Nice project! The crankcase damage in this engine occured because the owner didnt pay that much attention to the condition of the chain and sprockets, I recommend you changing the drivetrain from 428 to 520 for better strenght(just look for DT200R chain and sprockets, everything will fit bolt-on) and also use the chain lower guide(new avaible to buy cheap at yamaha dealer) in good condition, if you do that there will be no more problems with chain causing damage to the crankcases.
I raced the guy on that DT200R in 2016, it was only amateur cross-country type of championship but the WR200 turned out to be superior to DT :face_with_stuck-out_tongue: , 2 years later he sold me the bike.
Heres a pic of that DT, looked better than when i got her.

Lately I've been rebuilding brakes, currently waiting for the front & rear brake pump rebuild kits:

Hello,
I guess its time to show the best one of my bikes.
I bought her in '15, its an US-import bike.
She was sitting for a long time, I guess because of the broken clutch basket and worn out nicasil, but the bike was really in good condition, not modified and never taken apart, even tho there was few missing things.
I took care of the basic stuff and took part in the amateur cross-country championships in '16 and '17. I was 3rd both times in the "Junior" class (max driver age 21). Only the 2-stroke 250s were faster. The second event was very muddy and the WR got really beaten up. Clutch was totally gone about 100m before the finish line but thanks to help of my friend I was able to push the bike thru and finish the race. After that the WR got a complete rebuild and was ridden casually around the local terrains. Last year I took her apart partially once again to do the things I didnt do before, that was shock rebuilt, removing the dents from the FMF pipe, installing a slightly ported cylinder with a new sleeve and a Wossner piston and many smaller things. Today I fired her up for the first time but she needs adjustments, especially finding out the main jet setting. Generally I want to keep her looking as close to the original as possible, only modifications are: handlebars, exhaust, front springs from a '89 YZ250 and Boyesen reeds. Im kind of the oem-look freak and I love buying NOS parts, so she will stay this way. Now its time for the pics:

Thats how she looked in the ad

First ride

With her older sister

2016 Cross country amateur championships

2017 Cross-country amateur championship

After the clutch went bad

During the rebuild

After the rebuild

First ride

The power valve patent that is installed right now

High-quality sleeve

Some of the NOS parts I have laying around

Short vid from last year

Its been some time since last update, but the WR is running as always. Lately I've been riding with two old-yamaha gearheads and it was fun! You can check 3 movies we made on my yt channel -> https://www.youtube.com/channel/UCRVcP2LzhKi6GqQKIhwrAhg

And of course I noticed a lot of differences while riding on the YZ, either 125 or 250 when compared to the WR200. Both of them vibrate a lot, but thats normal as they dont have the balancer shaft. The 250 is hard to start, it really has high compression(never tried starting the 500cc 2t, that'd be a challenge!) and they both stall easier when riding with low engine speed. The 250 has a lot of bottom end power, the 125 is all about the top end power.
While the WR200 is all about the mid-range(on fmf exhaust). Its very easy to ride compared to the YZ's, easy to start and just roll on the idle between the trees. Its a very user-friendly bike. Of course it doesnt have the power of 250 or even YZ125 as the peak power Im sure is better in the YZ. Of course Ive been riding almost only on my WR for the past 4 years so its a different thing when you jump on a bike you dont know at all and ride for 10 minutes. All of them are awesome, just very different.

And last week we all went to the same old cross-country championship race where I was making my first steps on the WR. It was cold, it was wet and it was muddy. But it was AWESOME!

And I went home with the 3rd place trophy. Its a funny thing - 3 times I started in this race and every time I was 3rd, no matter the class or how many people were starting at that time

Here are all my trophies so far:

And you can check out this vid from the race, you probably wont understand much, but the WR is in 1:49 and 10:56
https://youtu.be/QERZncGW_dg

Adding some recent pics And a short movie (click)

So here it is, the hillbilly supermoto setup:

I totally love this bike

I have the front 17 wheel done:

And I will be using rear wheel from WR125X that fits bolt-on. Now Im saving money for the tires

@valtteri

I installed this wire, its somewhere in the middle of the bike(under the seat) and the cut-out was gone. I dont know if it will help you, but I had 3RM-00 CDI and it was the older style of a DT but this little mod fixed it. You might have a different wiring loom since you have a newer style of a DT, but Im just posting here what helped me with getting rid of this problem. Anyway there is a solution to that problem.

