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DTR Build Up

Scheduled Pinned Locked Moved DTR
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  • ConnorDTRC ConnorDTR

    @Calum That's where i found the other info i posted up lol, just need to wait for my dad to go out so i can steal the bathroom mirror! Hoping it'll be good for a bit, was so fun riding the bike! Also offroad is hard, i'll post a proper update in an hour or so

    CalumC Offline
    CalumC Offline
    Calum
    wrote on last edited by
    #55

    @ConnorDTR that's the one mate. Flat surface as possible. Nice ciruclar motion.

    Believe me, if you have read my.build thread then you know it can sort out a battered 21 year old engine that had clearly been run with the head gasket gone for a long time lol.

    Always Originate, Never Pirate!

    ConnorDTRC 1 Reply Last reply
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    • CalumC Calum

      @ConnorDTR that's the one mate. Flat surface as possible. Nice ciruclar motion.

      Believe me, if you have read my.build thread then you know it can sort out a battered 21 year old engine that had clearly been run with the head gasket gone for a long time lol.

      ConnorDTRC Offline
      ConnorDTRC Offline
      ConnorDTR
      wrote on last edited by
      #56

      @Calum What grit did you use? Pretty sure i've got some fine emery cloth here aswell, or is that still too rough? I've got 2000 grit but it's those crap little rolls that are about 10 cm wide from halfrauds

      CalumC 1 Reply Last reply
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      • CalumC Offline
        CalumC Offline
        Calum
        wrote on last edited by
        #57

        Oh dear! Yes I see what's happened here. That barrel could get away without a hone to ne fair. But you're the right thing.

        I was running my dt with too much fuel and it bore washed and scored similar. But wasn't the end of the world. Still runs.

        Always Originate, Never Pirate!

        1 Reply Last reply
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        • ConnorDTRC ConnorDTR

          @Calum What grit did you use? Pretty sure i've got some fine emery cloth here aswell, or is that still too rough? I've got 2000 grit but it's those crap little rolls that are about 10 cm wide from halfrauds

          CalumC Offline
          CalumC Offline
          Calum
          wrote on last edited by
          #58

          @ConnorDTR pretty sure it was 120, 240 &460

          Always Originate, Never Pirate!

          ConnorDTRC 1 Reply Last reply
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          • CalumC Calum

            @ConnorDTR pretty sure it was 120, 240 &460

            ConnorDTRC Offline
            ConnorDTRC Offline
            ConnorDTR
            wrote on last edited by
            #59

            @Calum That's the cylinder i'm going to save for a proper hone or if need be a rebore, also not going to use the same place as last time, £140, supplied me with cheap gasket set and a mitaka piston and it took 2 months... Think the reason it didn't run was because all the compression was leaking past the head gasket then. And that's pretty low, quiet a rough grit then? I have some 400 grit from doing my wheels, i'll give it a go tomorrow cheers

            CalumC 1 Reply Last reply
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            • ConnorDTRC ConnorDTR

              @Calum That's the cylinder i'm going to save for a proper hone or if need be a rebore, also not going to use the same place as last time, £140, supplied me with cheap gasket set and a mitaka piston and it took 2 months... Think the reason it didn't run was because all the compression was leaking past the head gasket then. And that's pretty low, quiet a rough grit then? I have some 400 grit from doing my wheels, i'll give it a go tomorrow cheers

              CalumC Offline
              CalumC Offline
              Calum
              wrote on last edited by
              #60

              @ConnorDTR a rebore is 30. Forged piston is 60 and a genuine head gasket is 20. Done deal. I get mine done at Yamaha.

              Always Originate, Never Pirate!

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              • ConnorDTRC Offline
                ConnorDTRC Offline
                ConnorDTR
                wrote on last edited by
                #61

                Gave my head the gentle skim, used 400grit wet and dry as that's all i had, just means it takes longer to skim down the high spots if anything.
                http://i.imgur.com/9XG04L0.jpg?1
                Used the cookers glass top, just because it was a bit more like a workbench lol

                http://i.imgur.com/kRSEAhz.jpg?1
                Here's the head in question, as you can see it's looking rather ugly. Did the old straight metal ruler over the head and see if any light passed underneath trick to see if there was any warpage, to my eyes i couldn't see much light. But i suppose a mm is like a mile when it comes to warpage. Haynes states anything more than 0.03mm is buggered.

                http://i.imgur.com/t41qiAV.jpg?1
                http://i.imgur.com/dVFpdzd.jpg?1
                This was after the first pass, looks a lot better, none of those huge scratches and the surface is becoming a lot flatter.

                http://i.imgur.com/9Oe9qRi.jpg?1
                This was the state of the first sandpaper

                http://i.imgur.com/lWPfBO6.jpg?1
                This is what i ended up with, i still believe that maybe i should just go a grade higher to get a more smooth finish. But atleast the ring of dirt round where the cylinder meets the head has gone.

