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DT125R FORUM

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  4. 1989 rebuild update

1989 rebuild update

Scheduled Pinned Locked Moved DTR
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  • O Offline
    O Offline
    oldman
    wrote on last edited by oldman
    #48

    0_1513043722601_20171211_175923-1224x1632.jpg
    Started on the brakes, rebuilt front master cylinder and refinished rear master cylinder and caliper mount, calipers next and genuine throttle cable if that arrives tomorrow 0_1513043713984_20171211_172125-1224x1632.jpg
    0_1513043752460_20171211_161718-1224x1632.jpg

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    • O Offline
      O Offline
      oldman
      wrote on last edited by
      #49

      Rebuilt/refinished front master cylinder, genuine throttle cable arrived as well, joy!0_1513070520688_20171212_091557-1224x1632.jpg

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      • CalumC Online
        CalumC Online
        Calum
        wrote on last edited by
        #50

        Looking good.

        Always Originate, Never Pirate!

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        • O Offline
          O Offline
          oldman
          wrote on last edited by
          #51

          Genuine cable operates carb and oil pump perfectly but stem that extends in to oil pump housing still too long to fit securing circlip? Definitely ordered correct year from Fowlers? Pattern part from same supplier I used for the red 88 yet to arrive but that was correct length to for circlip?
          Stripped rear caliper and really grotty, paint removed (not hard, flaking off mostly) and cleaned, in ultrasonic cleaner prior to refinishing and reassembly. Pitting on piston but have new one anyway.
          ANY comments about cable welcome?
          0_1513100245152_20171212_165703-1224x1632.jpg
          0_1513100277236_20171212_170606-979x1305.jpg

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          • O Offline
            O Offline
            oldman
            wrote on last edited by
            #52

            Here's a pic of caliper before work. Nice!0_1513100789264_received_10155356869674926-750x1200.jpeg

            declanD 1 Reply Last reply
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            • O oldman

              Here's a pic of caliper before work. Nice!0_1513100789264_received_10155356869674926-750x1200.jpeg

              declanD Offline
              declanD Offline
              declan
              wrote on last edited by
              #53

              @oldman have you tried adjusting the cable in the junction box housing

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              • O Offline
                O Offline
                oldman
                wrote on last edited by
                #54

                It's not the cable, it's the outer metal end that protrudes throughout the cable entry of oil pump. There is a recess in the end of this for a circlip to prevent cable being pulled out of the oil pump housing. On my 88 bike the length was perfect, meaning you placed the metal shaft through the housing and the circlip secured cable outer tight to the housing. The Yambits cable just did not work, did not pull oil pump pulley unless outer sheath pulled out of oil pump housing 8 to 10mm, also difficult to take slack out of cable at throttle end. Hopefully pattern part I used previously will be here tomorrow to compare, will post some pics when I go back I'm garage.

                declanD 1 Reply Last reply
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                • O oldman

                  It's not the cable, it's the outer metal end that protrudes throughout the cable entry of oil pump. There is a recess in the end of this for a circlip to prevent cable being pulled out of the oil pump housing. On my 88 bike the length was perfect, meaning you placed the metal shaft through the housing and the circlip secured cable outer tight to the housing. The Yambits cable just did not work, did not pull oil pump pulley unless outer sheath pulled out of oil pump housing 8 to 10mm, also difficult to take slack out of cable at throttle end. Hopefully pattern part I used previously will be here tomorrow to compare, will post some pics when I go back I'm garage.

                  declanD Offline
                  declanD Offline
                  declan
                  wrote on last edited by declan
                  #55

                  @oldman I did have this exact problem I had to make an adjuster using a clutch cable adjuster

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                  • O Offline
                    O Offline
                    oldman
                    wrote on last edited by
                    #56

                    Here is the caliper straight out of the ultrasonic cleaner ready for finishing, need a spray booth!0_1513105780208_received_10155357237199926-1200x750.jpeg 0_1513105792123_received_10155357234189926-1200x750.jpeg

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                    • O Offline
                      O Offline
                      oldman
                      wrote on last edited by
                      #57

                      Cable adjuster wouldn't work, cable length is fine, length of metal insert to oil pump housing too long,

                      CalumC 1 Reply Last reply
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                      • O oldman

                        Cable adjuster wouldn't work, cable length is fine, length of metal insert to oil pump housing too long,

                        CalumC Online
                        CalumC Online
                        Calum
                        wrote on last edited by
                        #58

                        @oldman There is supposed to be a rubber o ring that goes on that metal insert FYI

                        Always Originate, Never Pirate!

