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element
World Chat Champion
Joined: 23 Jan 2006
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 Posted: 00:20 - 25 Jul 2007  Post subject: 92' TZR125 rebuild.. |
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I ride a DT and had an impulse to by a TZR one night. The TZR is pretty much the same as the DT engines up to the latest ones (only a few slight modifications through the years) so I could learn to fix this bag o shite before I pull my 04 DT125RE apart in the near future  . I jumped onto ebay and found one local going for 200 quid. Went to see it and omg was it a state. link to the item..
https://w3.bikepics.com/pics/2007/11/12/bikepics-1085861-full.jpg
Basically translates into
Worn piston - Replaced. Turns out to be 1mm oversize
Water in the gearbox - New water pump seal and still filling with water  
Front master cylinder that has an air leak (have to pump the brake to work) - Fixed
Bent levers - Replaced
Lumps of rust or other crap in the tank - Fixed. Was a lump of something solid?!
Bent clip-ons Bidding on
Almost bald front tyre
A flat rear tyre that you cant pump up Fixed
bent forks/yokes or even the frame (Which I bet it is  )
Slightly bent back wheel
Rusted exhaust with a whole that was patched up. You can fit 4 fingers in the size of this hole. funny thing is 90% of the whole system is perfect and the last 10% is knackered - bodged with a metal based putty
Ripped seat
Worn, rusted. slack chain and sprockets
Proper knackered rear shock and rusted spring
Anyhow heard it run and it sounded fine . Looked at the clock... 27k miles!! The guy selling it (beefy bike gang blokey) said it was not much.. I asked when the last rebuild was and he said he didnt know  .
In the end I got it for 250. I thought even if I spent 500 quid doing it up it would be worth it so rode it home (that was an experience).. Try going from one of the highest bikes on the road to something that feels like a bloody minimoto
I rode straight into the garage and started pulling panels off and dropped the engine to inspect the piston/barrel. I had already looked up the exhaust port and noticed some scoring..
https://www.apbe19.dsl.pipex.com/tzr/tzrpiston1.jpg
https://www.apbe19.dsl.pipex.com/tzr/tzrpiston2.jpg
https://www.apbe19.dsl.pipex.com/tzr/tzrpiston3.jpg
The barrel doesnt look in bad shape at all though. Only light polish marks. I'll get some pics up soon.. I also checked the crank and there was no play. Not bad for 27k miles! Cleaned the head and the powervalve which was covered in oil/carbon
Ive also flushed out what I can of the milky crap in the gearbox with cheap engine oil. How can water get into the gearbox?
more pics
https://www.apbe19.dsl.pipex.com/tzr/tzrfrontwheel.jpg
https://www.apbe19.dsl.pipex.com/tzr/tzrrearwheel.jpg
Gonna change the wheels for the newer mag type. Then going to swap the swingarm to convert from the horrible looking drum brake
https://www.apbe19.dsl.pipex.com/tzr/tzrrearsets.jpg
Getting polished or powdercoated. Footrests to be replaced with pegs
https://www.apbe19.dsl.pipex.com/tzr/tzrunderbelly.jpg
Frame is being powdercoated black (If its not bent)
https://www.apbe19.dsl.pipex.com/tzr/tzrengine.jpg
https://www.apbe19.dsl.pipex.com/tzr/tzrengineout.jpg
https://www.apbe19.dsl.pipex.com/tzr/tzrnice.jpg
This is how I would like it to look but black and grey  [/img]
____________________
04' DT125RE (run-a-bout) // 89' DT125R (rebuilt + supermoto conversion)
SPARES FOR SALE. 2RK TZR // 82 DR125 // DT125R/E .... PM ME...
Last edited by element on 16:17 - 24 Mar 2008; edited 2 times in total |
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shaun_04
Brolly Dolly
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| derbi x-treme |
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derbi x-treme
Nova Slayer
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c-m
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| eddclarke |
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eddclarke
Brolly Dolly
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dougon2wheels
Nitrous Nuisance
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| element |
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element
World Chat Champion
Joined: 23 Jan 2006
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| Posted: 20:20 - 25 Jul 2007 Post subject: |
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i was thinking it was the water pump seals letting water into the gearbox. Wasnt sure though if there are other ways of getting water in the box. It was quite milky  Im in the proccess of getting the side casing off at the minute. Am I ok to just take the screws out and then take the casing off? worried things will start to fall out as I take it off!
Also the marks on the piston arnt gouges. If you run your nail across them you can just feel slight scratches if any. I was gonna get the barrel checked (but it looks fine to me), then replace little end, piston and rings. I might stick racing reeds in while Im at it too since they are only 20 quid. Worth doing or just a waste of money?
Also I noticed when I took the head off that there was 2 head gaskets.. Is this because the head is warped or was the previous owner trying to make the bike quicker? I havent got a steel rule to check if the head is flat so thats something else to buy..
Another question... How do I clean the oil level window? Its all white A few hot rides/oil changes?
____________________
04' DT125RE (run-a-bout) // 89' DT125R (rebuilt + supermoto conversion)
SPARES FOR SALE. 2RK TZR // 82 DR125 // DT125R/E .... PM ME... |
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| Ottobeil |
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Ottobeil
Scooby Slapper
Joined: 13 Apr 2007
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| Posted: 23:45 - 25 Jul 2007 Post subject: |
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I am looking at a TZR at the moment and placed my bid in this morning.
I serioiusly hope mine isnt like that. all though i will be respraying mine 
Good luck with it all and keep us updated
____________________
[Herchee Fun 50] .: Stolen :.