                CalumC 1 Reply Last reply
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                • ConnorDTRC ConnorDTR

                  Gave my head the gentle skim, used 400grit wet and dry as that's all i had, just means it takes longer to skim down the high spots if anything.
                  http://i.imgur.com/9XG04L0.jpg?1
                  Used the cookers glass top, just because it was a bit more like a workbench lol

                  http://i.imgur.com/kRSEAhz.jpg?1
                  Here's the head in question, as you can see it's looking rather ugly. Did the old straight metal ruler over the head and see if any light passed underneath trick to see if there was any warpage, to my eyes i couldn't see much light. But i suppose a mm is like a mile when it comes to warpage. Haynes states anything more than 0.03mm is buggered.

                  http://i.imgur.com/t41qiAV.jpg?1
                  http://i.imgur.com/dVFpdzd.jpg?1
                  This was after the first pass, looks a lot better, none of those huge scratches and the surface is becoming a lot flatter.

                  http://i.imgur.com/9Oe9qRi.jpg?1
                  This was the state of the first sandpaper

                  http://i.imgur.com/lWPfBO6.jpg?1
                  This is what i ended up with, i still believe that maybe i should just go a grade higher to get a more smooth finish. But atleast the ring of dirt round where the cylinder meets the head has gone.

                  CalumC Offline
                  CalumC Offline
                  Calum
                  wrote on last edited by
                  #62

                  @ConnorDTR you will want to do both the block and head mate since they are both ally.

                  Nice idea I like that. Can't imagine my old dear would be pleased if she caught me doing that back in the day haha!

                  Always Originate, Never Pirate!

                  ConnorDTRC 1 Reply Last reply
                  1
                  • CalumC Calum

                    @ConnorDTR you will want to do both the block and head mate since they are both ally.

                    Nice idea I like that. Can't imagine my old dear would be pleased if she caught me doing that back in the day haha!

                    ConnorDTRC Offline
                    ConnorDTRC Offline
                    ConnorDTR
                    wrote on last edited by
                    #63

                    @Calum It's going onto a different cylinder, i've got 2 lol. This one originally came with the engine, i just didn't want to use it because the bottom bolt for the powervalve cover was fudged. But i checked out this cylinder with the ruler and i couldn't see any light coming from underneath the ruler

                    But yeah i did wait for my Dad to go to work before i started doing that, he'd have actually strung me up if he saw this

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                    • CalumC Offline
                      CalumC Offline
                      Calum
                      wrote on last edited by
                      #64

                      I always skimmed the barrel just to clean it up. Make sure it's legit. I always used the paper after I finished the head. Cleans it up nicely.

                      Always Originate, Never Pirate!

                      ConnorDTRC 1 Reply Last reply
                      0
                      • CalumC Calum

                        I always skimmed the barrel just to clean it up. Make sure it's legit. I always used the paper after I finished the head. Cleans it up nicely.

                        ConnorDTRC Offline
                        ConnorDTRC Offline
                        ConnorDTR
                        wrote on last edited by
                        #65

                        @Calum I'll have a look to see if i've got anymore paper, you are talking sense

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                        • ConnorDTRC Offline
                          ConnorDTRC Offline
                          ConnorDTR
                          wrote on last edited by
                          #66

                          Well it's been a good 16 days since i uploaded my last update where i was on my way to fixing the bike, since then a fair bit has happened.

                          The headgasket skim and new athena gaskets worked a lovely treat, i'm no longer burning coolant or having any bubbling in my expansion tank. So that has sorted out my overheating problem. However that was actually nothing to do with the reason why my bike broke down, there was plenty of compression even though there was scores on the piston and cylinder.
                          http://i.imgur.com/njWanLL.jpg?1
                          *The excitement of my gaskets turning up
                          *
                          http://i.imgur.com/uMgOotS.jpg?1
                          To be fair, working on this engine is absolutely piss easy

                          http://i.imgur.com/A64U8GY.jpg?1
                          First time using this baby, 22nm for the head nuts

                          So when I put the engine back together and expected it to kick into life i was quite disappointed, kicked as hard as i could but nothing happened, i also noted a new grinding sound coming from my bottom end. So disheartened i decided "Fuck it" and put the bike back in the shed for next months payday to be spent rebuilding this engine. But a few hours later i thought i'd take a more diagnostic approach to it, i'd see why the bike wouldn't start. Decided to have a look at the spark plug see what it had to say, it looked completely fine. So i'd see if i had any spark, earth the plug to the cylinder and kicked to see a spark, however there was nothing. That was a start to getting her back, automatically assumed that it would be the coilpack.

