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  4. Yamaha DT125R '01 - Running Project

Yamaha DT125R '01 - Running Project

Scheduled Pinned Locked Moved DTR
portingignitech4dldtrwr200
135 Posts 27 Posters 92.5k Views 6 Watching
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  • DartyD Darty

    @andrewj1680 I know it's not perfect, cutting stuffers off is a big compromise to inlet air speed when using the standard Reed block.

    So to avoid that I'm using a VFORCE Reed block, still have to modify the mounts and cut the stuffers off, but the VFORCE will take care of the inlet volume and should give much better Midrange,

    @CYBER-NINJA Actually I did use a Orbital sander with 120 - 400 grit because these older swingarms have huge extrusion depressions under the thick paint, it looked very clumsy before, alot of material had to come away.

    alt text

    hand sanded in between and to Wet n Dry 600-800 grit, 1200 would be too anal.

    NINJAN Offline
    NINJAN Offline
    NINJA
    wrote on last edited by
    #78

    @Darty Came out damn good tho in the end, well worth the time and effort IMO. πŸ‘

    I need to do the same on my MX, I started with some wet & dry just to test it out, TBC..................

    SEDUCED BY THE DARK SIDE!!!

    DartyD 1 Reply Last reply
    0
    • NINJAN NINJA

      @Darty Came out damn good tho in the end, well worth the time and effort IMO. πŸ‘

      I need to do the same on my MX, I started with some wet & dry just to test it out, TBC..................

      DartyD Offline
      DartyD Offline
      Darty
      wrote on last edited by
      #79

      @CYBER-NINJA Thank you very much,

      It was about a days work, very satisfying to finish

      Keep it real

      NINJAN 1 Reply Last reply
      0
      • DartyD Darty

        @CYBER-NINJA Thank you very much,

        It was about a days work, very satisfying to finish

        NINJAN Offline
        NINJAN Offline
        NINJA
        wrote on last edited by
        #80

        @Darty Yeah lotsa elbow grease know doubt. I find using a good paint stripper with some steel wool works really well and also limits the scratches, then some wet & dry to smooth it all off, before you start on the polishing. All in all that method works very well and also it makes short work of the polishing. πŸ˜‰

        SEDUCED BY THE DARK SIDE!!!

        1 Reply Last reply
        0
        • A Offline
          A Offline
          andrewj1680
          wrote on last edited by
          #81

          0_1494210331154_Screenshot_2017-05-08-03-13-33-1.png 0_1494210363397_Screenshot_2017-05-08-03-13-45-1.png
          I did the whole polishing thing when I first started building my cr but by the time I finished I had decided I didn't wanna polish after every ride so I powder coated it black instead, did look the part tho

          DartyD NINJAN 2 Replies Last reply
          0
          • A andrewj1680

            0_1494210331154_Screenshot_2017-05-08-03-13-33-1.png 0_1494210363397_Screenshot_2017-05-08-03-13-45-1.png
            I did the whole polishing thing when I first started building my cr but by the time I finished I had decided I didn't wanna polish after every ride so I powder coated it black instead, did look the part tho

            DartyD Offline
            DartyD Offline
            Darty
            wrote on last edited by Darty
            #82

            @andrewj1680 Bang on! That would of looked mint, it's a shame alloy has to oxidise so quickly,

            Keep it real

            1 Reply Last reply
            0
            • A andrewj1680

              0_1494210331154_Screenshot_2017-05-08-03-13-33-1.png 0_1494210363397_Screenshot_2017-05-08-03-13-45-1.png
              I did the whole polishing thing when I first started building my cr but by the time I finished I had decided I didn't wanna polish after every ride so I powder coated it black instead, did look the part tho

              NINJAN Offline
              NINJAN Offline
              NINJA
              wrote on last edited by
              #83

              @andrewj1680 Oh man, that sure looks damn sweet, and such a shame to do all that work and then get all that lovely shiny metal blacked out. But hey-hoo I get why and it was your choice.

