DT125R FORUM

Okay, a few more NOS parts ordered and now the primary drive gear, clutch basket and generator nut all torqued to spec!

All 6 TZ750 clutch springs fitted with brand new clutch plates and NOS OEM damper rings installed.

I also replaced the factory pressure plate with a gorgeous billet RDLC Crazy pressure plate.

It's said to have better oil flow and looks to have a fair amount machined out of it, but I was surprised to see it's slightly heavier than the factory setup.

This milestone marks the completion of the bottom end There's just the matter of the water pump to install, I was really hoping to get a Chariot Performance uprated one, but they're no longer manufacturing them. And then there is a company that makes a stunning carbon fibre generator cover/chain guard. I did have my eye on a Chariot Performance one, but again they seem to no longer be making them sadly.

The cylinders are booked in with Mick Abbey for some mild porting work, then the heads need to be sent off for machining.

But once that's done it will mark the engine work completed for this project and I will turn my attention to the frame.

The frame has now been moved into the garage and I'm just trying to figure out how/where the steering damper should be fitted!

I do need to get back out on this bike! The front brake disc failed (annoyingly as this wasn't cheap) and the battery died over winter, even though it was on trickle charge, again very annoying.

I did manage to get some nice bits for this bike, but I've only manage to get around to fitting one of the parts as the bike is in a storage unit and I don't have all the tools there to do all the bits.

Firstly I have this beautiful VHM gold skull cap.

I look forward to getting this fitted.

I also have a pair of these beautiful carbon infills for the side panels (if I can remember where I've put them). I will fit these when I do the skull cap as it requires taking the fairings off.

This week a special parcel arrived from Italy, which was a beautiful carbon fibre rear seat infill to replace the FRP one I had there originally.

It almost looks plastic dipped in that photo, but I can assure you it's the real deal.

Very happy with the fit and finish (although the seat wasn't placed down properly in this photo, hence the gap).

Just buzzing to get out back on it now that summer is here!

Forum patched and updated. Fixed some database corruption issues which was having a knock-on effect with emojis so hopefully they're working now.

@Rallyfinnen It's annoying that images get ransomed. I simply don't have the bandwidth HDD space and/or money to host images.

That said, I have migrated my images to the server so that the issue of images being ransomed goes away for me.

Oh that's really awesome. I certainly hope it works out for you though. I think I'm done with the DTR platform for the time being and am concerned with my RD at the moment. But I am building an LC motor which one day may be transplanted into a DTR chassis...

@vtrtomuk Yeah, just have to enjoy it for what it is sadly.

I have had mine ported and got lots of supporting mods to boot. It goes alright, but my Aprilia decimates it completely. Still nice bike to have and you can get some improvements out of it.

Hi Glenn welcome to the Forum.

It's very quiet on here these days, everything migrated to Meta a long time ago, but I feel the real enthusiasts will remain here

Sounds like you've got a wealth of experience with these bikes, almost feels criminal to be breaking them nowadays though, price of them are soaring.

Hi there,

You're literally describing the characteristics of the big bore engine. It's not going to rev like the OEM setup, a big bore kit will drop over revs and this sounds like it's in the right ball park figure.

I'm not saying 9500 is the limit, but this is definitely past its peak power and I wouldn't expect any power gains past here.

The next step for retaining revvibility will involve more drastic tuning.

• Zeeltronic CDI Ignition System
  • Allows you to have a fully derestricted ignition system
  • Customise powervalve for the Athena kit
  • Squeeze out a few more RPMs
• Cylinder porting
  • Greater volumetric airflow through the cylinder
  • Allowing it to breathe easier
• Transfer window porting
  • The transfer windows most likely need porting due to the larger bore
  • Gasket match the cylinder to the cases
• Porting the cylinder base removing the obstruction to airflow from the reedvalve
  • Air flow is greatly disturbed by the cylinder spigot protruding into the intake
• Fit VForce4 Reed Block from Blaster
  • Proven to increase mid-range and overrev performance
  • Boyseen dual stage reeds can also help but seeing as your requirement is literally at the top end of the powercurve then you don't want dual stage
    

Just bear in mind, you're now demanding a lot more from the engine than stock and seeing as you're seeking peak power you're going to want supporting mods.

• Uprated clutch springs to avoid clutch slipping
• Forged connect rod to resist rod stretch/fatigue
• Forged light weight piston to withstand the demands

Oh okay interesting, are you able to fit a kick start and ditch the starter motor? The DTRE has a starter so maybe that frame is a better fit.

Do you mean dual piston caliper? Or do you want two calipers 🤭

https://ebay.io/m/yOnXyn

Or have one made using Nevs design

https://dt125r.co.uk/topic/1343/dt125-front-brake-caliper-bracket-dimensions/2?_=1772783708212

I'd would just listen to hotshot-iii - https://dt125r.co.uk/topic/3551/do-pipercross-air-filters-really-flow-better-at-all

I haven't ran an airbox on my DTR for 10+ years and I just used the stock filter the time I had it. So I don't have any opinion on it.

It used to be a common mod to drill more holes into the top of the airbox in order to get more airflow into the box.

If it were me, I'd leave it alone though, as parts are getting harder to come by nowadays and this is drastic considering.

If you wanted a quick test, just remove the airbox boot and see how the bike performs with no filter. This won't cause any damage if you ride it somewhere with minimal dust and for a short duration (like not years). It's not uncommon for people to not bother with air filters.

The Snorkel isn't restrictive.

It you're removing the snorkel then you need to open up the air box, else you'll stall the airflow.