If it sounds like this
https://www.youtube.com/watch?v=90BbYwkOnFs
then its an electronic cut-out rpm

Hello,
I think its time to introduce my DT200R build, but lets start from the beginning.
In the summer of 2013 I bought my first 'big' bike, a '96 DT125R. It was the time when these bikes were cheap. The one I found was about 30km from me and me and my buddy jumped on our bicycles to check it out(we werent 18 then). It was a bit beat up bike, we had to bleed the brakes before a test ride but it was cheap and overall nice bike.
Here's a pic from my first ride after buying the bike:

I learned how to work on it, done the full engine rebuild and was just riding around with a buddy and sometimes my gf back then(still have some xxx pics of that ).
In 2015 I bought a DT200R without the pink slip.(check the back of that Saxo VTS in the background, that was a fun car!)

Only had one ride on the 200 before I disassembled both of the bikes. Plan was simple, to put the 200 goods into the 125 road-legal frame. So I powder coated the frame first:

And then I bought my WR200(which is in another thread). I completely forgot about my DT's and just had fun riding and working on the WR. Meanwhile I bought another WR for parts for my ride, and then another one(both of them were beaters tho).

Fast forward to 2020, when I actually started working on the bike:

(DT200R shock on the left, WR200 shock on the right, after the service, wasnt cheap )

Some suspension work:

How the bike looks now:

Front brake is pretty much done(rebuild caliper, brake pump, new HEL hose). While putting together the rear brake caliper i butched my finger. Im having problems with the rear brake caliper mount as it comes from TDR and I had to drill the axle hole from 15mm to 20mm and now it sometimes touches the disc, it will need to be fixed.

But today I put together the engine!(almost done)
Its a 3XP engine from the WR's I bought for parts for mine main bike over the years.
First pic is from 2019 when I started putting together this engine

These pics are from today:

And I still have the 3ET engine somewhere in the shed. But while I have a 3XP engine almost ready to ride, I dont think Im gonna spend my money on rebuilding the 3ET now.

Generally, at the end I'd want my bike to look like this:

@SpookDog

It looks like this, this was the worst rim I had. It was a common problem in the WR200, the rims from YZ's and DT200R didnt rot as bad.

@Calum yes, they are aluminium, but the front DT wheel wont fit because of the different brake disc. I will probably just ride the both sets of enduro wheels and when they will be all bent I'll buy some new rims. Other than that I want to keep this bike as close to original as I can. Now it has the cylinder sleeve instead of nicasil plating already(which I think is a good choice for this bike) but I dont want to use the heavy steel wheels. I dont even think they would be that much tougher. Almost all of the DT's I saw had a bent on a front rim.
But yeah, I just like to go full throttle on the rubble covered roads sometimes

@Calum naa, you need to think more off-road, not dual sport types of old yama bikes

And also I forget to mention that I keep bending the original rims, of course they are known from rotting from the inside which i cleaned as good as I could, but there is no point for me to change them for new ones if they will be bent in a couple of rides.
But I have an extra set of enduro wheels too, so thats not a big problem

Today the black rear wheel from WR125X arrived.

Its a funny thing that I keep buying the SM stuff that I will barely use as I prefer the off-road wheels, but its a nice addition to have for the bike. And it was just so cheap I couldnt pass it.

So thats how the SM wheels setup of a guy that preferes offroad looks like:

(wheels are dirty on the pic, the first pic shows the black rear wheel after cleaning)

And currently Im waiting for my second WR frame to be back from powder coating. I will be switching the frame in the bike.

And I also got some work done on my 3rd project

Does anyone recognize this engine?

@SpookDog Love that plastics & decals color combo!

@alexmoto84

the '11' is +/- 1mm

@westy7070 I always use a thin layer of Loctite 5923 on the metal head gaskets. Never failed me. Many people use Reinzosil except the Loctite as it comes in smaller packages and should work as good.