              SEDUCED BY THE DARK SIDE!!!

              A 1 Reply Last reply
              0
              • NINJAN NINJA

                @andrewj1680 Oh man, that sure looks damn sweet, and such a shame to do all that work and then get all that lovely shiny metal blacked out. But hey-hoo I get why and it was your choice.

                A Offline
                A Offline
                andrewj1680
                wrote on last edited by
                #84

                @CYBER-NINJA I preferred the polished look but I'd of spent more time polishing it than riding it every time I took it out, Can you imagine trying to avoid every puddle you came across lol that wasn't for me if it's there I'm gonna ride it

                1 Reply Last reply
                0
                • DartyD Offline
                  DartyD Offline
                  Darty
                  wrote on last edited by
                  #85

                  alt text

                  alt text

                  (6mm Stainless Steel - Brass 13-14mm spacers)

                  I made DXF files for Waterjet cutting - for a Stainless Calliper adapter and spacers for a SM conversion using the 'YZF125' Brembo calliper.

                  If there are a few members here looking to do SM conversions, I could get a few kits together with bolts,

                  Just a limited run as I have the time for the moment.

                  Keep it real

                  1 Reply Last reply
                  3
                  • DartyD Offline
                    DartyD Offline
                    Darty
                    wrote on last edited by Darty
                    #86

                    32 degrees, sticky rubber, cotswold country lanes, 2strokes and considerable beer intake on par with University life.

                    I ride this thing 22 miles a day as a daily to go work, built this thing to be used and I just 'turn it up' a little on the Laptop for a blitz on the weekend somewhere.

                    Drawing this project to a close, and enjoying the result, or atleast this iteration of it so far...

                    alt text

                    I had some clearance issues with the Powervalve under expansion. I removed material in increments by machine sanding.

                    alt text

                    Custom bracket for the FMF Powercore1 can. Fits on a DTR well.

                    alt text

                    Built the headlight brackets,

                    alt text

                    WR400 Face swap.

                    alt text

                    There is no room left on this bike. Made a mount for the Ignitech Ignition, secure, doesn't suffer from heat exposure and most importantly it's accessible.

                    As for cooling, air flow is fine still.

                    alt text

                    Modified AS3 Silicone WR200 radiator hose's to suit this mongrel application.

                    This leads me to something interesting I found,

                    alt text

                    I needed a new WR200 coolant pipe, turns out later 4BF4 1995' WR200s use a larger 18mm bore coolant pipe.

                    I got one brand new old stock from Japan. I've rust protected it, primer and a Gold top coat for a little bling.

                    alt text

                    Then of course a 4BF4 Waterpump cover is required.

                    alt text

                    4BF4' Pictured above vs 125R/200R

                    alt text

                    alt text

                    I never knew Yamaha updated the cooling for the WR200, so I had help getting a used one.

                    alt text

                    IT ONLY JUST FITS... Tight bruuuh. I made a brace for the coolant down pipe as it's just a braised joint and I managed to split my last one like a clot.

                    Originally this mounts onto the WR200 Cylinder, so ideally this has to be done to the 125R barrel.

                    alt text

                    Cooling is now more than adequate,
                    alt text

                    WR200 Inlet, TM32 fitted. This inlet gives you more angle to use larger carburettor bodies.

                    alt text

                    WR200 vs DT125R. Inlet tract a little longer, Mounting points have to be modified and crankcase stuffers removed.

                    alt text

                    New YZ braided brake lines and removable exhaust joint to get the FMF onto the DEP.

                    alt text

                    (An oldschool mechanical display setup. Dorky but I love this older stuff.

                    alt text

                    The fun bits. Built to be ridden alot!

                    alt text

                    Using a base map close to a TZR125 4DL SP, It runs particularly well under 6K.

