Yamaha dt125re rebuild

[liquid-snake]

Fine looking machine there, the rust on the subframe isn't too bad compared my '02 R. Regrettably a younger version of myself opted for the grinder and hammerite bodge fix which has made it a devil to sort without proper blast/powdercoating. For the love of all thats holy if youre going to this much effort do it right and save headaches down the line.

I found my standard headlight to be complete garbage, in fact I used to refer to it as the "Prince of darkness". Don't recall trying any of the fancier bulbs out there but I've yet to be impressed with any bike headlight out there with the exception of the '02 ZX-6R. Oncoming traffic was always a case of aim-for-the-lights-and-2-feet-left with the DT.

Is this going to be a full nut/bolt restoration or more of a seriously deep clean? As for colour IMO you can't beat the yammy blue. Also saves the faffery with V5 colour changes.

[BraDT]

This more of a deep clean and things getting replaced if needed

The colour of the frame is going gloss black for now as need to stay within budget and wasn’t keen on the blue frame and black hide dirt well
Same for the swing arm and forks there going black

The tank plastics etc are staying blue with decals yet to be decided

95% of the rust if off the bike with grinding I know it won’t be the first time this bike gets done as this is my first attempt at the rebuild but next time will definitely be getting shot blasted and powdered coated

[BraDT]

All primed ready for paint tomorrow

https://i.imgur.com/wC5D8qA.jpg

[BraDT]

Banked holiday over and got the frame paint swingarm and few other little bits done it’s now to start putting back together and find out what needs replacing

[Calum]

Looking sweet bud.

[NINJA]

@bradt Black is the new black I see!!! :face_with_stuck-out_tongue_winking_eye:

[BraDT]

Easy colour to paint with and hides tho slight imperfections photos don’t show the shine enough will get more pics when forks and wheels are on

[BraDT]

Right I’m stuck, confused and baffled

I’ve taken the starter motor off with having problems of the annoying clicking noise new battery new relay all wire checked cleaned etc so I know it’s something with the starter
Should I be able to move this cog by hand ?
It doesn’t move at all could this be my problem?

https://i.imgur.com/Ll9LnEz.jpg

[Calum]

@bradt I don't think you should be able to move it by hand IIRC.

[BraDT]

Well starter motor been cleaned down etcand put back on engine fingers crossed

Engine back in bike now with front front forks and wheel

Finally getting somewhere

[Calum]

That's looking decent mate!

Nice job.

[BraDT]

@calum cheers mate

Right tonight after work I am changing the gear selector seal any tips or step step guide ?
Isit a case of digging the old one out and tapping the new one in ?

[Calum]

@bradt Easier to do when there is no gear lever in the way mate.

You will risk damaging the shaft and causing a permanent oil leak.

IIRC, it should not be difficult to remove the gear lever out put.

Whip the clutch cover off and remove it. Then remove the seal, then replace the seal, then replace the lever. IIRC.

[declan]

@calum I do mine with the shaft still in and it’s way easy bud

[BraDT]

@declan any tips ?

[BraDT]

@calum cheers mate sound complicated lol

[Calum]

@bradt It really isn't shaft just pulls out, giving you clear access to the oil seal.

[BraDT]

@Calum so clutch cover off any need to remove the clutch basket or anything else?

Really didn’t wanna tip the engine apart on this build wanted it to be simple and learn as I go but I have learnt it will never be a simple job

[Calum]

@bradt If you damage the shaft, it will always leak oil and you will need a new shaft. It's just hacky to do it in situe, but can be done.

I can't remember how it is on these engines, what is in the way.

But that should be pulled out from the clutch cover side. You don't need to remove it, just pull it clear of the oil seal so you don't damage it.

[declan]

@bradt I just levered it out with a small flat head cleaned up then pushed the other in I didn’t do nothing special but taking out the shaft is sensible just not for me