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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

    @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
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            • 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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              • 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
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                • 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
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                                • 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
                                      • NINJAN NINJA

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

                                        Have you ridden her yet???

                                        Louis-DT-WRL Offline
                                        Louis-DT-WRL Offline
                                        Louis-DT-WR
                                        wrote on last edited by
                                        #145

                                        @NINJA thank you 🙂
                                        I rode it before I stripped it down.... rapid!
                                        I've just got a few little things to sort out before taking it for a proper spin

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

                                          @NINJA thank you 🙂
                                          I rode it before I stripped it down.... rapid!
                                          I've just got a few little things to sort out before taking it for a proper spin

                                          NINJAN Offline
                                          NINJAN Offline
                                          NINJA
                                          wrote on last edited by
                                          #146

                                          @Louis-James COOL she should go better with the upgrades, let us know how she handles. 😉

                                          SEDUCED BY THE DARK SIDE!!!

                                          Louis-DT-WRL 1 Reply Last reply
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