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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
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  • 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
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              • 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
                          1
                          • NINJAN NINJA

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

                            Louis-DT-WRL Offline
                            Louis-DT-WRL Offline
                            Louis-DT-WR
                            wrote on last edited by
                            #137

                            @NINJA yes, this engine had a fair few leaks I sorted today

                            Oil pump

                            Gear lever seal

                            Water pump.

                            Also putting the water pump pipe back in caused many problems, took so many attempts to get it to seal.

                            But now have a fully functioning to 2stroke pump 😁.. as it was from the factory.

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

                              @NINJA yes, this engine had a fair few leaks I sorted today

                              Oil pump

                              Gear lever seal

                              Water pump.

                              Also putting the water pump pipe back in caused many problems, took so many attempts to get it to seal.

                              But now have a fully functioning to 2stroke pump 😁.. as it was from the factory.

                              NINJAN Offline
                              NINJAN Offline
                              NINJA
                              wrote on last edited by
                              #138

                              @Louis-James Nice one, I feel your pain, as I've very recently been there myself. :pouting_face: :pouting_face: :pouting_face:

                              It sounds like either a lot of gaskets have perished or not been fitted properly in the first place? Either way an overhaul of em all may be prudent??? 😉

                              SEDUCED BY THE DARK SIDE!!!

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

                                @Louis-James Nice one, I feel your pain, as I've very recently been there myself. :pouting_face: :pouting_face: :pouting_face:

                                It sounds like either a lot of gaskets have perished or not been fitted properly in the first place? Either way an overhaul of em all may be prudent??? 😉

                                Louis-DT-WRL Offline
                                Louis-DT-WRL Offline
                                Louis-DT-WR
                                wrote on last edited by
                                #139

                                @NINJA always when someone else does work 😂

                                I've thoroughly checked all over. The top end had been rebuilt with a wiseco piston.
                                I did check that.

                                But one of the last bits done to the engine was a new clutch and water pump seal.

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

                                  @NINJA always when someone else does work 😂

                                  I've thoroughly checked all over. The top end had been rebuilt with a wiseco piston.
                                  I did check that.

                                  But one of the last bits done to the engine was a new clutch and water pump seal.

                                  NINJAN Offline
                                  NINJAN Offline
                                  NINJA
                                  wrote on last edited by
                                  #140

                                  @Louis-James Well hopefully the only bumps you'll see from now on, will be the ones you are jumping over MX styleee!!! 😉

                                  SEDUCED BY THE DARK SIDE!!!

                                  1 Reply Last reply
                                  1
                                  • Louis-DT-WRL Offline
                                    Louis-DT-WRL Offline
                                    Louis-DT-WR
                                    wrote on last edited by
                                    #141

                                    So the oil pump was not flowing. Took it off and the outlet was block. Removed the hose tail and I drilled the smaller bore. Oil now flows through.

                                    Without taking the pump alart again I am unsure if I have drilled too deep and the oil is bypass internally. By blowing through it and operating the throttle.. it doesn't seem to flow more or less on throttle position. Does there need to be drive to the pump and is it a variable gear inside is what changes the flow?

                                    So going to have to inspect.
                                    Or compare to another.

                                    Also bike cuts out when put into gear with stand up or down.. I think it's a faulty sidestand switch
                                    A few little things to sort 🤣

                                    Anyway.. a few pics

                                    alt text
                                    alt text
                                    alt text

                                    alt text
                                    alt text

                                    1 Reply Last reply
                                    4
                                    • CalumC Offline
                                      CalumC Offline
                                      Calum
                                      wrote on last edited by
                                      #142

                                      Bike looks superb. Done an excellent job there. Definitely will be on that infamous hall of fame...

                                      Yeah side stand switch is common on all bikes. Should be relatively simple to figure out.

                                      Hopefully it's the switch and not the CDI.

                                      Yeah pumps can be weird to diagnose, better run premix whilst you're figuring it all out!

                                      Always Originate, Never Pirate!

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

                                        Bike looks superb. Done an excellent job there. Definitely will be on that infamous hall of fame...

                                        Yeah side stand switch is common on all bikes. Should be relatively simple to figure out.

                                        Hopefully it's the switch and not the CDI.

                                        Yeah pumps can be weird to diagnose, better run premix whilst you're figuring it all out!

                                        Louis-DT-WRL Offline
                                        Louis-DT-WRL Offline
                                        Louis-DT-WR
                                        wrote on last edited by
                                        #143

                                        @Calum thanks a lot man.

                                        It didn't have a side stand switch before.
                                        It was looped (wiring present) but I bought a universal switch. I'll do a circuit test on it.

                                        Yes I'm running premix arm. Engine is sweet!
                                        No leaks!

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

                                          @Calum thanks a lot man.

                                          It didn't have a side stand switch before.
                                          It was looped (wiring present) but I bought a universal switch. I'll do a circuit test on it.

                                          Yes I'm running premix arm. Engine is sweet!
                                          No leaks!

                                          NINJAN Offline
                                          NINJAN Offline
                                          NINJA
                                          wrote on last edited by NINJA
                                          #144

                                          @Louis-James The bike looks mint bud - TOP JOB!!! :thumbs_up_light_skin_tone:

                                          Have you ridden her yet???

                                          SEDUCED BY THE DARK SIDE!!!

                                          Louis-DT-WRL 1 Reply Last reply
                                          1
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