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                        • O Offline
                          O Offline
                          oldman
                          wrote on last edited by
                          #59

                          Thanks Calum, but the insert is about 8 to 10mm too long, I will post some pictures up as soon as I get a chance, grandad duty calls tomorrow so Thursday likely, should have repro cable by then as well.

                          declanD 1 Reply Last reply
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                          • O oldman

                            Thanks Calum, but the insert is about 8 to 10mm too long, I will post some pictures up as soon as I get a chance, grandad duty calls tomorrow so Thursday likely, should have repro cable by then as well.

                            declanD Offline
                            declanD Offline
                            declan
                            wrote on last edited by
                            #60

                            @oldman no the adjuster was for the metal housing like I said the exact same problem I had the adjuster made it so I can either adjust the metal housing in our out more

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                            • O Offline
                              O Offline
                              oldman
                              wrote on last edited by
                              #61

                              Repro cable arrived, see photo, with O ring perfect fit, I know it's not much, do you think original cable is designed for a bit of play in it?
                              If I put a cable adjuster to correct to correct(?) fit would also pull on oil pump pulley opening oil pump prematurely, as fitted inner cable perfect length and opens oil pump in sync with throttle.
                              0_1513162951720_received_10155358894284926-750x1200.jpeg

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                              • CalumC Online
                                CalumC Online
                                Calum
                                wrote on last edited by
                                #62

                                Don't forget, there were two types of oil pumps that came on these engines. Therefore I'd expect to see two different types of cables.

                                That bottom silver one looks more familiar to me, but I have the later engine. Earlier engines use different pumps.

                                Always Originate, Never Pirate!

                                declanD 1 Reply Last reply
                                0
                                • CalumC Calum

                                  Don't forget, there were two types of oil pumps that came on these engines. Therefore I'd expect to see two different types of cables.

                                  That bottom silver one looks more familiar to me, but I have the later engine. Earlier engines use different pumps.

                                  declanD Offline
                                  declanD Offline
                                  declan
                                  wrote on last edited by
                                  #63

                                  @calum yeah I have the same pump as you

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                                  • O Offline
                                    O Offline
                                    oldman
                                    wrote on last edited by
                                    #64

                                    Both the Yamaha cable and Yambits (unuseable) cable same length spigot, oil pump came with bike and same as my 88 so no reason to suspect change there. Perhaps I am looking for a problem that does not exist. Repro received today fits perfect though, Yamaha cable operates throttle and pump in unison so no issues with suitability, only that the circlip indent doesn't locate near to cable entry near oil pump housing as per the repro used previously. Will give it some thought and probably leave original in place, maybe make spacer that fits inside oil pump housing.

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                                    • O Offline
                                      O Offline
                                      oldman
                                      wrote on last edited by
                                      #65

                                      Stripped the front brake caliper, in poor condition, dust seal filled with brake fluid and piston fitted back to front, you can see a bit of the piston seal in the dust seal groove. Sure the damage was done when the piston was fitted by whoever. Chucked the lot in the ultrasonic cleaner before I touch it, cleaner need fresh fluid anyway.0_1513284449187_20171214_201327-1224x1632.jpg 0_1513284468055_20171214_201334-1224x1632.jpg 0_1513284489831_20171214_201343-1224x1632.jpg 0_1513284506861_20171214_201352-1224x1632.jpg

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                                      • O Offline
                                        O Offline
                                        oldman
                                        wrote on last edited by
                                        #66

                                        This is the caliper after ultrasonic clean.
                                        0_1513291995813_20171214_224839-1224x1632.jpg 0_1513292017354_20171214_224852-1224x1632.jpg

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                                        • O Offline
                                          O Offline
                                          oldman
                                          wrote on last edited by
                                          #67

                                          Calipers painted and rebuilt, fitted loose to bike, waiting for rear master cylinder hose to and front cable clip to arrive. Refitted carb with 240 main jet, again waiting for engine water hoses to arrive so I can fill and try starting engine (😨), speedo cable fitted and swingarm chain protector/upper roller fitted. Not too much to do now, wheels not back from Central yet and Galfer disc unlikely to arrive until new year.
                                          0_1513549593410_20171217_142416-1024x576.jpg 0_1513549605072_20171217_143425-576x1024.jpg

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