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Yamaha DTRE DTR DTX Merge project


hadley8899
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Hello and welcome to my build thread of my DT125

Ive actually jumped in a little late to be putting this up as the project is close to being finished as in a good day on her and shell be done now

Right the bike when i first bought it

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The first thing i noticed which i am still very curious about is what was ground off the frame under the tank ?

The frame is a 2004

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Whatever it was it looks like he was very hasty to get rid of it as hed also cut into the oil tank abit. Hopefully wasnt much important if he thought he didnt need it

Second of all i thought i best check out the frame number as you couldnt really see it under the powder coat. Which in fairness was all still very nice in the visible areas. I had a look of a scare when i couldnt find it

But now i have found it its still pretty much unreadable from the shot blasting

Will this cause problems with the MOT ?

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I proceeded to undo all the work of the previous owner and start from fresh so i stripped it down to the frame

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I have dont alot more but apparently i have posted more images than i am allowed to ??

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I then stripped off the top end of the engine and clutch cover to check it all out
While i did this i had my first real attempt at polishing metal
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I also had a go at polishing the outside of the barrel
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and the yokes
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I put the engine back together but i was soon to realise i wasnt happy at all with the way it looked
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I then painted both of the brake calipers Vauxhall arden blue.... I dislike vauxhals in general but my god they do a nice blue
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I then had the 2 pieces of subframe done and the swingarm (As i work as a powder coat i always have it on tap :))
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Put the little bits and bobs on while i was waiting for various other bits
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Engine sat there in all its sorrow. Id sent the bits of to be professionally polished after i realise my attempt at metal polishing wasnt so good
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My box of various painted bits
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Engine when i came back and i had reassembled
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The supermoto wheels i purchased. I had basically purchased all of the parts off a dtx which was being broken for 350 which i didnt think was a bad deal. Most of it was very tatty and not looked after but i dont mind that
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After id finished painting my fork legs i then put them back on the bike
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When i recieved my wheels back from the tyre shop i chucked them on
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At this stage it went very downhill for me as i went to put the front brake caliper on i realised that the supermoto brembo brake was a totally different mount to the dtrs forks. Luckily i did have the forks but they were very battered and bruised and i felt as if id wasted my time and money painting the forks :(
So the dtx were pulled from the corner and got stripped for new seals
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I thought as they were coming right down to just metal it would be best to powdercoat them gloss black rather than aerosol spray them
so off came the original paint
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My layout of all of the forks stripped
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This is the part of the dtx forks which gave me bigggg problems the bottom bolt (The big allen key) would not come loose as it was spinning internally (The reason i stripped the other forks was to see what was actually spinning. In the DTR forks they gave you a groove to put a bolt (well i used rear wheel bar) in the dtx they gave you nothing but a rounded surface to hold
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DTR damper rod grooves
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I tried taking the big chunk which was missing out of the DTX forks but i didnt want to sand to much as to weaken the structure
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Finally forks back together with new seals and brake on
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Upgraded to the gold chain :) Just need to get my bolts to replace those nasty looking brown ones holding the back sprocket
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Now this is the thread up to date. I realised the loom i have got is from an earlier model of dt and i also have the early clocks. Doesnt sound to bad until you realise nothing connects to anything
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This is the thread up to now
Today i managed to get the engine started, I posted a question in the garage section about the wiring of the new engine to old loom but as ive got it working now ill update that and do a quick write up on how i did it. I wont yet as i haven't tested any of the electrics side (charging, Lights etc)
Sorry for any spelling mistakes
I hope you enjoyed viewing
Ryan
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That is quite a lot of work and very blingy. Did you get an answer about the MOT? You need to have a number and, to be honest, I would make sure you can get the bike on the road before anything else. Is the bike road registered?

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Under the tank is suppose to be a bracket to hold the CDI. Why you would chop that off is beyond me.

They have also replaced the rear shock for a pre 2004 model. Not sure why.

And they have retrofitted the old Yamaha DT125R pre 2004 Oil bottle.

The oil bottle is suppose to be mounted on the rear left hand side of the bike underneath the panels. Inaccessible which is never a good thing but for originatily.

Looks like you've done a pucker job though mate, all things considered.

I would also consider that frame and it's legitimacy. There is suppose to be a grab rail on the rear left hand side of the bike. That's missing. And as said there should be places to mount the oil bottle on the bike.

