DT 125 mega overhall + engine rebuild. (picture heavy)

MartZ0r · Nova Slayer Joined: 24 Sep 2008 Karma :

BenR · World Chat Champion Joined: 23 Jun 2008 Karma :

Cool! Another DT project, love these bikes. A suggestion for the powder coating how about red for the frame & have the swingarm chrome plated? Thumbs Up

Good luck with it mate will be keeping an eye on this thread. Thumbs Up

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Current bikes: suzuki RG125UN wolf. Yamaha MT-07

MartZ0r · Nova Slayer Joined: 24 Sep 2008 Karma :

cheers ben, they are fun bikes to work on imo, would be a boring build if it wasnt so rusty! all those snapped threads and nuts iv had to weld back on all add to the fun.

i dont know anyone who does chrome plating and how much it costs, but it is a nice idea. atm its kinda looking towards a gloss black frame, with kawazaki green and black plastics (2 tone). with a silver swingarm/engine/forks.

badas · Scooby Slapper Joined: 22 Mar 2010 Karma :

nice bike,

i would definatly go for chrome swing arm,

as for colours... i would go for ilumines green frame and black (or carbon effected) plastic with monster energy graphics Wink

or replace hte illuminus green with uber bright orrange Very Happy

MartZ0r · Nova Slayer Joined: 24 Sep 2008 Karma :

badas · Scooby Slapper Joined: 22 Mar 2010 Karma :

if your lucky (i don't know what i can name and not name on these forrums) but on the bay, also google (use UK search only) motocross graphics

be warned for a decent set of graphics your looking at £90 to £130+

Smile

DrDonnyBrago · World Chat Champion Joined: 03 Jan 2010 Karma :

evoboy · World Chat Champion Joined: 20 Aug 2009 Karma :

MartZ0r · Nova Slayer Joined: 24 Sep 2008 Karma :

MugenSeiki · Could Be A Chat Bot Joined: 13 Oct 2008 Karma :

https://www.dualsport-fx.com/

https://www.dualsport-fx.com/gallery.html

https://pstolasdesign.no.comunidades.net/index.php?pagina=contactos

https://pstolasdesign.no.comunidades.net/index.php?pagina=1264103233

https://pstolasdesign.no.comunidades.net/index.php?pagina=1408182816

www.ddgraphics.co.uk
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www.dt125.co.uk

MartZ0r · Nova Slayer Joined: 24 Sep 2008 Karma :

right guys, finally some progress!

had my parts back from the bike shop. had the crank rebuilt with a new conrod kit and trued up, rebored barrel and a new piston kit and had some blind bearings removed, what a great job they did!

had all that done and a gasket set for £160.

Now onto the rebuild.

First i heated the cases up in the oven and dropped the nice new koyo crank bearings in the right side crank case and dropped the frozen crank into the bearing.

https://i276.photobucket.com/albums/kk27/MartZ0r06/Yamaha%20DT%20125R%20Rebuild/DSC00116.jpg

https://i276.photobucket.com/albums/kk27/MartZ0r06/Yamaha%20DT%20125R%20Rebuild/DSC00118.jpg

All the new bearings fitted, minus the primary shaft bearing as i struggled to get a new one that was exact and tbh the bearing was in mint condition anyways.

https://i276.photobucket.com/albums/kk27/MartZ0r06/Yamaha%20DT%20125R%20Rebuild/DSC00117.jpg

Gears installed and the selector forks all setup corrently

https://i276.photobucket.com/albums/kk27/MartZ0r06/Yamaha%20DT%20125R%20Rebuild/DSC00125.jpg

my fresh rebored barrel and new mitaka piston. the barrel was previously rebored to + 1.50, so the bike shop had to do bore + 50, so now the piston is a 2.00 oversize.

https://i276.photobucket.com/albums/kk27/MartZ0r06/Yamaha%20DT%20125R%20Rebuild/DSC00124-1.jpg

https://i276.photobucket.com/albums/kk27/MartZ0r06/Yamaha%20DT%20125R%20Rebuild/DSC00121.jpg

