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DT125R FORUM

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  4. DT200WR restoration project pic heavy

DT200WR restoration project pic heavy

Scheduled Pinned Locked Moved DTR
272 Posts 17 Posters 70.1k Views 5 Watching
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  • F Offline
    F Offline
    finnerz89
    wrote on last edited by
    #113

    If the lamps are standard my money is on the relay. Try disconnecting one and see if you get a flash then.
    Is the switchgear new?

    Current bikes:
    DT125X '07
    Street Triple R '11
    Aprilia ETV1000 '02

    Previous:
    DR650RSE '96
    FJ1200 '92

    Louis-DT-WRL 1 Reply Last reply
    0
    • F finnerz89

      If the lamps are standard my money is on the relay. Try disconnecting one and see if you get a flash then.
      Is the switchgear new?

      Louis-DT-WRL Offline
      Louis-DT-WRL Offline
      Louis-DT-WR
      wrote on last edited by
      #114

      @finnerz89 does a single flash then stats on.. always the small things take the time haha.

      F 1 Reply Last reply
      0
      • Louis-DT-WRL Louis-DT-WR

        @finnerz89 does a single flash then stats on.. always the small things take the time haha.

        F Offline
        F Offline
        finnerz89
        wrote on last edited by
        #115

        @Louis-James another thought, is the light in the clocks led? Try disconnecting that if it is

        Current bikes:
        DT125X '07
        Street Triple R '11
        Aprilia ETV1000 '02

        Previous:
        DR650RSE '96
        FJ1200 '92

        Louis-DT-WRL 1 Reply Last reply
        -1
        • CalumC Offline
          CalumC Offline
          Calum
          wrote on last edited by
          #116

          Yeah, could be your chinese clocks causing problems.

          Always Originate, Never Pirate!

          1 Reply Last reply
          0
          • F finnerz89

            @Louis-James another thought, is the light in the clocks led? Try disconnecting that if it is

            Louis-DT-WRL Offline
            Louis-DT-WRL Offline
            Louis-DT-WR
            wrote on last edited by
            #117

            @finnerz89 no because I'm only using the new clocks shell. All wires and bulbs I swapped over

            F 1 Reply Last reply
            0
            • Louis-DT-WRL Louis-DT-WR

              @finnerz89 no because I'm only using the new clocks shell. All wires and bulbs I swapped over

              F Offline
              F Offline
              finnerz89
              wrote on last edited by
              #118

              @Louis-James hmmmm 🤔

              Current bikes:
              DT125X '07
              Street Triple R '11
              Aprilia ETV1000 '02

              Previous:
              DR650RSE '96
              FJ1200 '92

              1 Reply Last reply
              0
              • Louis-DT-WRL Offline
                Louis-DT-WRL Offline
                Louis-DT-WR
                wrote on last edited by
                #119

                https://youtu.be/La0VeAoF2fU

                1 Reply Last reply
                1
                • F Offline
                  F Offline
                  finnerz89
                  wrote on last edited by
                  #120

                  Looking good 👍

                  Current bikes:
                  DT125X '07
                  Street Triple R '11
                  Aprilia ETV1000 '02

                  Previous:
                  DR650RSE '96
                  FJ1200 '92

                  Louis-DT-WRL 1 Reply Last reply
                  0
                  • F finnerz89

                    Looking good 👍

                    Louis-DT-WRL Offline
                    Louis-DT-WRL Offline
                    Louis-DT-WR
                    wrote on last edited by
                    #121

                    @finnerz89 thanks 🙂 I'll get some more videos outside on a nice day

                    1 Reply Last reply
                    0
                    • CalumC Offline
                      CalumC Offline
                      Calum
                      wrote on last edited by
                      #122

                      Yeah that looks mega!

                      Always Originate, Never Pirate!

                      Louis-DT-WRL 1 Reply Last reply
                      1
                      • CalumC Calum

                        Yeah that looks mega!

                        Louis-DT-WRL Offline
                        Louis-DT-WRL Offline
                        Louis-DT-WR
                        wrote on last edited by
                        #123

                        @Calum cheers mate.

                        Just finishing the final parts.

                        Going to inspect the oil pump drive gear to ensure its all ok as the guy before disconnected it.

                        The pump leaks from the oil seal. I've stripped, cleaned and ordered a new seal.

                        Always the last little things like the brake lights sensitivity etc to finish

                        alt text

                        alt text

                        1 Reply Last reply
                        1
                        • Louis-DT-WRL Offline
                          Louis-DT-WRL Offline
                          Louis-DT-WR
                          wrote on last edited by
                          #124

                          Need a bit of advice.
                          I'm not used to this clutch set up.

                          I only removed the clutch cover to fit a new oil pump gear.

                          But when I put it back on the Kickstarter wouldn't crank.
                          After playing around I got that back into action.

                          However there is no tension in the clutch lever.
                          I'm not sure it the clutch arm needs a full 360deg rotation.
                          I'm not very familiar with this setup.
                          The clutch operated fine before and was a new one when I bought the bike.

                          Part 11 in this diagram just wobbles around.. but I'm not sure if it's correct.