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No no it does look like a RE frame sorry. It's just missing a few bits.

The spanish built motors are not as well built as the Japan built ones, funny how that works... :/

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Also I notice that the headlight is going to be incorrect on that.

The RE does not need a frame to mount the headlight. They mount off the yokes. If I were you I'd look for the original cowling and brackets. They look much nicer than the older ones. And suit the SM look much more.

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Hello all and thank you for the replies. Its crazy how much this bike has been modified in the past. Im pretty certain the bike is fully legal i managed to get the last for numbers off the frame after alot of cleaning with scotch brite and they match the numbers on the logbook i received but the problem is ive got a good feeling that the mot tester will be funny about it as you cant read it you can only just about see its there. So by the sounds of what youve said the frame has been modded to suit all of the old dtr style plastics tanks oil bottles and ecus. The wiring loom and ecu i have is from a dtr as well and im currently having problems getting it all wired up properly. I do have a haynes manual now so i have all of the wiring diagrams. Also does anyone have a picture of the newer style headlight. and yes i did see on the rear shock that it was stamped 03.xx.xx and i found that abit wierd

And what do you lot think about what to do with the plastics ? I was thinking about having them vinyl wrapped but ive been quoted 230 for all plastics and tank which i thought was a bit sharp. What do you lot think is best to do to them to make them look nice ?

Cheers

Ryan

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There mate.

You can get a whole new set and graphics for that price.

I don't think you should have too much trouble. At the end of the day you can have the frame powdercoated and that will obviscate the numbers. These things happen. Might be worth having them professionally repunched or a VIN plate made up.

Plastics are correct. That Oil bottle is incorrect and it's missing the grab rail.

The CDI won't fit any other plugs. So the loom needs chopping.

I'm running an aftermarket ignition and it really is a must for the DTRE the ignition is pathetic.

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Nice job so far.The frame numbers can be made more visible by using a etching acid,as you can see that they are original I wouldn't give anyone a hard time doing a mto but thats me,as DDT said be woth running it down and see what your inspector says befor going farther.

One of the members here did his own plastic wrap to his DT and it looked good,he just bought sheets of 3m wrap and with a heat gun and I am sure alot of time did a great job.

The spray on plastic dip is something I would consider,or hydro diping it all.

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I rather hope the frame numbers dont cause a problem but im sure with a bit of talking he will understand :) and yes ive seen that hydro dip. Is it expensive ? and how durable is it ? has any one had any experience

I think i would love to get the new style plastics and i suppose id need tank aswell. I put the plastics on the bike today and to be honest im not overly happy with the way they fit and look. For example the front headlight cowl has been cut down to fit the front mudguard and it all looks very crude.

Ive managed to sort all of the loom out. Was a bit of a bi**h to get it wired to the DTR loom but with a bit of a chop here and there its done.

Where would i get all of the required plastics ? I bet yamaha would charge a bomb ??

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DTR plastics are relatively cheap to be fair. The older style can be picked up from a lad in portgual for not very much less than £100 for the lot.

DTRE ones are about the same for genuine ones from Yamaha.

Yeah mate that's because you have a DTRE rear fender on there. The DTRE plastics interlock with all the other plastics. Because you have a mismatch that is obviously not happening.

I'd saygrab yourself a set of new DTRE plastics. It's the graphics that really cost you. But there are quite a few aftermarket ones out there. Not to my liking but still.

If you have a look at that link I sent you you will see how they should look. If you scroll through there will be photos of how they interlock.

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To be honest its really annoyed me to how much this chap has messed about with this bike, There seems to be one hell of a mismatch of parts from a random bucket

Ill give my Yamaha dealer a ring and see how much they want for the plastics because im not happy at all with how these look and fit

Out of curiosity will i need the tank ? Or is the tank the same from the older model to new ?

And fair play bud that came up really nice looks like alot of time and money has gone into your dt

Cheers

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Uhh Yeah unfortunately you will need a tank! Kinda sucks.

And a new seat. As said they all interlock with one another. He obviously wanted a DTR so butchered the RE instead of buying one.

It ain't that bad.

www.ajsutton.co.uk will have prices for all the plastics and graphics and any other bit. As for seat and tank best bet is off eBay. It's unlikely a nice one will come up though.

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