Cases fitted together and started fitting clutch side and oil seals

https://i276.photobucket.com/albums/kk27/MartZ0r06/Yamaha%20DT%20125R%20Rebuild/DSC00126.jpg

Most of the clutch side done, not much left now

https://i276.photobucket.com/albums/kk27/MartZ0r06/Yamaha%20DT%20125R%20Rebuild/DSC00127.jpg

https://i276.photobucket.com/albums/kk27/MartZ0r06/Yamaha%20DT%20125R%20Rebuild/DSC00128.jpg

this is as far as i got for tonight. tomorrow im am taking the cylinder head to work as there is a snapped bolt stuck in the thermostat housin. so im going to need to retap it.[/img]

misterdave · Renault 5 Driver Joined: 08 Jan 2010 Karma :

What about XT/KTM orange for the frame and handle bars and then black or white for panels I think that would look nice although I love orange bikes xD
I just bought a DT so I think I need to do all this but I have no idea when it comes to bikes so will be a steep learning curve, may be a silly question but what is ultrasonic cleaning? is it just taking a rape alarm and stuffing it in the engine until the dirt falls off? haha
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Squires. Yamaha XT125X - sold. Yamaha DT125R ['97]

MugenSeiki · Could Be A Chat Bot Joined: 13 Oct 2008 Karma :

Using electricity to remove crap to put it short mate Laughing

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www.dt125.co.uk

MartZ0r · Nova Slayer Joined: 24 Sep 2008 Karma :

basicly yeah, i had a friend do it for me at work but im gonna have a go at the old DIY method for cleaning the swingarm.

the colour scheme you mensioned was what we decided to go with a few days ago. its a "safe" colour Very Happy

i saw a DT with a similar colour and it looked good Smile

misterdave · Renault 5 Driver Joined: 08 Jan 2010 Karma :

what colour did you decide? the orange or the monster colours?
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Squires. Yamaha XT125X - sold. Yamaha DT125R ['97]

27cows · World Chat Champion Joined: 01 Nov 2009 Karma :

Tasty. I love working on Yam strokers.
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The RXS100: vehicle of choice for Chuck Norris

MartZ0r · Nova Slayer Joined: 24 Sep 2008 Karma :

misterdave · Renault 5 Driver Joined: 08 Jan 2010 Karma :

Niiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiice Very Happy

keep us posted
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Squires. Yamaha XT125X - sold. Yamaha DT125R ['97]

badas · Scooby Slapper Joined: 22 Mar 2010 Karma :

how about gloss black wheels with orrange wheel trim Wink

??

nice progress so far, i really wish i got a DT now rather than the old honda mtx Sad

as far as looks go Razz

lol

MartZ0r · Nova Slayer Joined: 24 Sep 2008 Karma :

MugenSeiki · Could Be A Chat Bot Joined: 13 Oct 2008 Karma :

Yes , spokes turn and spin , coating over them while on the rim is asking for trouble Thumbs Up

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www.dt125.co.uk

MartZ0r · Nova Slayer Joined: 24 Sep 2008 Karma :

THE HOG · Derestricted Danger Joined: 12 May 2009 Karma :

nice project mate, good bikes these and a lot of them that are badly abused good to see one is getting the treatment it deserves keep it up mate

MartZ0r · Nova Slayer Joined: 24 Sep 2008 Karma :

update, fresh sprayed engine. taking some time to build this as im only able to really do work on it on the weekends. cash is tight unfortunatly so lack of updates!

i have now also got a Powervalve servo and all the assembly for it coming next week.

but here we go

https://i276.photobucket.com/albums/kk27/MartZ0r06/Yamaha%20DT%20125R%20Rebuild/DSC00191.jpg

badas · Scooby Slapper Joined: 22 Mar 2010 Karma :

lovely

fill the engine casing "Yamaha" text in with white or some other colour to make it pop out more Smile