                    This DT now shifts.. I use a 4DL servo setting which utilises the PV opening later than the DT or TDR 3SH.

                    alt text

                    It's far from perfect, but a safe base tune to run on as this is my daily as the weather is so good.

                    alt text
                    It's run in properly now, and it is glorious. It sounds fantastic over 10,000rpm.

                    Powerband is up at 9,500rpm and it pulls hard to 13,000.

                    DTR Gear ratios are perfect for this TZR head and it's acceleration characteristic is spot on, 0-62 less than 6 seconds.

                    More to come, more bits from Japan to arrive and then finally a Dyno session with a TM34ss fitted.

                    Stay safe!

                    Keep it real

                    declanD CalumC 3 Replies Last reply
                    3
                    • DartyD Darty

                      32 degrees, sticky rubber, cotswold country lanes, 2strokes and considerable beer intake on par with University life.

                      I ride this thing 22 miles a day as a daily to go work, built this thing to be used and I just 'turn it up' a little on the Laptop for a blitz on the weekend somewhere.

                      Drawing this project to a close, and enjoying the result, or atleast this iteration of it so far...

                      alt text

                      I had some clearance issues with the Powervalve under expansion. I removed material in increments by machine sanding.

                      alt text

                      Custom bracket for the FMF Powercore1 can. Fits on a DTR well.

                      alt text

                      Built the headlight brackets,

                      alt text

                      WR400 Face swap.

                      alt text

                      There is no room left on this bike. Made a mount for the Ignitech Ignition, secure, doesn't suffer from heat exposure and most importantly it's accessible.

                      As for cooling, air flow is fine still.

                      alt text

                      Modified AS3 Silicone WR200 radiator hose's to suit this mongrel application.

                      This leads me to something interesting I found,

                      alt text

                      I needed a new WR200 coolant pipe, turns out later 4BF4 1995' WR200s use a larger 18mm bore coolant pipe.

                      I got one brand new old stock from Japan. I've rust protected it, primer and a Gold top coat for a little bling.

                      alt text

                      Then of course a 4BF4 Waterpump cover is required.

                      alt text

                      4BF4' Pictured above vs 125R/200R

                      alt text

                      alt text

                      I never knew Yamaha updated the cooling for the WR200, so I had help getting a used one.

                      alt text

                      IT ONLY JUST FITS... Tight bruuuh. I made a brace for the coolant down pipe as it's just a braised joint and I managed to split my last one like a clot.

                      Originally this mounts onto the WR200 Cylinder, so ideally this has to be done to the 125R barrel.

                      alt text

                      Cooling is now more than adequate,
                      alt text

                      WR200 Inlet, TM32 fitted. This inlet gives you more angle to use larger carburettor bodies.

                      alt text

                      WR200 vs DT125R. Inlet tract a little longer, Mounting points have to be modified and crankcase stuffers removed.

                      alt text

                      New YZ braided brake lines and removable exhaust joint to get the FMF onto the DEP.

                      alt text

                      (An oldschool mechanical display setup. Dorky but I love this older stuff.

                      alt text

                      The fun bits. Built to be ridden alot!

                      alt text

                      Using a base map close to a TZR125 4DL SP, It runs particularly well under 6K.

                      This DT now shifts.. I use a 4DL servo setting which utilises the PV opening later than the DT or TDR 3SH.

                      alt text

                      It's far from perfect, but a safe base tune to run on as this is my daily as the weather is so good.

                      alt text
                      It's run in properly now, and it is glorious. It sounds fantastic over 10,000rpm.

                      Powerband is up at 9,500rpm and it pulls hard to 13,000.

                      DTR Gear ratios are perfect for this TZR head and it's acceleration characteristic is spot on, 0-62 less than 6 seconds.

                      More to come, more bits from Japan to arrive and then finally a Dyno session with a TM34ss fitted.

