I'll begin by saying that this build thread may take a few days to put together but I hope you all look forward to seeing it soon, considering that the project is about 80% completed!

Hi all, thanks for the fast response, I'm aiming to reply faster on here in the future!! Good to see some familiar faces. To answer NINJA first, I've had the bike 6 or so years, its already had a substantial ground up resto. Sadly the last year or so its become the work horse as I started on other projects. I've documented absolutely everything I've done so far in this time so I'll for sure put a build thread up so you can all have a look and maybe a laugh, you never know! Oldman, here is a pic, I can up load more if needed bud! Hi Calum, good to see you're still about, I have many questions regarding the CDI, I remember you're running the Zeeltronic Unit? Many questions to ask! Speak soon chaps!

Hi all. It’s been a super long time since I last posted. You’ll all be pleased to know that after 6 years of ownership I still have the old girl, although she’s starting to look a little tired these days. I’ve got a few little queries regarding the ypvs, where would be best to start a help thread on this, cheers Tom!!

This takes the build to the end of 2015, there's plenty more to come. However this had taken too many days to put together, so enjoy whats there and I'll start putting together the second half!

So I rode the bike for about 3 or 4 months with next to no problems until this happened.

Top end bearing failed and did this to the conrod.

It also did this damage.

So after rebuilding the engine I was back on the road in early September. This is what she looked like after the rebuild.

In the following February I decided to treat myself and get a DEP, good choice right?

After this I didn't encounter too many issues, only small things along the line.

Rear brake caliper went British on me and it seized up whilst I was riding. So I rebuilt it.

Spent a little money blinging the wheels out with some spoke wrapz, a bit like Marmite to some but I kinda like them.

After riding with a few mates who had DTx's I was itching for the Supermoto conversion. So I bought a front wheel off of an XT125X, this is what it looked like.

I was surprised as it pretty much bolted up however the brake caliper needed working out along with the Speedo drive.

So after some research I drove six hours for these, they were perfect, new tyres, new front disc and a Brembo caliper to go with them, awesome!

The next day I test fitted them, the rear wheel is bolt up, the front needed a little work but I couldn't wait much longer. This photo was the end of 2015.

Thanks for the kind words guys! It's difficult to go for a unique look these days but I like how it turned out!

@spookdog I'm in Dorset, near the coast. There's three of us down here that I know have DT's. Mines currently off the road in prep for the summer but the other two I see on a very regular basis!

Haha Snap Calum! I've owned mine just coming on for three years. Bought it as a rolling project, which then turned into, new inner and outer sills, boot floor and rear arches. Happy days. Tempted to post a build thread! haha

Ayye these things happen man. When I got it back it never quite ran right. So that was what spurred on the "proper" rebuild. Cheers pal, always will be a work in progress!

I was overwhelmed by the number of views my old build thread has, only after a year and a half of being posted onto this forum. Firstly wanted to thank everyone who has taken the time to have a nose, also want to thank everyone who will take the time to check this one out.

Unfortunately the old build thread was more of an overview, there were a lot of the finer details that I overlooked, this thread goes into the real nitty gritty, answer questions I am sure that others are looking for answers to.

Before the pics, I want to thank everyone who has helped myself along the way, there is a record of this on the old forum and on the new one, parts, parts support and general chatter, all very useful!

Starting from the Beginning, I was scrolling through eBay during the later part of 2013, I had a jingle in my pocket (this was when we were dealing with real paper money). I spotted this particular bike for sale, local to me for £1500, which at the time was quite a wedge for what it was, however it "only" had 16,000 miles on it (also fairly high for its age).

With a few messages between myself and the seller, we eventually settled a date for payment and delivery (yes if you can believe it he did deliver the damn thing). Any way, the photo's below show you in detail what my money got me, which looking back wasn't a lot however the bike (on the whole) was complete and ran (sort of).

First photo of the two bikes together. From the summer of 2012, I had purchased and ridden the red motorcycle, which was a Yamaha XT125X, a factory supermoto but was a tad on the sluggish side, however to it's credit it did about 2,000 miles with little or no maintenance required, which was ace for me as I was a novice mechanic at this point!

Another shot, nothing new to see here apart from that Continental TK85 front tyre, which had somehow been fitted backwards on the rim.

At the time when I first posted these images to my social media, and all of the DT pages, alot of people were interested in the white side panels, which looked ace from a distance but were actually blue with a serious amount of white paint layered on top of them. At the time I didn't realise that the 230 Lanza had used white tank panels, which were starting to become hard to source.

The bike was fitted with a full DEP system, there was no receipt for this part, so was unsure of it's age however the expansion chamber was holed in places, and had a fairly old and rusty looking dent in it. I later learned that the bike hadn't been up-jetted to meet this mod.

