DT125R ARCHIVE

Calum122 · Guru

RE: 4DL TZR Engine Unmaintained!

Calum122 · Guru

What I will say is this. I'm definitely one to prejudge. Always do it. Did it when I received the barrel.

But I'm missing one crucial thing. I haven't even ran it. And I don't know enough about porting engines to be able to say whether that's good or not. Neither do photos really do it any justice.

There is only one way to find out and that's take it out on the road. For all we know this could be some serious beast. I did ask for mid range and no high rpm silly stuff since I want more YZ power rather than a Honda RS125 power delivery.

So it'll have to wait till I get it on the road before I can really say.

Energized · DTR Legend

Yes indeedy, now get cracking and get her run in and tested mate! wink

slob · Guru

Great work, look forward to some videos when it's in the bike for it's road test.

Victor · Guru

Going to be a big boost going from the DT barrel to that barrel+carb without the porting, i'm sure you won't be disappointed

Lovely project top job Calum

Calum122 · Guru

Yeah thanks for the kind words.

I'm sure whatever the case it will be better.

You know how it is though. You hope wish and dream and that never matches reality.

So long as by the end of it it's not just a fast dtre but rapid one I'll be happy.

Still got a wee while to go though. Which is frustrating.

mr karnage · Guru

I think you got what you asked for mate

he's got pics on his website for a tzr barrel that someone wanted to use on track and road and it's looks like a full race tune

there's even a review from the guy who wanted it doing and praising his work

I'm getting mine done soon from mick abbey, he's only a 20 minute drive away from me

Calum122 · Guru

I'm sure it's fine. I showed it to the Local Yamaha Mechanic near me, who himself ports his own barrels. He said wouldn't worry about the dowel. On his ports he has the bolt exposed that holds the PV together lol. He commented saying that he's really enlarged that exhaust port.

Bottom line is though when I spoke to the Mechanic before the work he said if I do get it done then I'd have to run premix. Which is not ideal tbh. So a less aggressive port will hopefully mean I can still run autolube.

mr karnage · Guru

The standard exhaust port really let's the engine down, I've heard people raising the port by a a couple of mm themselves

Can't you change the autolube settings with shims for a longer stroke? Or have I got it Wrong?

Calum122 · Guru

Okay, so I'm putting in the TZR this weekend. Nitch gut. Nev the collar that sits between the swingarm. how did you remove it from the engine? the collar is too small and will not take the DTR spindle. Can't progress until that is out. The carb, obviously, isn't going to fit without some form of modification. I need to sort something out. I've got the week off so don't need the bike. Am really tempted to leave it off the road for a few weeks.

Because I like wasting money, I bought ANOTHER VHSA carb because it said 'Blue Printed'. I'm not so sure and am tempted to write a letter. it's slightly different but not massively. I'm no expert. So I have two VHSA carbs. I'll just use the best of both and sell the other.

Here on the new VHSA it's had the mouth machined out. There is no longer a lip. And that's where what the eye can see.

Engine looks nice in the frame. Just can't wait to sort it out.

So HELP please lol And also if you want me to get both carbs side by side I can if anyone is interested.

NEV · Guru

I think the bloke who I bought the engine off Calum, must have already taken the collar you're on about ,out, as the spindle went straight through no problem. as for the carb, I've managed to get the 38mm Keihin to fit nicely where it is now, the petrol tank tap was being a big problem, but have managed to sort it now so the tank sits nicely on the frame.

Calum122 · Guru

Cheers nev just the person I was aiming that post at.

Hhmm interesting. Hopefully I might be able to use a drift to remove the collar and the dt spindle should fit straight though. I don't know. It may be a split engine case jobby.

slob · Guru

Heat is your friend, but obviously it has it's risks like that scooter lol.

Calum122 · Guru

It has been one long, hard, tiring road. But she is finished, well almost.

It's taking me about a week to do this properly:

I've needed to swap out the fly wheel
Generator
The 4DL inlet had no chance of fitting. So needed to bore out the old DT inlet to compensate for the new blue printed 32mm VHSA
Currently running a RAM air filter instead of air box. For jetting purposes this is just a simpler method.

When swapping over the generator I encountered my first problem. Torqued the genny up only to have the crankshaft completely lock up. I double checked the wrench, then the book. Nope Set up correctly but the crankshaft is seized. Sugar. Stripped it off. Had a look for damage. Nothing. All looked good. Checked the wrench. Then the book. Then refitted the fly wheel. Was fine. Not sure what happened there. If anyone knows feel free to let me know.

I then had complete and utter total electrical failure. This left me scratching my head since everything was working perfectly prior to the engine swap. I rode home on it Friday. Well apparently the ignition switch connecting block managed to completely disintegrate. Without me even touching that as part of the engine conversion. So bullet crimps was the only way to have this fixed. She fired into life off the starter motor. She is a quiet one compared to the DT engine. Wtf? Lol. Sorted the tickover and had her idling nicely.

I decided to let my brother take it up the road (in case it seized lol). Naturally it's smoking loads and this is hindering performance by quite a factor. He suggested that I push him and then he'd put it in gear. Yeah did that....nothing happened. Clutch wasn't engaging. Great crack.

