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Post Info TOPIC: My 1997 dt125r project (french spec bike)


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My 1997 dt125r project (french spec bike)
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Hi all, im new to this forum, and bought the bike as a winter project,  i

 

used to use a dt125 years ago in asia (1992) aircooled, its a different model, older spec engine, but i had loads of fun on that bike of my dads . It was full power and i had the exhaust cut open and emptyed of gubbins, it really screamed after that... So i fancied this watercooled version.

 

I have a full a licence and had it since the 90s, so power isnt an issue, (i also have a hornet 600) 

 

I bought the dtr with a siezed piston, siezed crank and a sump full of water due to it being parked outside, and somone nicked the gearbox / clutch oil cap.... There was even leaves inside... 

 

Anyway ive split the engine, cleaned it out, installed the required bearings, and bought a almost new original yamaha crank (4300mls on it) from a great guy on ebay uk.

 

Anyway its all reassembled with the exception of the piston kit, Ive just honed the bore and ordered a £30 piston kit from ebay, although it came with a wossner 8002da piston installed which im wondering if i should reinstall, it has a scratch on the lower portion of the piston, from the siezeure, but ive polished it up and rubbed down the scratch.  Is there a difference power difference between a cheaper cast piston (from bitz for bikes on ebay) and the wossner forged piston i have?

Im guessing the bike was 22-26hp from stock (it wasnt restricted like uk models) its a 4bl model with powervalve pulley functioning on the cables. 

 

Apart from a nexone (big-one) silencer and wossner piston, its all there and original, right down to the unused tools.

 

It came with 63000kms on the clock, a like new jap chain with good sprokets. Ive changed the crank, seals, crank bearings, little end bearing, cleaned up the powervalve (got new seals but not installed yet) . Clutch looks good, its been used in the city toing and froing from nice to monaco of all places, by a jeweler lol

Cleaned up the rusty tank interior, cleaned out the carb, disassembled cleaned and reassembled the whole bike and lubed everything, got a new spark plug and airfilter, struggling with finding an original 1997 graphic for the right side rad cowling, buffed up the plastics... 

 

Anything else you guys recomend, especially engine wise?

 

Cheers rick



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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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RE: My 1997 dt125r project (french spec bike) bought siezed (head gasket gone) and gearbox oil cap missing (parked outsi
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get some pics up pal

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still trying to figure how to upload lol Ill get there!!!

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some pics of engineless bike and the scored forged wossner piston



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Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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engine is up at my uncle's place, hes got more tools than a dealer (ex ship engineer), the bike mostly reassembled is in my garage, and I have an assortment of bits in a box in the livingroom to keep me busy of an evening while watching tv with the mrs lol it was ment to be a joint project with my 15yr old lad, but so far its me doing all the donkey work lol

When I bought it in Nice City centre it was chained to a rail in a motorbike parking place, opposite the police station for 8 months it sat there since the head gasket went on the previous owner, (safe place to park a bike!!) although I had 7 diffrent police come over and ask me whos bike I was disassembling and slowly putting in my ford focus estate... of course it slowed me right down having to keep producing the papers...

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Haha great story!

Yeah there are a few things.

PERSONALLY stay away from cheap piston kits. If you must then I'd recommend a Mitaka piston kit.

I've noticed no difference in power from a wossner only the necessity to upjet!

If the head gaskets gone then you'll want to gently skim the head and barrel using a sheet of glass and some wet and dry. And one thing that is an ABSOLUTE MUST on these bikes is a GENUINE or an ATHENA head gasket. Can't stress that enough.

Chances are that it's a pattern on there atm that's why it went. Pattern ones are white. Gen and athena's are black.

Not familiar with those codes on any engines i've stripped but probably wasn't looking. I'm sure someone can help.

I'm sorry but they were not 22-26 bhp standard. More like 15 bhp. I'm running a aftermarket programmable ignition with full DEP system and it doesn't reach that sort of power. But as you rightly said, full bike license so power shouldn't be an issue. But the main thing is power delivery IMO. And the DT can be fun on the delivery side. Sure nothing compared to your bikes haha.