The rear tyre was just as sketchy as the front, a fairly bald looking Continental, which was thankfully on the right way around. From experience these are good "knobbly" road tyres but they don't last five seconds, an extremely soft tyre. In this photo you can also see the fairly hefty looking dent, which was thanks to the side-stand!

The first repair job that was completed on the bike was the stubby brake lever, which interestingly was the bike's only MOT advisory, however looking back I am skeptical of this.

This is that infamous dent mentioned above, sadly this had been this way for a little while, which had caused the pipe to rust.

Another shot of the rear of the bike, this gives a good view of the bald rear tyre, along with the worn out tail pipe, which now features the scratched to buggery side plastics!

This dent was a battle scar that the bike had acquired along the way. What I have recently understood, is that this particular bike was first registered and owned in Stanmore, in Northwest London. The bike spent nearly 4 years before being moved to Bristol, which is where its been since around late 2009/2010.

The first new part, funnily enough these levers are ebay specials and I still to this day have them fitted on the bike, with little or no issues!

New Clutch lever, with the RED? Renthals, starting to suspect the previous owner might have been colour blind, slightly!

Leaking fork seals, these were a tricky job to get right. Interestingly this wasn't the last time I put new seals in them either. After having the bike on the road for about 6 months they started to leak again!

Replacement Swingarm arrived, what's cool about this part is that they didn't change between '88 and '07, which is perfect as there are plenty of them about!

This is the last photo of the bike together as I got it, now the project begins. This was taken in the earlier part of 2014, January-ish.

Managed to source a NOS exhaust end can that was local to me, the item was in great condition, it came posted with the old Yamaha packaging, which was pretty cool.

My next job on the list was setting up the fuel/air and the fuel/oil ratio on the bike. It was running really flat and was dumping oil and causing barrel wash, this was a bit of a game and I never really resolved the running issues until early 2017, but I'll get around to that.

New Swingarm and Endcan fitted, started to look a bit nicer, not so battered about the place.

Back when AJSutton weren't so expensive, this package contained new tank plastics!

eBay Jackup Kit (50mm), perfect for me as I'm on the taller side, easy enough to fit, I've still got these on the bike with no issues so far!

This shows the holes that had started to come through in the DEP expansion chamber. I did look to get these welded but to be honest it would have looked rubbish plus the chroming was well gone on this pipe!

Introducing this, managed to source this from my local parts guy, I believe he's on this forum, I am sure he'll see this thread and reply! Cheers Gerry!

This pipe wasn't in great condition, however it wasn't rotten, so I source some Hammerite matte Black.

Rust proofing the pipe, with my special solution!

Starting to look as good as new!! Very happy with the outcome of this!

I never understood the emissions valve and that system YAIS? if I remember rightly. Was a faff to fit and was a faff to run right.

YAIS valve thing?

Since I acquired the bike there were no mirrors fitted, even though at the time they weren't down on the MOT, I did decide to invest in a set of these and run them under the bars!

Fitted a tail-tidy, which was at a decent angle. The original plate was about the same size as a credit card, which wasn't a big issue although from about 5 metres away you wouldn't be able to read it!

First glimpse of the bike put together. Lots of new parts, front and rear tyres, rear wheel bearings, fixed a lot of the bad wiring. Managed to get the indicators working, managed to also get the power-valve working, which was ace!

Cool low angle shot!

Managed to get an MOT, with no advisories - happy days, certainly looks awesome!

Final first rebuild photo was of the new Renthals that arrived the day of the MOT, so of course it would be wrong to not fit them!

First few months out were good fun, managed to get the bike put together for the early part of the summer. Ran it to and from college for the last term and then as I was heading home from work the good old famous happened!

The engine went pop!! 17,000 original miles isn't bad on these parts though!

More photos of the engine being stripped down!

With the engine now repaired I wanted to make a start on the wiring loom. Sadly the rear part of the loom was a mess, it was functional but only just. I was learning all I needed to know as I going along.

The frame was starting to show signs of its age!

Quick lick of paint and it was just about okay - for now!

With the bike now fairly worked on, I rode it about for 3/4 months with little or nothing go wrong. Along the way I started to replace parts that were starting to look worn out in preparation for the following MOT (5 months away).

A new job on the list was a new set of clutch friction plates. The clutch had never felt 100%, so I decided to order in some Mitaka parts and crack on! Easy enough job todo. Whilst the casing was off I fitted the infamous kit starter set, which has been super useful!

Managed to scoop a replacment seat. The one that came with the bike was okay but it had a tear along the rear which had caused the material to rip, which had allowed water in to rot the foam in the seat. This one ran me £10 from eBay, nicee!