                      Stay safe!

                      declanD Offline
                      declanD Offline
                      declan
                      wrote on last edited by
                      #87

                      @Darty my power comes in at around 9 but only pulls for a bit is this normal just because you have a fancy set up?

                      1 Reply Last reply
                      0
                      • DartyD Darty

                        32 degrees, sticky rubber, cotswold country lanes, 2strokes and considerable beer intake on par with University life.

                        I ride this thing 22 miles a day as a daily to go work, built this thing to be used and I just 'turn it up' a little on the Laptop for a blitz on the weekend somewhere.

                        Drawing this project to a close, and enjoying the result, or atleast this iteration of it so far...

                        alt text

                        I had some clearance issues with the Powervalve under expansion. I removed material in increments by machine sanding.

                        alt text

                        Custom bracket for the FMF Powercore1 can. Fits on a DTR well.

                        alt text

                        Built the headlight brackets,

                        alt text

                        WR400 Face swap.

                        alt text

                        There is no room left on this bike. Made a mount for the Ignitech Ignition, secure, doesn't suffer from heat exposure and most importantly it's accessible.

                        As for cooling, air flow is fine still.

                        alt text

                        Modified AS3 Silicone WR200 radiator hose's to suit this mongrel application.

                        This leads me to something interesting I found,

                        alt text

                        I needed a new WR200 coolant pipe, turns out later 4BF4 1995' WR200s use a larger 18mm bore coolant pipe.

                        I got one brand new old stock from Japan. I've rust protected it, primer and a Gold top coat for a little bling.

                        alt text

                        Then of course a 4BF4 Waterpump cover is required.

                        alt text

                        4BF4' Pictured above vs 125R/200R

                        alt text

                        alt text

                        I never knew Yamaha updated the cooling for the WR200, so I had help getting a used one.

                        alt text

                        IT ONLY JUST FITS... Tight bruuuh. I made a brace for the coolant down pipe as it's just a braised joint and I managed to split my last one like a clot.

                        Originally this mounts onto the WR200 Cylinder, so ideally this has to be done to the 125R barrel.

                        alt text

                        Cooling is now more than adequate,
                        alt text

                        WR200 Inlet, TM32 fitted. This inlet gives you more angle to use larger carburettor bodies.

                        alt text

                        WR200 vs DT125R. Inlet tract a little longer, Mounting points have to be modified and crankcase stuffers removed.

                        alt text

                        New YZ braided brake lines and removable exhaust joint to get the FMF onto the DEP.

                        alt text

                        (An oldschool mechanical display setup. Dorky but I love this older stuff.

                        alt text

                        The fun bits. Built to be ridden alot!

                        alt text

                        Using a base map close to a TZR125 4DL SP, It runs particularly well under 6K.

                        This DT now shifts.. I use a 4DL servo setting which utilises the PV opening later than the DT or TDR 3SH.

                        alt text

                        It's far from perfect, but a safe base tune to run on as this is my daily as the weather is so good.

                        alt text
                        It's run in properly now, and it is glorious. It sounds fantastic over 10,000rpm.

                        Powerband is up at 9,500rpm and it pulls hard to 13,000.

                        DTR Gear ratios are perfect for this TZR head and it's acceleration characteristic is spot on, 0-62 less than 6 seconds.

                        More to come, more bits from Japan to arrive and then finally a Dyno session with a TM34ss fitted.

                        Stay safe!

                        declanD Offline
                        declanD Offline
                        declan
                        wrote on last edited by
                        #88

                        @Darty btw that bike is legendary well fucking done man

                        DartyD 1 Reply Last reply
                        0
                        • declanD declan

                          @Darty btw that bike is legendary well fucking done man

                          DartyD Offline
                          DartyD Offline
                          Darty
                          wrote on last edited by
                          #89

                          @declan Cheers boss, yeah I guess it hasn't risen much, it's not running right at top end RPM's. Possibly the Reeds failing.

