DT125R FORUM

Not a good weekend for projects sadly. Today felt like a good time to tackle the the gearbox rebuild. [image: AP1GczON28f-2MsafJeD5d-5vpCddgE_F7wvwMw4mUgLb2qd4IhmX86P39IsZ82b_iWLEnwRqePbVAtntY2GH_ynSVKF-Pj2PWn_o11HKdPfEkiASpdPOuL8lcdFL_PBfKHjAhmRSBCEGtLjRGsR2fvnMhUA=w1341-h1083-s-no?authuser=0] Input shaft stripped ready to lay the gears onto the 1st gear conversion. [image: AP1GczOIOkdYg_118U84DE74bmnWa2tQKSoRjs7q2MOk0Q5fzTisZFT3fIl-MQKf_FuyjrvEYTMzvxMkhDYxFqDSyI7_TcHsUlsHK2RMHJcIgquU3WpNel8Fhugb5EeV3yOXCvv07VUZmQfQuSEcscoq6L-0=w1920-h901-s-no?authuser=0] [image: AP1GczOalIT8UP8GvsIu6oaCiebY2y1koDXD4F2rR4NZNUMeZhXVep5MHVKU92rHWzH24zPCUFbygSgL6E50bZfOwWG7Jm06MIV3hEjj8kd54GM1CLMGcMtcyoZvWKled2_dqcZEUpRv4ArxwKagYBJ8p_au=w813-h1083-s-no?authuser=0] All rebuild, new bearings, shims and circlips. [image: AP1GczO0QU9H7znj-nhFz4Cy18H8C6M08FS17ilL7ci8C9UVT24jFQ3yAVfARsbqKWkbHVAmy-v82EmVU1LFPcYTp0BPrMOdINfIRPttvzDjPvQfG7TyEwS_t2lEg_DFnWm_IVWg1en5V51sbSJk1a2LyzbB=w1920-h956-s-no?authuser=0] So far, so successful. Next tackling the output shaft. [image: AP1GczM5AdnAIDxi9C0cdm6iB-EQHGx1JXF0L7cjDoDM0JZsEhucD3y83x0wSP59PILgj3EGebFH0sLD02_NWCU3n4QVScZlhIonncHAx9tsflH_A6oXPv8Z_lS381ccF8N9qaGcmDhGjs_Kk5859zBhub4l=w669-h1083-s-no?authuser=0] Was going extremely well...until it came to dismantle third. [image: AP1GczO2Xjf9Y9WDogyaSfLEhfo_IP15jgPuKi_7M_zm2hUgacLm0cejxlpzFvdjoRv-F2aEkWNmIHKT0OSxbMPm9edFoMeWjJ1NMlepxIUHz8myGNfoxzAHBacbnRjoXDwnuAeFOCrppphFla0WHSMRzuRy=w556-h1083-s-no?authuser=0] This was not coming off and the prognosis wasn't good. Rough running third gear with swarf coming out of it. [image: AP1GczM62rE4VM-9MSlHtq3hT_6tAjAGc24wkdjOxyvjaJynqnqa5B8AwuSffkKGCxUp8L6uAOtp4AhpDkOswpwC8IH-SWsKlEzs7co4o5C1LtMxj1aklyd7e86f6J2AmzKg1jLQaMLcTIvSvdvjOrAyIzXO=w890-h1083-s-no?authuser=0] The layshaft's damaged beyond repair and so was third gear. Luckily the layshafts can be had brand new and I managed to find third gear. So sadly that's the cost of a used gearbox, but then that tells me for scrimping on the gearbox. The layshaft's coming from Japan so I'll have to park this rebuild for now.

@Calum said in GoProKid95's 2006 DT125RE (Supermoto Conversion): Aww I'm sorry it got robbed! Always heart breaking to see that. Looks like a lot of hard work was put into this as well! It's not a proper DT until it's been stolen

Sounds like you've covered the fueling system, which means it's going to be an electrical component. You will want to buy a new spark plug, HT Lead and iginition coil to rule out those items. Next will be the pickup, if that starts to deteriorate then it will start to missfire. Then unfortunately the CDI. But CDI's rarely fail, but I guess it is 30 years old.

@giorgio95 Must be first DTR with cdi on the back of the oiltank ? Wire in speedo you messed with white/black from the reed switch ? Thats linked to the cdi then ypvs servo. Sounds like it could just be a bad connection in the circuit somewhere if its kicking in when you move it. Easiest and proper way to set the ypvs cables on the pully wheel under the cover is like this. On the pully wheel in between the cables is a notch in the wheel, when you switch your ignition on and the ypvs spins over its cycle when it comes to a rest the notch should line up with the dot directly behind it. If it does thats it set properly just make sure the cables are tensioned up ok. Same applies if you have to adjust them to get it to line up and then your good to go.

Never even thought of a lithium battery. Thanks @CYBER-NINJA

Whats wrong with the motor? Have you inspected it? My startermotor for my xt600 got a cleaning and new brushes at around 110.000km, its now at 172.000km, and still working fine.

Once again, many thanks