xD

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seat was ripped, later turned out that the last owner was a lazy git and it had 3 covers underneath.
rear tyre has no tube, chain and sprockets are destroyed, swingarm is rusty and so is the frame in a few minor places.
The heated grips arent even connected to anything and speedo drive doesnt work.

The left hand side panel was missing, so i ordered a set from the guy from the 'filed' guy, with a new seat cover too.

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an annoyingly large amount of that orange paint on the casings.

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few odd rusty points, and the swingarm pivot is seized solid. was solved by heating it up and smacking it out. mechanical sympathy out the window on that one after a week of 3 in 1 oil and a lump hammer. The heated grips look a scalpel and some gashed knuckles to get out, due to the miles of wire underneath.
although i was pleasantly surprised to find, that under the billion monster stickers, there was a set of mint renthal 971's.

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that swingarm is the bane of my life.

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The return of the orange curse. glad the pv was all there, didnt fancy buying the servo.

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one of my dads friends kindly polished the silencer, which now looks good as new.

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The tank paint was a ****ty job. nobody had ever stripped the paint before, and underneath the black i found red, blue, yellow, silver, then black again.
then the mother of all dents :( it had nearly an inch of filler. no joke. so after hours of sanding and refilling it was ready for the paint. photos of the paint job and filling are on my dads phone, so will add them later.

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The rust on the pipe. hours of wire wool and tcut did improve , but it sure aint perfect.

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Brake pads
air filter
16-49 jt sprockets
ebc rear disk and pads
speedo cable
fork oil and dust seals
wheel bearings all round
inner tube
D.I.D chain
10W fork oil
lever covers
and a few other bits
doesnt look much for £210 :(
my dad treated me to a huge box of stainless steel bolts, washers and bits, cheers dad.

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i went with the 16-49, it made for decent acceleration and work well offroad, what did you guys go for?

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The bolt was seized solid in the bottom of the leg, but i had bought a spare set of wheels, forks and yolks for just 50 ;)
so we drilled out this bolt and took one from the spare set. i chose to use this leg rather than a spare because the paint on the
spare was ****e in comparison.

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a buddies dad is a partner in a powder coating shop, and did this amazing job on the swingarm.

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its pitch black out, 11 at night and all we have is a crappy lamp, but somehow me managed to drift in the new swingarm bearings using g cramps and a sach clamp.
engineering perfection ;)

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i couldnt afford and didnt have the time to to strip the frame for a powder coat, so i sprayed it myself, and it holding up well, for now, lol.

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the carb after a good clean, which helped the idling issue alot, but its still not quite right.
im going to order some new jets and needle etc. its a mikuni tm28ss on the 03's right?
people keep telling me its a vm26, but thats a roundslide. facepalm.

behind the carb is some spare plastics for my mums supermoto. best mother ever.

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Polisport halo, with h4 halogen bulb. excellent light output. i wanted a stock one, because it came with a broken orange acerbis dhh, but couldnt find one to suit my
budget so went with this. very glad i did.

 

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forks back in the bike, after the SECOND rebuild. dont ask D:

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back together, with all the new parts. the gaters havent been put on properly yet, because after the disaster on the forks last time, i wanted to make sure they didnt leak.

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The electrics were destroyed, big thanks to alain, a truck mechanic friend that basically built me a new loom.

The light will be put on soon, with some mini indicators.

got some new hel braided lines to fit, a few decals and a set of michelin t63's to replace the ****ty road tyres, will upload pics soon.


 

 

 

 

 

 

 

 



-- Edited by MuSkaaa x on Saturday 11th of May 2013 11:01:22 PM



-- Edited by MuSkaaa x on Saturday 11th of May 2013 11:03:29 PM

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Guru

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Nice. Lovely build. Lots of photos all assorted nicely. Very good read that thanks.

Welcome.

Yeah the round slide were on earlier models. Flat slide is what you want lol.

What digits are stamped on the barrel and head? Is it 3mb for the cylinder and 3bN om the head?

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The Leviathan Project

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Nice work Muskaaa, you can see that you've put some serious graft into the bike, you must be well proud of it.

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DTR Legend

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Welcome buddy and what a class project you have on the go!

Great example of a resto project. She's looking sweet!

The progress seems to be  coming along swiftly too :)

Keep us posted mate top job so far!



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thanks :) yeah those are the barrel and head numbers :)
amazingly it still had the frame number, so had no problem getting it back on the road xD



-- Edited by MuSkaaa x on Sunday 12th of May 2013 02:10:18 PM

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still an ongoing project, its on the road and flew through the mot :)
desperate for some more off road biased tyres, its horrible in the mud lol.
Thanks for all the feedback guys, the forum has provided some great tips so far :)
will upload some more pictures soon 



-- Edited by MuSkaaa x on Sunday 12th of May 2013 02:09:43 PM

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Guru

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Lookin good mate get sum enduro tyres and ul be luvin that mud and welcome to forum

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DTR Senior Member

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Welcome! looking really good that. Get yourself some michelin ac10's they're huge!

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had thought about some ac10s, but i have to ride to skl everyday, and to my girlfriends quite abit;
i ride whatever the weather so i need something that handles well in the wet :)
anyone had any experience with michelin t63?



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i shall give the ac10s a go then :) found some for 85 for a pair, much better than the 140 for a pair of t63's lol.



-- Edited by MuSkaaa x on Monday 13th of May 2013 04:01:00 PM

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good job there mate

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03 Supermoto'd Dtr 

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When I had my enduro setup I still used my bike daily for school, girlfriends etc. and still handeld fine in the wet with ac10s I would definatley recommend them mate.

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All about the ac10's ok ride on road but great off road



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Haha. Yes easy. That looks boom!



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The Leviathan Project



DTR Legend

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you have some nicely pruned hands

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K6 DRZ 400sm



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Used all of these in the past never had any probs with any of them


Michelin Enduro MS FIM Approved
Michelin Enduro comp 3 FIM Approved
Michelin Enduro comp 4 FIM Approved
Michelin Baja Rear
Michelin Desert Front
Michelin AC10 Rear
Michelin AC10 Front
Mitas EF06 Enduro front
Mitas E09 Rear
Mitas E09 Front
Mitas C02
Trelleborg T913 Front
Trelleborg T914 Front
Trelleborg T994 Front
Trelleborg T434 Front
Trelleborg T913 Rear
Trelleborg T915 Rear
Trelleborg T644 Army Special
Pirelli MT21
Pirelli MT83 Scorpian Enduro
Metzeler 6 Days Extreme
Bridgestone Gritty ED663 Front
Bridgestone Gritty ED660 Front

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Havent really posted any pics of the finished ride, but here's my cat.



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DTR Legend

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I think ac10's are brilliant on the road! And even better off road

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FASTER FASTER UNTIL THE THRILL OF SPEED OVERCOMES THE FEAR OF DEATH



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Bought myself some 100% accuri goggles in gunmetal, with the mirror lens, came with the clear one too xD
the girlfriend treated me too a new skid lid too, top wench ;) 

 

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Dad gave me his old Tech 7's too, as he doesnt need them anymore (sold his CR250 for a daytona) surprisingly comfortable.

 

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Gave me his old bumbag/toolbag too, holds a ridiculous amount of tools.

 

 



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