Hello,
I think its time to introduce my DT200R build, but lets start from the beginning.
In the summer of 2013 I bought my first 'big' bike, a '96 DT125R. It was the time when these bikes were cheap. The one I found was about 30km from me and me and my buddy jumped on our bicycles to check it out(we werent 18 then). It was a bit beat up bike, we had to bleed the brakes before a test ride but it was cheap and overall nice bike.
Here's a pic from my first ride after buying the bike:

I learned how to work on it, done the full engine rebuild and was just riding around with a buddy and sometimes my gf back then(still have some xxx pics of that ).
In 2015 I bought a DT200R without the pink slip.(check the back of that Saxo VTS in the background, that was a fun car!)

Only had one ride on the 200 before I disassembled both of the bikes. Plan was simple, to put the 200 goods into the 125 road-legal frame. So I powder coated the frame first:

And then I bought my WR200(which is in another thread). I completely forgot about my DT's and just had fun riding and working on the WR. Meanwhile I bought another WR for parts for my ride, and then another one(both of them were beaters tho).

Fast forward to 2020, when I actually started working on the bike:

(DT200R shock on the left, WR200 shock on the right, after the service, wasnt cheap )

Some suspension work:

How the bike looks now:

Front brake is pretty much done(rebuild caliper, brake pump, new HEL hose). While putting together the rear brake caliper i butched my finger. Im having problems with the rear brake caliper mount as it comes from TDR and I had to drill the axle hole from 15mm to 20mm and now it sometimes touches the disc, it will need to be fixed.

But today I put together the engine!(almost done)
Its a 3XP engine from the WR's I bought for parts for mine main bike over the years.
First pic is from 2019 when I started putting together this engine

These pics are from today:

And I still have the 3ET engine somewhere in the shed. But while I have a 3XP engine almost ready to ride, I dont think Im gonna spend my money on rebuilding the 3ET now.

Generally, at the end I'd want my bike to look like this:

Its been some time since last update, but the WR is running as always. Lately I've been riding with two old-yamaha gearheads and it was fun! You can check 3 movies we made on my yt channel -> https://www.youtube.com/channel/UCRVcP2LzhKi6GqQKIhwrAhg

And of course I noticed a lot of differences while riding on the YZ, either 125 or 250 when compared to the WR200. Both of them vibrate a lot, but thats normal as they dont have the balancer shaft. The 250 is hard to start, it really has high compression(never tried starting the 500cc 2t, that'd be a challenge!) and they both stall easier when riding with low engine speed. The 250 has a lot of bottom end power, the 125 is all about the top end power.
While the WR200 is all about the mid-range(on fmf exhaust). Its very easy to ride compared to the YZ's, easy to start and just roll on the idle between the trees. Its a very user-friendly bike. Of course it doesnt have the power of 250 or even YZ125 as the peak power Im sure is better in the YZ. Of course Ive been riding almost only on my WR for the past 4 years so its a different thing when you jump on a bike you dont know at all and ride for 10 minutes. All of them are awesome, just very different.

And last week we all went to the same old cross-country championship race where I was making my first steps on the WR. It was cold, it was wet and it was muddy. But it was AWESOME!

And I went home with the 3rd place trophy. Its a funny thing - 3 times I started in this race and every time I was 3rd, no matter the class or how many people were starting at that time

Here are all my trophies so far:

And you can check out this vid from the race, you probably wont understand much, but the WR is in 1:49 and 10:56
https://youtu.be/QERZncGW_dg

@Stevie-Wonder actually I have a second rear wheel for sale with gold rim, but the rim is not so good looking anymore. Trying to sell it locally at the moment. And to be honest I loved the looks of the WR on 17's, but its just not the same.

@Calum I never used my bikes for transportation, just for fun. And sure, after installig 17's I was driving in light terrain, meaning casual forest roads and it was a lot of fun too, as its so easy to get some sideways action on them. But as soon as I had to go thru some sand it was a pain and often I had to get off the bike and push it.

On the DT Im building I'll put on some 50/50 tires on the 21 & 18 wheels.