                          Waited to borrow a multimeter from a friend, but still wanted to know what this new grinding noise i was hearing. Tracked it to the left hand side of the engine lol, guess where this is going. Took the side cover off and found that the flywheel had worked it's way completely loose, how embarrasing. It was just spinning on the crankshaft. I never actually tightened it up properly. So i put the bike in gear, held the rear brake on and tightened the sucker as much as i could. Now that it was tight i kicked the bike again, bursted straight into life. What a relief, makes all the same noises as before, a strange ticking (like a ratchet) noise which i fear are my big ends or crank bearings trying to escape from where they live.

                          Anyhow i rode off to see my friends at the pub 8ish miles away, made it without any problems to be fair, apart from hitting reserve right outside of the pub. That scared me a bit, not used to a bike with a manual petcock.

                          Anyways the bike was working all fine so i decided to take it to college, 20 or so miles away. Got there perfectly and all. On break i decided to show my friends the bike and we'd go for a little ride/drive. 2 minutes in and my throttle cable gave up the ghost, however it had only came out of the weird slider thing in the junction box. So i borrowed some tools from the college and just put it back into it's holder thing, however the bike was now idling like a sack of shit. I had no clue what was happening, but it needed choke on to even get it to start and i had to play with the throttle to keep it going. I knew that this meant some sort of an airleak, but i couldn't fix it there at the college i was going to do it at home.

                          So it came time to go home and everything was going fine, apart from having to ride with the choke on and play with the throttle at the lights. About half way through my journey the throttle cable went again, i would NOT recommend the yambits throttle cables. They had this problem of coming loose in the junction box and also there is no oil pump adjustment. So i'm stuck at using 1l of oil every 200ish miles lol.

                          With no tools on me i pushed it to my friend who worked about 15 minutes away, got it all fixed and then continued my way home vowing to put the bike away until i had fixed all these problems. Well i got going again then my bloody flywheel worked loose again, bloody thing. Called up yet another friend to bring me some tools, tried to get the flywheel back on however it had at the woodruff key. With no access to a van and towing a bike being the scariest thing i have ever attempted. I decided to try my luck pushing the bike the rest of the way back home. 3 hours later and 5 miles up the road, me tired as anything, in the dark, cold and it was tipping it down, absolutely starving and thirsty i gave up. Finally got a van and got home. Never wanted to see the bike again.
                          http://i.imgur.com/68Ifl4U.jpg?1
                          Much preferred the car in the past few days, such a sense of security. Also alot warmer

                          However come today i've been rounding up a new woodruff key, a washer for the flywheel, some thread lock and soon a new throttle cable i've got to work. My stator is in one hell of a mess, the flywheel has destroyed most of the coils. But i fitted my new key, put the flywheel onto it, slid the washer onto the shaft, put some thread lock on the nut and the threads. held the flywheel with the correct tool this time and used a 1/2 ratchet and 17mm socket (brother has my torque wrench the only time i've actually needed it) i torqued that baby up good and proper. Couldn't move it anymore with a massive ratchet. The spec on this is 56 Nm if anyones interested.
                          http://i.imgur.com/tJBFFuH.jpg?1
                          here's the offender, nicely sat where it will hopefully stay for a while

                          So the bike starts again, scared to ride it anywhere now so going to sort out some breakdown cover, still need a new throttle cable and want to give it a bottom end rebuild as it sounds like a bag of nails

                          Sorry for the short novel

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                          • ConnorDTRC Offline
                            ConnorDTRC Offline
                            ConnorDTR
                            wrote on last edited by
                            #67

                            God damn just realised how much i look like i'm sponsored by halfords with all the tools lying around lol, making the most of my trade card

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                            • CalumC Offline
                              CalumC Offline
                              Calum
                              wrote on last edited by
                              #68

                              Oh dear not good.

                              That's kinda why I prefer the DTRE flywheel. It locks the woodruff key off from ever moving.

                              I have had the throttle cable go. Had to adjust idle so at least I could sit on it at 3mph home lmao.

                              I like driving a car, but it don't beat the bike.for me. Even the Starlet. Love it but give me a dt.

                              Always Originate, Never Pirate!