                          https://www.fowlersparts.co.uk/parts/4098902/wr200r-4bf1-1992-999-a/clutch

                          NINJAN 1 Reply Last reply
                          0
                          • Louis-DT-WRL Louis-DT-WR

                            Need a bit of advice.
                            I'm not used to this clutch set up.

                            I only removed the clutch cover to fit a new oil pump gear.

                            But when I put it back on the Kickstarter wouldn't crank.
                            After playing around I got that back into action.

                            However there is no tension in the clutch lever.
                            I'm not sure it the clutch arm needs a full 360deg rotation.
                            I'm not very familiar with this setup.
                            The clutch operated fine before and was a new one when I bought the bike.

                            Part 11 in this diagram just wobbles around.. but I'm not sure if it's correct.

                            https://www.fowlersparts.co.uk/parts/4098902/wr200r-4bf1-1992-999-a/clutch

                            NINJAN Offline
                            NINJAN Offline
                            NINJA
                            wrote on last edited by
                            #125

                            @Louis-James Did you not take any pics before you dismantled it???

                            SEDUCED BY THE DARK SIDE!!!

                            Louis-DT-WRL 1 Reply Last reply
                            0
                            • NINJAN NINJA

                              @Louis-James Did you not take any pics before you dismantled it???

                              Louis-DT-WRL Offline
                              Louis-DT-WRL Offline
                              Louis-DT-WR
                              wrote on last edited by
                              #126

                              @NINJA I didn't dismantle anything.
                              All I did was removed the casing and replaced the oil pump gear.
                              I didn't touch the clutch.
                              alt text

                              alt text

                              NINJAN 1 Reply Last reply
                              0
                              • Louis-DT-WRL Louis-DT-WR

                                @NINJA I didn't dismantle anything.
                                All I did was removed the casing and replaced the oil pump gear.
                                I didn't touch the clutch.
                                alt text

                                alt text

                                NINJAN Offline
                                NINJAN Offline
                                NINJA
                                wrote on last edited by NINJA
                                #127

                                @Louis-James Well that's weird, maybe you have just discovered a fault before it ruined all your hard work???

                                SEDUCED BY THE DARK SIDE!!!

                                Louis-DT-WRL 1 Reply Last reply
                                0
                                • NINJAN NINJA

                                  @Louis-James Well that's weird, maybe you have just discovered a fault before it ruined all your hard work???

                                  Louis-DT-WRL Offline
                                  Louis-DT-WRL Offline
                                  Louis-DT-WR
                                  wrote on last edited by
                                  #128

                                  @NINJA I think I need to remove the clutch arm and rotate it. See what I find tomorrow haha
                                  Wish I did it when the engine was out.
                                  The water pipe it the biggest pain to fit.

                                  1 Reply Last reply
                                  0
                                  • F Offline
                                    F Offline
                                    finnerz89
                                    wrote on last edited by
                                    #129

                                    I had a similar issue on an old bike, the clutch arm operates like a rack and pinion, the arm being the pinion part. I had to engage it further down the rack to get the full range of movement. It's spring loaded, I hope that makes sense lol.

                                    Current bikes:
                                    DT125X '07
                                    Street Triple R '11
                                    Aprilia ETV1000 '02

                                    Previous:
                                    DR650RSE '96
                                    FJ1200 '92

                                    Louis-DT-WRL 1 Reply Last reply
                                    0
                                    • F finnerz89

                                      I had a similar issue on an old bike, the clutch arm operates like a rack and pinion, the arm being the pinion part. I had to engage it further down the rack to get the full range of movement. It's spring loaded, I hope that makes sense lol.

                                      Louis-DT-WRL Offline
                                      Louis-DT-WRL Offline
                                      Louis-DT-WR
                                      wrote on last edited by
                                      #130

                                      @finnerz89 it has a stability spring on the arm.
                                      But it should be resisted by the 5 clutch springs.
                                      Thanks yes it is a rack and pinion type

                                      NINJAN 1 Reply Last reply
                                      0
                                      • Louis-DT-WRL Louis-DT-WR

                                        @finnerz89 it has a stability spring on the arm.
                                        But it should be resisted by the 5 clutch springs.
                                        Thanks yes it is a rack and pinion type

                                        NINJAN Offline
                                        NINJAN Offline
                                        NINJA
                                        wrote on last edited by NINJA
                                        #131

                                        @Louis-James These any good to ya???

                                        http://mybikemanuals.com/yamaha/yamaha-wr-owners-manuals/

                                        https://www.ebay.co.uk/itm/WORKSHOP-MANUAL-YAMAHA-WR200R-/332115601413

                                        SEDUCED BY THE DARK SIDE!!!

                                        Louis-DT-WRL 1 Reply Last reply
                                        1
                                        • NINJAN NINJA

                                          @Louis-James These any good to ya???

                                          http://mybikemanuals.com/yamaha/yamaha-wr-owners-manuals/

                                          https://www.ebay.co.uk/itm/WORKSHOP-MANUAL-YAMAHA-WR200R-/332115601413

                                          Louis-DT-WRL Offline
                                          Louis-DT-WRL Offline
                                          Louis-DT-WR
                                          wrote on last edited by
                                          #132

                                          @NINJA thanks for that the link has the manual. Hopefully sort it tomorrow

                                          NINJAN 1 Reply Last reply
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