If you want to improve the situation, grab a DT230 or DT200WR snorkel.

These were almost a nightmare to source 16 years ago, I can't imagine trying to source one now. My bike was stolen in 2010 and they smashed my headlight, the only one I could find at the time at one of the lugs snapped off.

Looks like there is one for sale on eBay: https://www.ebay.co.uk/itm/117220896053?_skw=DT125re+headlight&itmmeta=01KTM8B5217RAZTYS7W99928FR&hash=item1b4ae8ed35:g:y7gAAeSwpAdqHbG7&itmprp=enc%3AAQALAAAA0GfYFPkwiKCW4ZNSs2u11xBZmLIU--K9J71U9lN1jJvKGElmcMKBjUzhn5JV3gvFr%2BI2mNwns0SlbUycS%2Bw9y3Qsk%2FC9Cp56dPrHcSEz%2FAr0Zq5el9BEEdpE--23lnRC8fU0%2Fsn13ryM871mf1jmM1dUjkmiSvaLNgJjb67pd3KfdVjuND8nPx720y4ajz9BPqgS8GUW%2FCNLpWF1MTDMkYcIXC7cHLcpOan7woIP1A2k2vjESEOPdlk4W2oy4yUcxyO%2BXWy347GqH%2BHrWnu%2F2Og%3D|tkp%3ABk9SR5bRrIjVZw

Looks like there are some copies on eBay as well: https://www.ebay.co.uk/itm/188014865985?_skw=DT125re+headlight&itmmeta=01KTM8B521KCQCFP6HVFB9B97Z&hash=item2bc68f2e41:g:v4oAAeSwOt5pf0Q6&itmprp=enc%3AAQALAAAA8GfYFPkwiKCW4ZNSs2u11xBGAd3jIpQ1I%2FPeoct0WRAbZx%2BSpsbDaUmQIjZgqRPgUJo7nG5bGWKGBRZtJJ4k6kWqRTJdLi2QjCbWA%2FBE6jgcnSjbxqmpxc5alD7AkePHPryhwNx3wJMQx9Nn2c%2FJBb%2FaX0A7Z%2BlEzJ6pVoqrlh3sZUh2UZ%2BqkVZwe2vBfwA2F39HuV9O1D2z%2FSIMHbNWWFAOiiE%2BG%2F8xlRqkrAHFOwt3oKAIwYBpeHVG82hZBHdODyJwGkKG5Ef9gkphJk0fgSnlvoW%2FpV6wkCrHIDEqggbFJ3LfV5W5qwYpTWvJNjb1RA%3D%3D|tkp%3ABk9SR5bRrIjVZw

That's right, I forgot about the clutch switch!

Check the left hand crankseal for air leak as well.

I will have to check the Mikuni carb for how the air screw works, does it bleed air or allow fuel through.

Either way, the choke is going to increase the fuel and air via the independent fueling circuit.

I am led to believe the circuitry for this should be rudimentary.

If I recall correctly, it runs on it's own circuit, from the battery to the fuse holder and through a relay. The relay js actuated via the button on the controls.

I'll have to grab my Haynes and have a proper look for you when I get a moment, unless there are already circuit diagrams available here.

Oh awesome.

Is it an improvement over the factory headlight?

Well this last month a disgusting amount of money was dropped on parts for this engine.

• Two Keihin PWK 28mm Carbs
• Two Vforce Reed Blocks
• Billet Inlet manifold
• EBC Clutch Kit + Heavy Duty Springs
• 6 TZ750 Genuine Clutch Springs
• Zeeltronic Ignition System
• Billet Kick Starter Lever
• Magura Hydraulic Clutch Lever
• Chariot Performance Billet Clutch Basket
• Wiseco Blaster 200 Piston (573M06800)
• Modified Idle Gear with bearing

These Wiseco pistons replace the stock Athena pistons due to the 115mm long rods I'm running and the +4mm stroked crank shaft. The head still needs to be machined to accommodate the longer stroke and the wrist pin on these pistons is different to accommodate the longer rod.

This idle gear is lovely, totally unnecessary but was only £60 but seemingly not available to purchase anywhere I looked.

The Magura wasn't cheap, but it's going to be necessary when running all 6 TZ750 clutch springs just to keep the power from slipping the clutch.

(the other two springs are in the post I had to source elsewhere).

Now that I have the basket, I can finally assemble the clutch basket with my straight cut primary gears.

Basket is beautifully made, claimed to be the best on the market and I can see why. It was missing the Belleville washer that sits between the basket and the fastener plate, I bought a genuine basket to chop up and salvage but it wasn't on that basket (apparently they're fitted to 1986 models and later). I managed to find a company that sell them so ordered from them and fitted. Wasn't cheap but I'm glad it's in.

I did replace the steel bolts with some lighter titanium ones (hopefully they withstand the abuse the basket is going to take!)

About 50% of the weight, but hopefully not at the expense of strength!

The washer is installed with the raised edge facing you. The fastener plate will clamp down onto this edge.

Engine is coming together nicely now though.

Well sounds like a fantastic purchase.

I thought I recall the 3SH models being quite sought after and sounds like a good buy for the money. Sadly Imgur is blocked in the UK so I can't see the images right now, I'll have to have a nosey on a VPN.

Yeah, there is an okay aftermarket scene for tuning, anything that'll fit the DTR engine will fit the TDR engine. It's the TZR 125 (2RK???) models that had different engine setups, but the TZR Belgarda shared the same platform as the DTR.

No, the 4DL would have a straight inlet. These don't fit the DTR as thr carb then fouls the shock absorber.