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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 69.4k Views 5 Watching
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  • 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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            • 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
                              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
                                    • 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
                                        0
                                        • NINJAN NINJA

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

                                          Louis-DT-WRL Offline
                                          Louis-DT-WRL Offline
                                          Louis-DT-WR
                                          wrote on last edited by
                                          #147

                                          @NINJA will do not too keen on knobblies on the road.. but definitely suits it physically

                                          NINJAN 1 Reply Last reply
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