DT125R ARCHIVE

petrol is great and evaporates away any left overs just dont smoke or do this indoors ... I find with some things give a good clean with petrol and old toothbrush nothing arbrasive then swill with a little more fuel and stick in a sealed bin bag over night realy loosens up old grime or oil ..

dont be tempted to sand scrub or scrape at anything it should come clean with a little elbow grease .

sure other will have better or other ways of doing it so hang five and wait for more answers .

ok- cases cleaned- sprayed up and baked. looking very nice
new gearbox bearings are now here.
awaiting sealant for cases, then then putting back together starts.

not looking forward to that bit at all. any tips on where to start lo...been watching the video of the engine strip down and reading Norfes strip guide...but really not happy still lol.

have plastic bags with all the bits in and in no rush to get done, but want it right!

Also thinking i could do with replacing the crankcase screws- the ones that hold cases together- any idea where i can them and what sizes i'm looking at?

Yep. Make sure they're square. You shouldn't need a drift. I just used my finger through the middle.

some one should have done a step by step with each part numberd to what to put back in first 2 -3 ect .

real pain in the ass to put 2-3 things back in only to have to remove to get no 4 in I used to lay things out in order I removed them then work backwards for puting them back .

some pics- when checking the gears and the selector forks are installed correctly- how do i know which is neautral?  turning the selector drum each time drops into a gear but no way of knowing

Yeah I know right! You really do whizz through it.

I need to do this to my spare when i get time

yeh well i need to get the flywheel off and thats stubbed me and then i just have to split the case

I didnt have the flywheel puller tool with me (its in my garage in ireland or the uk) used the old sweede, I dont recommend but I used a work mate, viced the flywheel with wood, placed a large piece of bubble wrap( and tensioned bed sheet) under the workmate/engine and got a nylon hammer on the loosened flywheel bolt... few good whalops and it came free... but be careful if you try this... dont bugger the thread (trying without the nut on the thread) and dont use a regular hammer it will wreck it.. nylon or rubber doesnt damage used corectly...im a diesel engineer by trade and was careful... learned the hard way years ago...

Little tip I use Dread, is to get a bit of thickish cardboard, draw round your crankcase cover then mark roughly where the bolts go on it, using a Philips screwdriver make a hole in every bolt hole mark, so that when you next come to taking bolts out it helps in two ways, one to keep all bolts safe, and secondly to make sure each and every bolt you take out, can go back into the hole you took it from, just keep it safe somewhere, for the next time you need it. I now use a plastic bucket lid for mine, instead of cardboard.

Oh and yes they are M6 bolts, except for the oil drain bolt which is M8.

good tip Nev...will use that in future :p

THat was my thinking Cal...but dont fancy making mess if wrong size goes in..or not long enough etc?

Still mate it's pretty obvious where they go. If you screw it in and it's sticking out then obviously the wrong size.

one question- may have put little too much sealant on? when it goes off can i just peel whats on the outside off? never used this stuff before?

just finishing the engine re-assmemby- seem to have little play in the clutch area? where the main shaft that the clutch basket sits on there is slight movement back and forth not much but noticable? is this supposed to have a little room for movement or should it be solid?

Am i looking at pulling it back apart now?