DT125R ARCHIVE

Calum122 · Guru

RE: 4DL TZR Engine Unmaintained!

Calum122 · Guru

Okay. It's been a long ass while but finished work for the rest of the year now so have spare time to crack on. I've been worried about this part for a while not....not sure why?

It was surprisingly easy and satisfying. Can't say whether it works or not. It seems to select gears and the crank rotates. So that's some. I genuinely thought it would take longer to do this than it has. Just followed the Haynes manual and working through it slowly and carefully.

Seems legit. I only stopped because I actually have reached the point whereby I'm putting it back together but don't have all the new shiny bits for it yet. So that's new.

Nuff the talk here's some pictures.

Gently tapped the rebuilt crank in.

I have been so worried about this part ^^^^^^^^

Wondering how I'm every going to put that back together. Well I cable tied the gears together BEFORE I TOOK THEM OUT. Seemed to work a charm. They dropped straight in no problems.

Then the forks... well that was a little tricky to get my head round cause I for got to take photos but Haynes explained it very well. THANK GOD!

Getting these little bastards in took me a while to realise that you need to remove the support first then put it back in once you're happy with it.

Advice on how tight those crankcase bolts should be? My torque wrench doesn't go down that low. So I just did them fairly tight but not too tight? Bit worried about that actually.

So here's where I'm at so far.

Want to put carbon reeds in there before I put the inlet back on. So will have to wait. Also want to put a new clutch in there as well. So need to order one of those.

Will try and finish the majority of this off this weekend.

Then it'll be the interesting stuff. Need to take the cylinder off my bike. Send it to a tuning specialist. get some sexy work done to it. Back it on this bottom end.

Sort the carb out. Got the VHSA 32mm Delorto (4DL Carb).

Sort out my Zeeltronic.

Run it in then Boom. Summer tears!

I'm thinking of running it in using the 4DL cdi first. Then switch to the Zeeltronic.

Got a pre 96 airboot new from Yammy. This will be heated up so it can take the bigger carb :D

I have already got one but it's startin to perish.

yamahayz125 · DTR Senior Member

good job so far bud and its great to see a engine being built with decent parts. dnt know how people can put cheap rubbish in their engines I all ways go for the best myself as if u buy cheap u buy twice

dread123 · Moderator

given me the kick up ass to finish my spare engine rebuild too hahaha.. got crank back rebuilt- so its re-assemble time for me too hahaha...putting gears back in is my worry too :p did not cable tie together as cleaning all the parts!! Thinking about sending spare barrel off for some porting work too?

Calum122 · Guru

I was really surprised. Maybe the gears are wrong but i was able to freely rotate them all then select gears. I did not think i would get it first time round.

Also cause this is a belgarda it doesn't really match the haynes bur never the less it was still really clear. I think so long as you got the manual you'll be fine.

I'm going to finish as much as i can off today.

dread123 · Moderator

yeah just had look at the box with gears in...lol decided to fit my aftermarket pipe after painting instead :p...will look at the box again tomorrow lol

Calum122 · Guru

This will probably be the last post I make on this this yeah.

Awaiting parts now. New tab washers. New clutch and springs. Carbon reeds.

All of which i'd expect in the new year. I've also dropped my old cylinder off at skellerns yamaha for a hone and new piston. No need for rebore which is good bstill original bore too! 20k miles :D

So here's the last of it. Been assembling the primary drive gears and clutch assembly. Also added the kickstart to the tzr.

Enjoy.

This took me a while to figure out. Just persistence in the end got me there. Be interested to see whether this works or not.

madrevs · DTR Senior Member

Looking good used to have one of those 4dl tzrs it was rapid to say the least

Calum122 · Guru

I'm not looking for rapid. Just enough to match the looks. Nah mean :D

Calum122 · Guru

Cherry on the cake...

Energized · DTR Legend

Oh yesssssssssssssssssssssssssssssssssssssssssssssssssssssssssss spoke to them and they said they should have the zeel ready for the DTR in january, so i can't wait to order mine then :)

1DOWN5UP · DTR Respected Member

Did it come with all the plugs on cal

Calum122 · Guru

Yes mate. Looks lovely. I'll try get some videos up :D

mr karnage · Guru

The Haynes manual mentions torque settings, I went by that

Make sure it's all tight once it's together, otherwise you'll end up with air leaks and it's a right ball ache trying to find them

Calum122 · Guru

Yeah tell me about it.

This is my first ever engine rebuild. I've got no prior mechanical experience. Never worked in a garage just my bike in the last 12 or so months. So I'll be surprised if i've done it right first time.

AndyYam · Guru

Looking good cal! Cant wait to see a video. I'll be in contact with Borut at zeel again soon as i'll be ordering mine for my 350 build. Looks like you did a superb job on the rebuild. Encourages me to do my 350 engine build!

Calum122 · Guru

Cheers mate. I'm really pleased with how it's gone. Fingers crossed she fires up all okay :\

Calum122 · Guru

Posty is on it like sonic. Carbon reeds completes more of the engine.

So that will also take the 32mm carb. 4dl intake.

-- Edited by Calum122 on Friday 27th of December 2013 06:26:12 PM

AndyYam · Guru

Youre using a DT125lc yeis bottle? The tzr's had the same shape but without the yeis on the side. not sure if the internal sizes are different or if you're bother but thought id mention it.

Calum122 · Guru

Nah i'm using a 3et bottle. The lc bottle doesn't fig. Just wanted to bung up the hole with something. Shame cause that bottle looks better :(

Calum122 · Guru

Bottom end is complete

AndyYam · Guru

Looking good Cal! you worked out where to mount the choke?

Calum122 · Guru

Not a clue. Can you swap the choke out for another dellorto model? Don't really want the one that ks on there.

NEV · Guru

Cal, can you get a pic of the choke on that del'orto carb on your 4dl? I have a couple of del'ortos in my garage I might be able to cannibalise a manual choke from, I know I also have a couple of del'ortos with an electric choke from Speedfights you might be able to use too.

Calum122 · Guru

I think I might be alright. Swap out the choke for one of these i'm thinking matey.

CLICKY

AndyYam · Guru

Personally I'd extend then cable and mount it on the handle bars. would be cool to have access to the choke without having to feel around the carb lol.

Calum122 · Guru

I'm not big on the idea. I like having it on the carb personally.

AndyYam · Guru

img3.imageshack.us/img3/234/dscn4867.jpg

http://thisoldtractor.com/gtbender/mg_images/dellorto_carb_diagram_vhsa.jpg

www.dellorto.co.uk/merchandise/products_details.asp

http://www.dellorto.co.uk/merchandise/products_details.asp?PartNo=11752&CategoryID=2&PartsectionID=54

-- Edited by AndyYam on Sunday 12th of January 2014 12:14:14 AM

NEV · Guru

Won't one off a Mikuni fit? looks about the same.

Calum122 · Guru

I'm waiting for Seiki to unspam my comment but yeah found a link of eBay for about a tenner