Project DTZr.....a DT125R love story

[MadGyver]

Welcome to the DTZr, a love child of....1 bike with parts from other 3 and lot of ....love....parts.

A first year 4BL model,it began it's life somewhere in Germany and then came to Greece in 1996 to a rental shop,after that came to my possession.

Unfortunately most of the pics from early stages are lost,due to data corruption years ago in my HDD.

It's condition now is this

The 3 bikes from where parts used.
TZR 125 2RH gearbox and clutch assembly
TZR 250 3MA wheels,disc brakes,
DT 200R 3ET Forks with air valves,shock absorber,alloy swingarm,headlight,headlight mask,right radiator

love...parts
Athena 170kit
DEP exhaust system
new Mikuni 28 with power jet kit to be fitted
parts in general.....

PS.I was going to buy a DT200R but every one found was raped at best.

[MadGyver]

Plastics repair.
Plastics where damaged and brush painted with car chassis paint.Grey stuff is putty for plastics.

[Calum]

Looking very smart bud. Loving the fact you're "Keeping it within the family" so to speak...

[MadGyver]

The crank before and after.

[MadGyver]

The cracnkcases,before and after cleaning and smoothed/matched/checked inside

TZR 125 2RH gearbox (one model of the old TZR had the same gear ratios with the TZR 125RR Belgarda),that one is fitted.
Had to find some different bearings to install,not same with the DT.

[MadGyver]

Repairing a hard to find DT200R 3ET alloy swing arm,and this considered good condition.

[Louis-DT-WR]

@MadGyver I like that colour swing arm good work

[Yamboy46]

This is a interesting build. Nice one dude.

[MadGyver]

Hello,after a long time,it's a slow project due to some personal matters from time to time.
"Last minute" tuning to crankcases for matching,widening,angles retaining and "little" tuning to Athena cylinder/head (trasnfer port shape and sizes,exhaust port shape,size and timing,combustion chamber volume,compression)

[MadGyver]

Wheels condition when purchased and finished

[Calum]

Fabulous stuff!

[NINJA]

@MadGyver Top job bro, have you resprayed them yourself???

[MadGyver]

Thank you all.
Yes almost everything is painted,machined by me,only an custom axle-spacers for the front-back wheel and a welding back of the frame tail base because of a broken bolt was done to a machine shop.

[MadGyver]

This is the frame after the paint removal and acid treatment for the rust,then painted,before paint,cold zinc was applied to the frame for rust protection.That stage and the frame in original condition was lost in the data corruption.

[NINJA]

@MadGyver Nice paint job. :thumbs_up_medium-light_skin_tone:

[MadGyver]

This post is deleted!

[MadGyver]

Hello after a long time.
I had to open the crankcases because of a faulty gearbox part (even checked I've missed it).
Did some further tweaking to the cases,matched them 99+% I believe,and gave a texture to help flow and "grab" more mixture,widened a little the reed valve space and removed some metal from the low right corner for the RZ350 reed valve to be installed.

[MadGyver]

The finished DTZr,it's on the road,I am doing some runnin km's and will go to a friends dyno.

Passed technical inspection with "flying colors".
I didn't put the 3ET headlight because it's no good for night,if you want to see and not just others to see you.

PS.I will shorten a little the front fender.

[Nottsbiker]

Bike looks great and similar (not wheels) to my old DTR that I built years back (profile picture).

I've just bought a 3ET light unit for my 200WR as I believe that they are the same so I'm gutted to hear that they are poor output but I want to go back to stock as the 125X unit I've got does come in white and therefore looks odd.

Interesting that you've also gone down the 3ET swingarm route as I've got one ready to go on my 3SH build - great minds think alike!

[Calum]

@madgyver Yeah that looks mint to be fair. Done a great job on that.