Never had this problem before. Scratching my head again. Stripped the clutch cases back down and had another look. Sure to be sure with your own eyes you could see that the clutch is not engaging. No doubt about it. Stripped it to pieces and put it back together and tried again.
And I finally understand what you guys mean. The gearbox is sooooo smooth. It really is lovely. It just needs Powervalve sorting. Cosmetics doing and running in. I took a video of it first starting will upload tonight. This is it for my TZR thread. Will now just be updating my project thread. The last post for this will be a GoPro of the engine ran in and ragged down that lane I always go down for a comparison. Fingers crossed it should be a goodun!

AndyYam · Guru

WOOOOOOOOOO nice one Cal, well done. Look forward to the video. Sounds like you've overcome a few issues. What did you do about the collar in the rear engine mount? I've just sold my tzr engine and the guy is putting it in a supermoto DT ( what a weirdo! ) :P. I'll try and get him on the forum to pester you. I've said you're the man to talk to about it.

Calum122 · Guru

Ah I should amend this thread. Lmao. That was a right nightmare. That took me the best part of three hours to sort that out. It was a rubber grommet with a metal collar inside it. All glued to the engine. I drilled the collar out and chisled the rubber. It's not perfect but it's done the job. In fact I noticed a fair few mm play in the standard dtr engine. Now the tzr has none. So sound.

Calum122 · Guru

Still running it in but I took it from 0-11K rpm today. Wow. No powervalve at the moment. Having problems with the Zeeltronic. However fck me the power came on strong and I don't know how fast I was going when I hit 6th. Literally though pulled like a train. This is with a 12 tooth sprocket on the front. I was easily going faster than a standard DTR. Front wheel lifting in the powerband as well. Real good fun.

She's on 300 miles and this was purely so I can get the fueling correct. The top end wasn't spanking new anyway. But yeah. She ran really nice. Will get a GoPro up as soon as it's ran in. Hopefully I'll have sorted the ignition out too.

I put the standard ignition back on and took it for a blast. What a load of sh*t lmao. The OEM ignition is terrible. Highly recommend the Zeel (when it works...)

AndyYam · Guru

Sounds good mate. whats the problems with the zeel then?

Calum122 · Guru

I don't know mate. It's intermittent. I'll be uploading the video of the problem soon

This is literally the video of the bike when I first got it started after the rebuild

MDK · DTR Legend

video not loading for me ?

Luke · Guru

Same here, get an error.

Calum122 · Guru

Yeah. Doesn't work on my computer. But on my iphone it runs fine.

My google chrome doesn't load embedded videos on this site. Kindsa pisses me off.

Calum122 · Guru

AndyYam · Guru

Sounds nice. Keep us posted on the zeel issues.

Victor · Guru

Works for me, sounds sweet. Nice job

Dt Danny · Guru

sounds nice cal, but when yo did a close up on the engine was that coolant i saw coming out from near the exhaust area ?

Calum122 · Guru

Exhaust Joining Rubber wasn't attached :/ But The Speed is pretty much there. I go down the same road as the other tests so you can see the speed comparison between standard, Zeeltronic and now the 4DL

Luke · Guru

Looks nice. You ran it in now then?

Will have to fit that exhaust you had made up on and give it another blast for sound comparison. :D How come you haven't fitted the new pipe?

Victor · Guru

How fast does it top out at?

How fast out of 1st gear?

Does it power wheelie second?

Calum122 · Guru

She goes alright. It doesn't want to wheelie as well as it did before. I think it's just not jetted correctly! The car behind be clocked me at 80 mph and that was maxed. It's running 12 teeth on the front so you'd expect it rev out like that. But conversely you'd expect it to power wheelie in all the gears.

I don't have a speedo but I'd say 10-15 mph in first. Maybe more maybe less. It's hard to say. It's not very tall but that's because I've got such a small sprocket on the front.

I just haven't had time Luke. I'm a very busy man lol. I need an end can for it. I need to weld on some brackets for it. I will do it soon. I'm in no hurry.

Ultimately I'm in the position to judge. THIS IS IN NO WAY FASTER THAN THE APRILIA. 4DL or not the Aprilia would have it all day long. I will GoPro a new video of the two but I can already safely so it's slower. By how much will be interesting. And remember this is more than a standard 4DL. With all the mods like Zeeltronic, Ported cylinder, blue printed carb I just can't see it myself.

I'm going to up a tooth on the front to 13 just to get a little more top end out of it. The gearbox on this is lovely I will say that. The ratios are no. You can hear that a lot of the gears I've short shifted and yet it still pulled quite well. For various reasons but mainly because It's still in a sort of break in period and I don't want to cain it.

I'm semi pleased with it. I'm disapointed to say that appart from the Jetting and underslung, there is no more I can do to this to get more power out of it. This is as fast as it's going to get. But then again hopefully it's not compensated too much on reliability. I don't mind a top end once a year. Hopefully that'll be all it will want for a fair few K.

I'll try and get a GoPro of this and the RS before the RS goes.

I will say this though. I nearly wrote off powering it through those lanes. It was tank slapping like a mofo.