[RXS 100] x 2
[TZR 125] x 2 |
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element
World Chat Champion
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element
World Chat Champion
Joined: 23 Jan 2006
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| Posted: 10:02 - 27 Jul 2007 Post subject: |
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Right... Got the water pump seal out.. Just need to get a new one, fit it, get a new piston, rings, gaskets and little end bearing and then I can stick the whole engine back together
____________________
04' DT125RE (run-a-bout) // 89' DT125R (rebuilt + supermoto conversion)
SPARES FOR SALE. 2RK TZR // 82 DR125 // DT125R/E .... PM ME... |
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element
World Chat Champion
Joined: 23 Jan 2006
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| Posted: 01:32 - 29 Jul 2007 Post subject: |
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Right. New piston kit, small end bearing and water pump seal fitted. I got everthing bolted back together and filled up with gearbox oil. Ive also scrubbed most of the frame and engine but theres still alot of grime to clean.
Also fitted a new brake lever and a wholenew clutch lever.
next is to tidy up the frame, swiingarm, rearsets, seat cowling, clipons..... replace the rear shock, get the fork legs off so i can check if they are straight and then put the engine back in so I can run it about and check everything is ok before getting the frame/new swingarm/fork legs sandblasted and powdercoated and converting the rear drum to disc.
more pics soon..
____________________
04' DT125RE (run-a-bout) // 89' DT125R (rebuilt + supermoto conversion)
SPARES FOR SALE. 2RK TZR // 82 DR125 // DT125R/E .... PM ME... |
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c-m
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| Posted: 12:19 - 30 Jul 2007 Post subject: |
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element
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| Posted: 01:29 - 02 Aug 2007 Post subject: |
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element
World Chat Champion
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| Posted: 14:12 - 04 Aug 2007 Post subject: |
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ok. Started to polish the swingarm up with an drill and a wire disc. Starting to look well nice. Ive also started the rearsets and the exhaust. Next the Frame...
Also gearbox is STILL taking in water. The water pump impeller fited tightly into the seal so I cant see it leaking from there. So where else is it taking water from?
Polished frame or powdercoated black frame....
Im also thinking of street fightering it 
____________________
04' DT125RE (run-a-bout) // 89' DT125R (rebuilt + supermoto conversion)
SPARES FOR SALE. 2RK TZR // 82 DR125 // DT125R/E .... PM ME... |
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element
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| Posted: 00:28 - 05 Aug 2007 Post subject: |
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element
World Chat Champion
Joined: 23 Jan 2006
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| Posted: 01:55 - 06 Aug 2007 Post subject: |
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today I replaced the master cylinder and it's sorted the brakes. I think the disc maybe warped though because the wheel binds at a certain point £70-80 for an EBC replacement. Feck that. This one is slightly concaved too so it deffo needs replacing now.
Also flushed out the gearbox oil. No doubt it will turn to crap again
Not as bad as it was when I first got it but its still crap..
____________________
04' DT125RE (run-a-bout) // 89' DT125R (rebuilt + supermoto conversion)
SPARES FOR SALE. 2RK TZR // 82 DR125 // DT125R/E .... PM ME... |
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Old Thread Alert!
There is a gap of 231 days between these two posts... |
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element
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AJI
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| sagalout |
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sagalout
Nearly there...
Joined: 09 Jun 2006
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| Posted: 10:43 - 25 Mar 2008 Post subject: |
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Interesting project this - the TZR125 was my first bike, back in 1990, and the only bike I ever bought brand new. Always had a bit of a soft spot for it |
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element
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element
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element
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| Posted: 14:28 - 17 May 2008 Post subject: |
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been a while and since ive lost the data cable to my fone I cant upload any pics but progress has been made... haha ive had this bike almost a year... Next year it "should" be finished.. I knew it was gonna be a long one..
so far ive..
stripped bike to rolling chassis
stripped, filled and primered tank ready for spraying
stripped, cleaned, polished petrol cap
polished rear master cylinder
stripped both rearsets ready for powder coating
stripped most of the paint off the frame
filled and primered seat cowl
started removing decals and sanding body panels
cleaned up tons of bolt heads
polished rear caliper mount
still need
replacement rear shock (original one is dead)
swingarm from a disc model tzr (to be powdercoated)
clip-ons (to be powdercoated)
forks from a 16" front wheel TZR (to be powdercoated)
front caliper (from a 16" front wheel TZR)
braided brake lines
new brake pads
new chain and sprockets (gold chain)
new wheel bearings (all round)
front mudguard
to do
triple clamps to be powdercoated
finish stripping frame to metal then powdercoated
rearsets to be powdercoated
frame mounts/brackets to be powdercoated
headlight frame to be powdercoated
re-cover seat
weld exhaust (until i find a decent replacement)
fabricate tail tidy
wheels to be powdercoated
more in another 3 months no doubt....haha
____________________
04' DT125RE (run-a-bout) // 89' DT125R (rebuilt + supermoto conversion)
SPARES FOR SALE. 2RK TZR // 82 DR125 // DT125R/E .... PM ME... |
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| binge |
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binge
Emo Kiddy
Joined: 03 Jul 2004
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| Posted: 11:17 - 18 May 2008 Post subject: |
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Just out of interest, Are you getting that tyre replaced?
I ask because you got nitromors allover it! 
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike - |
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gaz56
Borekit Bruiser
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Phil_Norwich
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Old Thread Alert!
The last post was made 15 years, 346 days ago. Instead of replying here, would creating a new thread be more useful? |
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