                          It's amazing how much more torquey it is than before, it's not a bad commuter bike still πŸ˜‚

                          Keep it real

                          Stevie WonderS 1 Reply Last reply
                          0
                          • DartyD Darty

                            32 degrees, sticky rubber, cotswold country lanes, 2strokes and considerable beer intake on par with University life.

                            I ride this thing 22 miles a day as a daily to go work, built this thing to be used and I just 'turn it up' a little on the Laptop for a blitz on the weekend somewhere.

                            Drawing this project to a close, and enjoying the result, or atleast this iteration of it so far...

                            alt text

                            I had some clearance issues with the Powervalve under expansion. I removed material in increments by machine sanding.

                            alt text

                            Custom bracket for the FMF Powercore1 can. Fits on a DTR well.

                            alt text

                            Built the headlight brackets,

                            alt text

                            WR400 Face swap.

                            alt text

                            There is no room left on this bike. Made a mount for the Ignitech Ignition, secure, doesn't suffer from heat exposure and most importantly it's accessible.

                            As for cooling, air flow is fine still.

                            alt text

                            Modified AS3 Silicone WR200 radiator hose's to suit this mongrel application.

                            This leads me to something interesting I found,

                            alt text

                            I needed a new WR200 coolant pipe, turns out later 4BF4 1995' WR200s use a larger 18mm bore coolant pipe.

                            I got one brand new old stock from Japan. I've rust protected it, primer and a Gold top coat for a little bling.

                            alt text

                            Then of course a 4BF4 Waterpump cover is required.

                            alt text

                            4BF4' Pictured above vs 125R/200R

                            alt text

                            alt text

                            I never knew Yamaha updated the cooling for the WR200, so I had help getting a used one.

                            alt text

                            IT ONLY JUST FITS... Tight bruuuh. I made a brace for the coolant down pipe as it's just a braised joint and I managed to split my last one like a clot.

                            Originally this mounts onto the WR200 Cylinder, so ideally this has to be done to the 125R barrel.

                            alt text

                            Cooling is now more than adequate,
                            alt text

                            WR200 Inlet, TM32 fitted. This inlet gives you more angle to use larger carburettor bodies.

                            alt text

                            WR200 vs DT125R. Inlet tract a little longer, Mounting points have to be modified and crankcase stuffers removed.

                            alt text

                            New YZ braided brake lines and removable exhaust joint to get the FMF onto the DEP.

                            alt text

                            (An oldschool mechanical display setup. Dorky but I love this older stuff.

                            alt text

                            The fun bits. Built to be ridden alot!

                            alt text

                            Using a base map close to a TZR125 4DL SP, It runs particularly well under 6K.

                            This DT now shifts.. I use a 4DL servo setting which utilises the PV opening later than the DT or TDR 3SH.

                            alt text

                            It's far from perfect, but a safe base tune to run on as this is my daily as the weather is so good.

                            alt text
                            It's run in properly now, and it is glorious. It sounds fantastic over 10,000rpm.

                            Powerband is up at 9,500rpm and it pulls hard to 13,000.

                            DTR Gear ratios are perfect for this TZR head and it's acceleration characteristic is spot on, 0-62 less than 6 seconds.

                            More to come, more bits from Japan to arrive and then finally a Dyno session with a TM34ss fitted.

                            Stay safe!

                            CalumC Offline
                            CalumC Offline
                            Calum
                            wrote on last edited by
                            #90

                            @Darty Oh my, yes bud this is fantastic!!!!! πŸ˜„

                            Always Originate, Never Pirate!

                            1 Reply Last reply
                            0
                            • MightymanM Offline
                              MightymanM Offline
                              Mightyman
                              wrote on last edited by
                              #91

                              Very interested to see the dyno results!

