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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 70.5k Views 5 Watching
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  • 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
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      • 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
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                • 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
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                      • 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
                                  0
                                  • Louis-DT-WRL Louis-DT-WR

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

                                    NINJAN Offline
                                    NINJAN Offline
                                    NINJA
                                    wrote on last edited by NINJA
                                    #133

                                    @Louis-James You're welcome - I'm not sure if they are for your model, as there's quite a few to download online. Just do a search for your model/year and you'll probably find the correct one??? 😉

                                    SEDUCED BY THE DARK SIDE!!!

                                    1 Reply Last reply
                                    0
                                    • D Offline
                                      D Offline
                                      DTR+NSR
                                      wrote on last edited by
                                      #134

                                      Is the clutch hub and basket lined up correctly seem to remember you can fit the dt one 4 different ways but will only work in one position

                                      Louis-DT-WRL 1 Reply Last reply
                                      1
                                      • D DTR+NSR

                                        Is the clutch hub and basket lined up correctly seem to remember you can fit the dt one 4 different ways but will only work in one position

                                        Louis-DT-WRL Offline
                                        Louis-DT-WRL Offline
                                        Louis-DT-WR
                                        wrote on last edited by
                                        #135

                                        @DTR-NSR thanks guys it's all sorted now.
                                        Good thing I checked because the water pump didn't have a gasket in there 😂
                                        This is what happens when other people rebuild

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

                                          @DTR-NSR thanks guys it's all sorted now.
                                          Good thing I checked because the water pump didn't have a gasket in there 😂
                                          This is what happens when other people rebuild

                                          NINJAN Offline
                                          NINJAN Offline
                                          NINJA
                                          wrote on last edited by
                                          #136

                                          @Louis-James A bullet dodged there dude!!! :thumbs_up_light_skin_tone:

                                          SEDUCED BY THE DARK SIDE!!!

                                          Louis-DT-WRL 1 Reply Last reply
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