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RE: My 1997 dt125r project (french spec bike)
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Rwszc wrote:

some pics of engineless bike and the scored forged wossner piston


 ISINT THAT A WISECO PISTON



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Thanks guys...

Removed a black head gasket and skimmed the surfaces, + polished exhaust port, powervalve, honed/deglazed bore,

Wiseco? Maby its the numbers i was guessing its wossner...

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Yeah my wossner piston was charcoal grey round the edges.

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wiseco it is then.... Im here for advice after all and if i can help anyone along the way great ( I'm a marine chief engineer the only 2 stroke i usually deal with are V16 Detroit diesels lol), this piston was never black sides i sanded off some carbon marks that is all, no black sides...

I'm temped to get it going, however the engineer in me is tempted to get max flow from it.

www.motorcyclespecs.co.za/model/yamaha/yamaha_dt125r%2096.htm others mentioned 26bhp, but my little brother bought a YZF r125 (a1 licence), i did the test ride and checks etc.....the french unrestricted DT125r aparently is an A licence requirment... (unlike the uk version) so Im interested to see the difference between the two bikes when i get the dt running...

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Heres my Wossner like Calypso says grey sided






-- Edited by NEV on Wednesday 5th of February 2014 08:35:20 PM

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looks nice!!!!! does it have the drilled hole under the bottom side im still trying to figure out where my piston camefrom

 

numbers on the domed crown are 30099-36  second rowis 6 digits with x over all of them then 3rd row 8002da????

 

inside W56 Z



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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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begining to wonder if mine is just worn with use ie no  grey sides???



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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol

NEV


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It's possible aye, numbers seem to tally for the size the extra ones on mine are because of the oversize, with yours being the standard

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yea mine is the standard bore, its just under 56 on the piston and 56 on the factory barrel, even after the honing...

 



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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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thinking of trying the brake spray method on the exhaust, as its heavy (im assuming heavy with 2 stroke oil!!!) so Im wondering if the brake cleaner spray will work or do i need to crack out the grinder and welding gear + respray. its original yamy front tube with Nexone/big-one rear silencer..

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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol

NEV


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theres aslo the caustic soda way, be careful its a bit dodgy, look on youtube on how to do it

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used caustic soda on the house drains in Yorkshire lol It didnt seem to be working so I added hydrochloric.... big mistake boom... big mess (1 was 15 then lol) parent wernt happy... lol the old days lol.

Dont know the words for caustic soda here in france... some things are a struggle....

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Try its chemical compound formula Sodium hydroxide, also known as caustic soda, or lye, is an inorganic compound with the chemical formula NaOH.

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Ill give it a whirl down at the local hardware (costarama) cheers

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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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Itching for my piston kit to arrive from uk.. got the gaskets, waiting for a oil screw cap too. cant wait to fire it up.... its been years since Ive riden a dt and never a watercooled.... Ive tiddied up the wossner piston I think Ill reuse it, although i havent seen the cheapy new piston yet... but I think Ill use the kit just not the piston... bleed and renewed the dot4 fluid, its not lashing rain today... come on post... piston kit and oil filler cap....

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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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Yes I bet you can't wait to hear the mighty beast roaring, in her natural habitat.

I bet you can't wait to feel that 2 stroke power surging throughout your entire body.

The wind in your hair, the sweet smell of intoxicating 2 stroke sneaking up your nasal passage....



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I used to rip up imposable mud trails and rocky riverbeds in se asia, no one for miles around... i was under 20yrs old then, gained a few self stitches and superglued gashes from it too... no doctors for 7hrs distance!!! even got washed down a monsoon swelled river with the old aircooled dt... I was on a promace and the typhoon wast going to stop me.... It had a good try and waterlogged the bike. but pushing a DT for a few miles aint tough...

Looking forward to getting up in the alps and testing the carb icing function to the limit, 45mins behind my place is the ski resorts of the alps, so I throughly intend to do some snow ripping before the month is up...

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Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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That's the life, just a bloke and his bike enjoying what mother earth has to offer.