Next up was for some more power! DEP, looks ace!

Next up was my dodgy rear brake. It had started to seize up so decided todo fresh disc and pads along with a new rear piston and oil lip seals!

After the rear caliper rebuild I finished this end of the bike with a classic Yammie decal for that extra 5hp!

The bikes tailtidy was rubbish so I picked up an R and G, which is a super nice part, really well made!

The following week, the bike was stolen off the driveway, even with it locked to the house. I was fairly certain I'd never see it again. Thankfully with the help of facebook I managed to track down where it was being spanked. The next day I went to go and grab it, as it had been abandoned on a local open space!

After this, the bike never really ran right. So I finally decided todo the SM swap, with the wheels and I also started to keep the thing indoors! hah

The next few photos, show the build, post the theft, then getting it back, replacing the bits that had become bad and then making a start on the build!

The build in total hadn't cost an enormous amount, however what I have since noticed is that the parts were plentiful at the time, where as they now super hard to come by!! Shame really as they're good bikes but Yamaha are slowly starting to halt some parts!

@spookdog Hi mate, the wiring is currently stripped right back on the replacement unit. I think I may have it sorta resolved now, gonna fit it tomorrow and see if it runs!

Hi all,

I’ve identified my stator/magneto as dead. I’ve sourced a replacement unit, which has been removed from a working engine, however when it arrived the wiring is cut from the block connector.

I’ve still got the original so am familiar where the wires need to go, however three of them are solid white, so could they go to any of the three pins?

Thanks in advance,

Tom!

Dicking about with bigger brakes this week, what's everyone else up to?

@spookdog I'm in Dorset, near the coast. There's three of us down here that I know have DT's. Mines currently off the road in prep for the summer but the other two I see on a very regular basis!

I think eventually, he might see sense and try to continue to deliver his products to the UK. There has always been a need for them, I think that transportation and COVID definitely isn't helping his business!

Hi all,

Can anyone confirm the dimensions of the Pin that runs through the underside of the swingarm that the suspension links connect to? I am collecting and fitting new bushes and I've got some spare but don't have the means to drop my current swing arm off to double check!

Thanks in advance

@karumaspt

Okay, so to run the later wiring setup on an earlier engine I believe you will also need a later stator as opposed to the earlier one that is fitted to your earlier engine.

Someone will be able to confirm this but from 04 onwards the stator is mounted facing inwards on the inside of the outer cover. The flywheel on 04 onwards is mounted facing outwards. On earlier machines the stator is mounted under the flywheel adjacent to the crank seal and bearing.

I've been having a look at part numbers and the stators are not compatible between 04-07 and earlier models, this may be simply down to the stator mounting plates being slightly different or the resistance in the "bobine"/coils being different.

How hard would it be to source an entire later engine for your bike where you are from? I suspect eradicating your early engine to match the wiring and electrical system would make it fairly easy for you. Down the line if you're not happy with the power delivery, most of the top ends are interchangeable with a bit of machine work!

When I removed my stator last month for testing it looked to be the original unit with my bike, which leads me to conclude that my stator is approximately 12 years old with about 25000 miles on it - genuine Yamaha unit.

@calum For sure, the reason why I removed my side stand was to allow the machine to warm up whilst I'm not sat on it. It's true enough though as my side stand is still plugged in and hidden in my airbox for safe keeping.

I will consider removing it, bathing it and then refitting and seeing how I get along with this! Thanks again for the help, always appreciated!

@karumaspt

Thanks for detailing your setup!

As mentioned by a couple of people above I believe the issue may lie with the nature of the “Frankenstein” setup. Understandably Yamaha didn’t make too many changes over the 30 years they produced the bike but the biggest changes were primarily in the electrical schematics, CDI and the electronic components used to keep the system in a normal state.

The first issue you highlighted, is the possibility of the timing being off or out. On all “standard” DT engines the flywheel and stator only fits a certain way and therefore doesn’t warrant any adjustment. So a stock engine with its stock management (assuming the year and codes match) should be bang on out of the box.

For aftermarket CDi’s the ignition timing can be advanced and retarded but I think the first course of action would be getting a setup that is reliable and works properly before spending money on another unit to then fry it with in it a few months or year.

I think the best option going forward is determining the part numbers you’ve got on the components you’ve got installed and are in good condition and try to use that as the basis for your electrical setup. If the majority of the parts you own happen to be from later machines between 04 and 07 then use that.

@markus-w

Yes I will do! I’ve got two stators now, I’m almost certain the original unit is definitely past it’s best so I will look to get it repaired and keep as a good spare for me!

I will keep the thread up to date with progress as it’s still not resolved yet, fingers crossed the new unit might resolve my issue!!