Ttr125l playbike build - Page 2

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Ttr125l playbike build

This is a discussion on Ttr125l playbike build within the Bigger Minis Forum forums, part of the General Talk category; So got a email today piston rings are backordered till Feb so I guess a few weeks delay on top of regular shipping times...

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Thread: Ttr125l playbike build

  1. #16
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    So got a email today piston rings are backordered till Feb so I guess a few weeks delay on top of regular shipping times

  2. #17
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    Ok everyone here is my current parts list and price, please keep in mind i have ordered many extra parts that may not be needed i can update this as discover what may have to be changed and what actually needs to be used from this list.

    RC Racing

    65mm Forged Piston $110

    EBAY

    Yamaha Zuma 125 Big bore cylinder head kit 61-66mm Bore with cam $240 Ebay also available on jiangwayne This head will not fit 58.5mm Bores valves will hit cylinder!
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    Billet rocker Arm Cover for Zuma 125 $40
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    Billet Cam Breather Cover for Zuma 125 $28
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    Tusk Full Gasket Kit TTR125 $28

    Zuma 125 Cam chain $25

    OEM Parts

    BOLT, STUD 1 (5ML-E1391-00-00)
    4
    7.96
    [COLOR=rgba(0, 0, 0, 0.]Sprocket Cam Chain (5HH-11549-10-00)[/COLOR] 1 34.17
    Crank Bearing ([COLOR=rgba(0, 0, 0, 0.]93306-205YX-00) (Stock TTR Could use originals i decided to replace)[/COLOR] 2 28.47
    ARM, VALVE ROCKER (1P3-E2151-00-00)
    1
    24.64
    ARM, VALVE ROCKER (1P3-E2161-00-00)
    1
    23.51
    SCREW, VALVE ADJUS (5FM-E2159-00-00)
    4
    7.96
    NUT (90170-05800-00)
    4
    4.08
    SHAFT, ROCKER 2 (5HK-E2156-00-00) (Stock TTR Shafts are identical)
    2
    7.98
    PLATE (5ML-E111F-00-00) (Stock TTR cam Plate is identical)
    1
    1.99

    Racing Planet USA

    Naraku Adjustable Camshaft Timing Gear $37

    Local Shop (standard Price List)

    Lightened flywheel $50
    Press Sleeve in Cylinder $50-100
    Bore Engine Cases $50 (does not include splitting cases)

    Current Total $1034
    this price can be lower but it reflects the parts I chose. Because Big minis are fun haha! there are definatly was i could have saved some cash!

    I have no clue what else ill have in store or if this will even work
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    Last edited by greenducky55; 05-17-2015 at 01:18 PM. Reason: Updated parts list with new changes to build

  3. #18
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    Way cool project!!! Dood (a member here) told me he did one years ago using a Taiwan issue Yamaha 130cc scooter head. He had to make a new manifold, oil intake passages and a custom piston if I remember right. I think it produced 17 hp. Keep us posted!👍👍👍

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    I know for sure the bolt pattern and timing chain cutouts fit I had bought a base gasket prior to doing this and it matches perfect. Oil passeges seem to match as well. We will see the head and billet made it into customs last night so hopefully it will arrive next week. I'll at least get to mock it up against the stock cylinder and see if I need to order a different timing chain. I rememeber seeing a post from Dood that he ad done it but no details with it. I hope I can build it and hopefully we can get the ttr125 back onto the mod scene

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    I hope this works!

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    So good new Head and billet parts have cleared customs no delivery date determined yet.
    Big bore kit is still on back order due to rings out of stock till feb. If anyone else is attempting this right now the 63mm Kits are in stock.

    Got my kill switch installed no key set up on my bike. It works like a charm. Hope this E-start saves my kicker gear/countershaft
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    So a few weeks back i made a mistake and ordered a 2 valve older model 58.5mm Big bore kit bright side i was able to use it for some research. If i ever wanted to build a 2 valve motor i believe i could use this setup as well only paid $60 for it so no big deal haha. I am hoping the gaskets and ect are the same on my other cylinder. but we will see.