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Well almost there now, remounted the engine, fitted the 2t oil tank, installed the cleaned carb, greased swingarm (ars* as some rollerpins fell out and couldnt get 1 back in so re assembled minus1) but its swing arm not wheel bearings so should be fine, just to fill the sump oil, grease gun on mono sus, and the small end bearing , then it will be run in time....... that new graphic on the starboard side, + a tank of petrol and it will be run in time Pics whil follow as soon as I remember to bring the camera lol


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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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Disassembled the Exhaust and put the Yamaha front bit to soak in caustic soda (after endless searching its called soude caustique here in france) came in liquid form so couldnt exactly boil it...

end can is a crappy looking big-one (nexone) which started to get the polish treatment (then my dremmel died) so drilled the rivits and cleaned out the crap instead, Looking forward to getting this thing running, went through all the electrics with WD40, installed some new parts ie indicators, and tried to fix the RPM snapped coil spring, bit this is tricky, so only a running test will see if it works, ......... this bikes taken some work and energy, If a DTR forum Good guy sells me the side graphic I need you will get some good photos and one happy Rick (me)

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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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Never tried the caustic soda treatment before... i did it 2 times over 2 nights with pretty neat caustic soda, then a huge rince for 30 mins with hose while occasionlly smacking it with a rubber mallet..... odd thing is carbon bits are still falling out... is this normal 4 days on... the more the better of course but it was 4 days ago (dryed since) and carbon bits are still coming out in chunks... lol Perhaps I should have cut it open and cleaned manually then rewelded???

Its driving me crazy... I ordered a small end bearing from a certain fella in portmouth on ebay 1st feb and am still waiting for it... starting to get real narky about the delay...

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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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Running at last!!!! my post in the electrics department explains it was the flywheel not fitting over the stator properly as my new crank is a 2004.. bike engine is 1996. the fitment is slightly different using a a uk 2004 crank on a 1996 french spec full power DT.

Bike is running a bit like a dog, but i honed the bore and its all new bearings, so I guess it takes time to settle in, although its running like a 50cc at the moment... struggling like hell on hills even in 2nd gear... cleaned the carb to as new... just before running it, its a fueling and or power valve issue... I think..... although its making a noise on uphills and hard acceleration, it sounds like the noise my 200cc xr used to make when pinking on bad petrol. however it revs freely downhill and on flats,
fuel tap is a bit dodgy too, maby because its not seen fuel in over 12 months.. , i de rusted the tank as best I could, but it still taints the fuel a little(there is a little filter pre carb and im going to fit an after market paper filter I have), so maby the slightly tainted fuel affects things... Im hoping the more i run it the better it will get.......

it starts easy when warm, but a total swine to start cold choke on or off its a pig to start, i found bumping it down hill works much better... good news is its cooling properly and no leaks (except the petrol tap for the first 10 mins now thats sealed its self)

and front brake isnt as good as the rear brake for unknown reason (bleed thru new fluid on both brakes) maby a bit of wd got on the disc as some point......

its dark now but photos will follow soon.... prob tomorrow... but its looking better than it runs at the moment...

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cheers Rwszc rick...

Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol



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Very interesting story to this dt!
You might have the PV set up wrong if its really struggling. Common mistake is that it probaly 180degrees out.
About that needle roller falling out of the swing arm.. should really replace the full set now. It could cost you double if not as urll naker the tubes that go inside the barings/over the pivot bolt. Plus itlle upset the handling if one side is missing some needles. As a chief marine engineer i would of thought that u woulda got small things like that sorted properly and not bodged it ? Lol


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Lol its a work in progress this bike, I bought it as a siezed challenge with leaves in the sump. ITs been bodged to get it running but when its running good Ill sort the little issues like pivot bearings, neither clocks work (but milage meter works as does the temp), both hand levers are bent and a pain in the arse to use, before putting it into daily use Ill sort all this... Ive spent 400£ just on parts so far, including 10 micron filters to install between the tank and carb at a later stage..... My usual prob is time as I work 100hr weeks somtimes...

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Some say Live to ride, I say ride to live, and depending how you ride, decides how long u live lol

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