                              TDR 125 - 2001

                              1 Reply Last reply
                              0
                              • J Offline
                                J Offline
                                Jens Eskildsen
                                wrote on last edited by Jens Eskildsen
                                #92

                                Yeah me 2 πŸ˜ƒ

                                1 Reply Last reply
                                0
                                • C Offline
                                  C Offline
                                  conmador
                                  wrote on last edited by
                                  #93

                                  hey, are the calipers you designed for the dtx front brake? or is it for dtr front brake? because if it is for dtx front brake i would be interested

                                  1 Reply Last reply
                                  0
                                  • MiniaM Offline
                                    MiniaM Offline
                                    Minia
                                    wrote on last edited by
                                    #94

                                    Thats a cool dtr!

                                    Yamaha DT125R Blue 2002, XT 125 1982, Yamaha WR250Z 1992, BMW GS650F 1994, Benelli BN302 2015

                                    1 Reply Last reply
                                    0
                                    • DartyD Darty

                                      @declan Cheers boss, yeah I guess it hasn't risen much, it's not running right at top end RPM's. Possibly the Reeds failing.

                                      It's amazing how much more torquey it is than before, it's not a bad commuter bike still πŸ˜‚

                                      Stevie WonderS Offline
                                      Stevie WonderS Offline
                                      Stevie Wonder
                                      wrote on last edited by
                                      #95

                                      @Darty this is what’s sat at the top of my tabs list for the past 4 weeks, your bike build. It’s Mk1 stage with the aprillia headlight and YZ wheels is probably my biggest inspiration for my bike to date. Timeless classic looking crosser and I can’t relp but keep looking at or referring to the pictures of it late at night πŸ˜‰ (when I’m on eBay that is and not a certain other website πŸ˜‚)

                                      DartyD 1 Reply Last reply
                                      0
                                      • Stevie WonderS Stevie Wonder

                                        @Darty this is what’s sat at the top of my tabs list for the past 4 weeks, your bike build. It’s Mk1 stage with the aprillia headlight and YZ wheels is probably my biggest inspiration for my bike to date. Timeless classic looking crosser and I can’t relp but keep looking at or referring to the pictures of it late at night πŸ˜‰ (when I’m on eBay that is and not a certain other website πŸ˜‚)

                                        DartyD Offline
                                        DartyD Offline
                                        Darty
                                        wrote on last edited by
                                        #96

                                        @dtStevie98

                                        Lost but not forgotten, back on a standard Top end, bent Shifter fork and Clutch issues, bent caliper hanger, seized caliper piston, slightly bent yokes as it turns out from long ago, and the Dep Expansion pipe that is only 65% left in existence.

                                        I also dented the tank very badly and cannot pull it out, it's trashed,

                                        alt text

                                        alt text
                                        And the Power-valve which was 'fully sent'. It blew the remaining pin out the exhaust,, I think as the bottom end didn't grenade itself.

                                        It was doing 80mph in 5th gear and still pulling, so it was mission accomplished.

                                        Full Yeet.

                                        Keep it real

                                        1 Reply Last reply
                                        0
                                        • DartyD Offline
                                          DartyD Offline
                                          Darty
                                          wrote on last edited by Darty
                                          #97

                                          *Nobody

                                          ME:

                                          *A custom inlet tract for a DT125R.

                                          alt text

                                          Couple beers and some eyeballing and you can make whatever you want.

                                          Getting to old for Pod filters and hacking shit bits together. So if you could, why not re-design OEM equipment in your favour?
                                          Knocked these up on Solidworks to be a straight swap into the frame and Airbox.

                                          The brief, for my application, getting an inlet tract as straight as possible for 34mm or larger Carburettor to fit around my YZ490 shock, which is way larger than the original DTR unit.

                                          alt text

                                          alt text

                                          Science bitch.

                                          alt text

                                          I have access to a 3D printer, so I've been designing and making prototypes just for a bit of fun after work,

                                          alt text

                                          Technology these days....,

                                          Keep it real

                                          Walney-ReptilesW 1 Reply Last reply
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