Yamaha dt125re rebuild
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@bonus ahh I know your frustration. Mine is a 1991 DT125R and it too has had a life of being neglected and thrashed around. All the bits are still in one piece and working order thankfully except for the front head light unit. Got to find a replacement for it.
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Tbh I never thought about shot blasting at first until I sent all day yesterday grinding and sanding down shot blasting would of been a lot easier and not as painful
But anyways most of rust is gone few little bits and primed the back end yesterday this was the most effected area from rust
https://i.imgur.com/OzPv7aL.jpgMaybe another sandover and few stickers to remove and replace and will prime the rest and get the paint on
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Fine looking machine there, the rust on the subframe isn't too bad compared my '02 R. Regrettably a younger version of myself opted for the grinder and hammerite bodge fix which has made it a devil to sort without proper blast/powdercoating. For the love of all thats holy if youre going to this much effort do it right and save headaches down the line.
I found my standard headlight to be complete garbage, in fact I used to refer to it as the "Prince of darkness". Don't recall trying any of the fancier bulbs out there but I've yet to be impressed with any bike headlight out there with the exception of the '02 ZX-6R. Oncoming traffic was always a case of aim-for-the-lights-and-2-feet-left with the DT.
Is this going to be a full nut/bolt restoration or more of a seriously deep clean? As for colour IMO you can't beat the yammy blue. Also saves the faffery with V5 colour changes.
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This more of a deep clean and things getting replaced if needed
The colour of the frame is going gloss black for now as need to stay within budget and wasn’t keen on the blue frame and black hide dirt well
Same for the swing arm and forks there going blackThe tank plastics etc are staying blue with decals yet to be decided
95% of the rust if off the bike with grinding I know it won’t be the first time this bike gets done as this is my first attempt at the rebuild but next time will definitely be getting shot blasted and powdered coated
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All primed ready for paint tomorrow
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Right I’m stuck, confused and baffled
I’ve taken the starter motor off with having problems of the annoying clicking noise new battery new relay all wire checked cleaned etc so I know it’s something with the starter
Should I be able to move this cog by hand ?
It doesn’t move at all could this be my problem? -
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@bradt Easier to do when there is no gear lever in the way mate.
You will risk damaging the shaft and causing a permanent oil leak.
IIRC, it should not be difficult to remove the gear lever out put.
Whip the clutch cover off and remove it. Then remove the seal, then replace the seal, then replace the lever. IIRC.
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