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DT125R FORUM

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  4. Project DTZr.....a DT125R love story

Project DTZr.....a DT125R love story

Scheduled Pinned Locked Moved DTR
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  • MadGyverM Offline
    MadGyverM Offline
    MadGyver
    wrote on last edited by
    #1

    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
    0_1540919955261_DTZr_now.jpg

    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.

    1 Reply Last reply
    4
    • MadGyverM Offline
      MadGyverM Offline
      MadGyver
      wrote on last edited by
      #2

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

      0_1540923217282_Image(167).jpg
      0_1540923242590_Image(165).jpg
      0_1540923448633_22112009(002).jpg
      0_1540923495704_IMG_0077.JPG
      0_1540923510300_IMG_0102.JPG

      1 Reply Last reply
      2
      • CalumC Offline
        CalumC Offline
        Calum
        wrote on last edited by
        #3

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

        Always Originate, Never Pirate!

        MadGyverM 1 Reply Last reply
        1
        • MadGyverM Offline
          MadGyverM Offline
          MadGyver
          wrote on last edited by
          #4

          The crank before and after.
          0_1541092613101_DSC00018.JPG
          0_1541092630378_DSC00032.JPG
          0_1541092665509_DSC00072.JPG

          1 Reply Last reply
          2
          • MadGyverM Offline
            MadGyverM Offline
            MadGyver
            wrote on last edited by
            #5

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

            0_1541092813280_DSC00020.JPG
            0_1541092832578_DSC00029.JPG
            0_1541092912692_DSC00024.JPG

            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.

            0_1541093315315_DSC00133.JPG
            0_1541093331178_DSC00135.JPG
            0_1541093344689_DSC00136.JPG

            1 Reply Last reply
            2
            • MadGyverM Offline
              MadGyverM Offline
              MadGyver
              wrote on last edited by
              #6

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

              0_1541093963152_DSC00074.JPG
              0_1541093976012_DSC00082.JPG
              0_1541093987395_DSC00078.JPG

              0_1541094010664_DSC00086.JPG
              0_1541094026701_DSC00087.JPG

              0_1541094240958_DSC00097.JPG

              Louis-DT-WRL 1 Reply Last reply
              3
              • MadGyverM MadGyver

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

                0_1541093963152_DSC00074.JPG
                0_1541093976012_DSC00082.JPG
                0_1541093987395_DSC00078.JPG

                0_1541094010664_DSC00086.JPG
                0_1541094026701_DSC00087.JPG

                0_1541094240958_DSC00097.JPG

                Louis-DT-WRL Offline
                Louis-DT-WRL Offline
                Louis-DT-WR
                wrote on last edited by
                #7

                @MadGyver I like that colour swing arm 🙂 good work

                1 Reply Last reply
                0
                • Yamboy46Y Offline
                  Yamboy46Y Offline
                  Yamboy46
                  wrote on last edited by
                  #8

                  This is a interesting build. Nice one dude.

                  1 Reply Last reply
                  1
                  • MadGyverM Offline
                    MadGyverM Offline
                    MadGyver
                    wrote on last edited by MadGyver
                    #9

                    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)

                    20181126_180251.jpg
                    20181013_160659.jpg
                    20181013_155014.jpg
                    20181013_154922.jpg

                    1 Reply Last reply
                    2
                    • MadGyverM Offline
                      MadGyverM Offline
                      MadGyver
                      wrote on last edited by
                      #10

                      Wheels condition when purchased and finished

                      IMG_0025.jpg

                      IMG_0033.jpg

                      IMG_0050.jpg

                      NINJAN 1 Reply Last reply
                      3
                      • CalumC Offline
                        CalumC Offline
                        Calum
                        wrote on last edited by
                        #11

                        Fabulous stuff!

                        Always Originate, Never Pirate!

                        1 Reply Last reply
                        0
                        • MadGyverM MadGyver

                          Wheels condition when purchased and finished

                          IMG_0025.jpg

                          IMG_0033.jpg

                          IMG_0050.jpg

                          NINJAN Offline
                          NINJAN Offline
                          NINJA
                          wrote on last edited by
                          #12

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

                          SEDUCED BY THE DARK SIDE!!!

                          1 Reply Last reply
                          0
                          • MadGyverM Offline
                            MadGyverM Offline
                            MadGyver
                            wrote on last edited by
                            #13

                            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.

                            1 Reply Last reply
                            0
                            • MadGyverM Offline
                              MadGyverM Offline
                              MadGyver
                              wrote on last edited by
                              #14

                              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.

                              DSC00050.jpg
                              DSC00059.jpg

                              NINJAN 1 Reply Last reply
                              1
                              • MadGyverM 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.

                                DSC00050.jpg
                                DSC00059.jpg

                                NINJAN Offline
                                NINJAN Offline
                                NINJA
                                wrote on last edited by NINJA
                                #15

                                @MadGyver Nice paint job. :thumbs_up_medium-light_skin_tone:

                                SEDUCED BY THE DARK SIDE!!!

                                1 Reply Last reply
                                0
                                • CalumC Calum

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

                                  MadGyverM Offline
                                  MadGyverM Offline
                                  MadGyver
                                  wrote on last edited by
                                  #16
                                  This post is deleted!
                                  1 Reply Last reply
                                  0
                                  • MadGyverM Offline
                                    MadGyverM Offline
                                    MadGyver
                                    wrote on last edited by MadGyver
                                    #17

                                    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.

                                    alt text

                                    alt text

                                    alt text

                                    1 Reply Last reply
                                    0
                                    • MadGyverM Offline
                                      MadGyverM Offline
                                      MadGyver
                                      wrote on last edited by MadGyver
                                      #18

                                      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.

                                      alt text

                                      alt text

                                      PS.I will shorten a little the front fender.

                                      CalumC zarkotomZ 2 Replies Last reply
                                      3
                                      • NottsbikerN Offline
                                        NottsbikerN Offline
                                        Nottsbiker
                                        wrote on last edited by
                                        #19

                                        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! 🙂

                                        1 Reply Last reply
                                        1
                                        • MadGyverM 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.

                                          alt text

                                          alt text

                                          PS.I will shorten a little the front fender.

                                          CalumC Offline
                                          CalumC Offline
                                          Calum
                                          wrote on last edited by
                                          #20

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

                                          Always Originate, Never Pirate!

                                          1 Reply Last reply
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