                              ConnorDTRC 1 Reply Last reply
                              1
                              • CalumC Calum

                                Oh dear not good.

                                That's kinda why I prefer the DTRE flywheel. It locks the woodruff key off from ever moving.

                                I have had the throttle cable go. Had to adjust idle so at least I could sit on it at 3mph home lmao.

                                I like driving a car, but it don't beat the bike.for me. Even the Starlet. Love it but give me a dt.

                                ConnorDTRC Offline
                                ConnorDTRC Offline
                                ConnorDTR
                                wrote on last edited by
                                #69

                                @Calum
                                I've not really seen the DTRE flywheel, but to be honest this could have been avoided if i torqued it up properly in the first place. Just makes me not trust the bike much as i've broke down twice now in one week.

                                I will have to buy a proper yamaha throttle cable, but i tried to do the whole coast thing but my reed cage had come loose so the bike wouldn't idle at all.

                                But at the moment i much prefer driving a car, even if it's not a special car. But i suppose that will change when i trust the bike and it's warmer weather

                                CalumC 1 Reply Last reply
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                                • ConnorDTRC ConnorDTR

                                  @Calum
                                  I've not really seen the DTRE flywheel, but to be honest this could have been avoided if i torqued it up properly in the first place. Just makes me not trust the bike much as i've broke down twice now in one week.

                                  I will have to buy a proper yamaha throttle cable, but i tried to do the whole coast thing but my reed cage had come loose so the bike wouldn't idle at all.

                                  But at the moment i much prefer driving a car, even if it's not a special car. But i suppose that will change when i trust the bike and it's warmer weather

                                  CalumC Offline
                                  CalumC Offline
                                  Calum
                                  wrote on last edited by
                                  #70

                                  @ConnorDTR yeah been there lmao. I feel your pain. I will no doubt go through the same problems as you whilst I get my bike up to scratch lol

                                  Always Originate, Never Pirate!

                                  ConnorDTRC 1 Reply Last reply
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                                  • CalumC Calum

                                    @ConnorDTR yeah been there lmao. I feel your pain. I will no doubt go through the same problems as you whilst I get my bike up to scratch lol

                                    ConnorDTRC Offline
                                    ConnorDTRC Offline
                                    ConnorDTR
                                    wrote on last edited by
                                    #71

                                    @Calum Nah just tighten everything up properly and you'll be sound pal lol

                                    CalumC 1 Reply Last reply
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                                    • ConnorDTRC ConnorDTR

                                      @Calum Nah just tighten everything up properly and you'll be sound pal lol

                                      CalumC Offline
                                      CalumC Offline
                                      Calum
                                      wrote on last edited by
                                      #72

                                      @ConnorDTR There will be something I'll miss that's for sure!

                                      Always Originate, Never Pirate!

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                                      • ConnorDTRC Offline
                                        ConnorDTRC Offline
                                        ConnorDTR
                                        wrote on last edited by ConnorDTR
                                        #73

                                        Right well it's been 2 months since the last update, and 300 miles later the bikes shagged again. Only conked out on me a mile from home this time though luckily, on a lovely hot day too. The first we've had in ages 😞 so home now and i took the spark plug out, all looks fine there. Did the stupid thumb over the spark plug hole and kicked the bike, it couldn't even push my thumb off. So i put some oil down the bore and kicked again. This time it actually had compression.

                                        So obviously need to do a top end and properly this time, but i've also got a horrible clunking sound from the bottom end and without knowing the previous history of this engine i'm going to do a full rebuild. However obviously this takes time and money, something which i'm short on at the moment having just renewed my car insurance, having to pay for uni deposits etc. So this is going on the side again for a while 😞 Right at the beginning of nice summer too! been getting tempted at selling it to be honest, but i've put so much work into this! I don't really enjoy it all to much, scared of it constantly breaking and hardly enjoying offroading. The bike has no low end power and is hard to cruise at a single speed.

                                        So thinking of either selling up, breaking the bike or stop being a little bitch and rebuild the engine, fit a 3 wire servo and go supermoto! Sad really i wanted a bike for summer

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                                        • DartyD Offline
                                          DartyD Offline
                                          Darty
                                          wrote on last edited by
                                          #74

                                          Hang in there dude, she's a nice DEET. It feels like a money pit, but it will be worth it. Your project has definitely pushed me starting full rebuild this year, and just saying fuck it to however long it will take, and blowing spare cash a little bit at a time.

                                          I know if I sell mine now, I'll only want another one later on.

                                          Keep it real

                                          ConnorDTRC 1 Reply Last reply
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