    Cylinder and piston
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    TTR base gasket on that cylinder you can see the cam chain passage is different
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    Zuma base gasket on TTR bottom end. Oil passage blocked. This is why i plan to use the TTR cylinder with the Zuma Sleeve
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    Here is the base gaskets on top of each other for reference
    Click image for larger version. 

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    Head gaskets of each stacked
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    Have much more research to do as in check where the zuma cylinder head gets oil.
    also all of my oem parts came in this week as well

    Edit: looks like it goes up the same way as our motors so no worries on the how the head receives its oil.
    Last edited by greenducky55; 01-19-2015 at 10:07 PM.

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    Well head was supposed to be here yesterday. Since I was at work I couldn't receive it needed a signature. So now have to wait for Monday to pick it up from the post office. Oh well till Monday.
    YZ250F4ever likes this.

  10. #24
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    a Klondike bar?
     
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    I am doing a TTR build as you know and I am really enjoying your build.
    -ALEX MONTEER #423 Hidden Content

    My Bikes
    DIRT:
    2013 yz450F (built race bike)
    2011 Yz450F (practice bike)
    2008 Yz250F (full mod)
    2005 TTR125 (moded yz85 conversion Gf's bike)
    2015 ssr160tx (lots of upgrades coming)

    Street:
    2009 DRZ400SM (full mod)
    2007 SDG 140cc

  11. #25
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    Cool

    Alright Picked up the goodies today. Did some mock up work. Well here is some pics and plenty of words haha!
    Bottom of the head should
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    Head with the billet covers on. (cam cover needed to be flipped was way to excited haha)
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    Intake side (going to need a custom intake manifold our stock one is not near to fitting the bolt holes are too narrow
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    Exhaust side: fits my BBR header perfect
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    Cam (its a cam dont know how the profile will perform we will see can always have webcam do a custom if I need to)
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    To be continued in a few minutes lol

  12. #26
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    Assebly of the head was a total pain in the rear. but i know some trick now that make it alot easier.
    1. Install the cam, valves, springs, retainers, keepers first
    2. the exhaust rocker is a super right fit, you have to push it up and past its install location and then place in its location its way too tight to do straight in ( i don't know if this would be true on a stock zuma head.
    3. i had to debur a few things there are some rough casting spots (china quality control) all of the machined spots fit great

    Intake side no covers
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    Exhaust side no covers
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    TTR cam sprocket on bottom Zuma sprocket on top (same teeth count different diameter)
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    zuma head gasket on its own head valves are super close on this gasket. its a 58.5mm head gasket and the head is spec for 61mm + bores we will see how it looks when my piston and rings come in. (they shipped out today from china)
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    TBC....
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  13. #27
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    TTR head gasket on zuma head (for comparison)
    This is where some welding and machine work is gong to be needed more details on my plans on next pictures
    Click image for larger version. 

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    zuma head gasket on ttr cylinder
    Plans are to weld on more material to the outside of the block where the cam chain would slide through ( will make more sense when i get it done
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    Head bolted to ttr motor for mock up purposes. ended up only using the shorter cylinder studs from the zuma and the stock ttr alen head bolts ( ill update the parts list today)
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    TTR head in front of zuma for height comparison
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    this is how short the ttr cam chain is so going to order a zuma cam chain and then if that doesn't work ill order a custom on from tsubaki
    Click image for larger version. 

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    to be continued

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    Engine mounted in TTR frame (had to cut off the upper motor mounts off of the frame otherwise intake valve cover hits) ** may not be true if you use stock covers**
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    SO exhaust bolted to the head perfect but came up a little short on the stock frame mounting hole (could make a little bracket to offset but ill probably just cut and weld a new one to the frame)
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    And now for some quick mock up with the plastics on if you used the stock covers it wouldn't even gain any attention from a non ttr owner (but where is the fun in that!!!)
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    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Click image for larger version. 

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    so that's it for now wait for a few more parts and then off to all the machine work! looks like this should work like a charm

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    Really looking good!!

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