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Old 02-24-2017, 03:52 PM   #31
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I found today the left ignition side case has bad damage from the bike throwing the chain. The clutch pivot retainer screw has been ripped off and a big chuck of the clutch pivot shaft housing along with it. You can see the pivot shaft through the side of the case.

Given that, I'm now in the hunt for a set of cases for a 77-79 DT250 1M1. Will consider a complete motor. I will at least need a replacement left ignition side case.

Pictures coming.
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86 YZ250S, 84 RZ350L KR, 82 IT465J, 81 YZ465H X 2, 81 ZIT465H, 79 DT250F, 78 DT400E X 2, 78 YZ400E, 78 DT175E, 77 YZ400D X 2, 77 YZ250D, 76 Bultaco 250 Pursang Mk 9, 75 DT250B, 74 Suzuki TM250L, 72 DT2 MX X 2
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Old 02-24-2017, 07:25 PM   #32
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The new piston seems to be readily available. This motor #2 is in way better shape than the other one. Obviously this damage shut down the life of this otherwise low time motor. The tranny and crank in excellent condition.

I'm going to look into having the first set of cases rebuilt at the main bearing seats. I'm thinking mill out the cases removing those steel inserts and make solid round aluminum repair inserts, weld them in and line bore. I got this really good machinist welder guy in Bountiful that I'm going to go visit.

Has anyone out there herd of doing the above to a set of cases??????
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86 YZ250S, 84 RZ350L KR, 82 IT465J, 81 YZ465H X 2, 81 ZIT465H, 79 DT250F, 78 DT400E X 2, 78 YZ400E, 78 DT175E, 77 YZ400D X 2, 77 YZ250D, 76 Bultaco 250 Pursang Mk 9, 75 DT250B, 74 Suzuki TM250L, 72 DT2 MX X 2
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Old 08-25-2017, 03:27 PM   #33
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Default Barn Find 1977 YZ250D

Success! Good things come to those who wait! I've been chasing this bike more or less since April! Finally got my hands on it and it's in the shed! One owner standard bore original piston (not verified) 99.9% complete YZ250D. Starts 2nd kick, runs and shifts through the gears OK. Has a massive air leak on and around the dry rotted intake manifold and likely the main seals to the point it will only really half way run/ride on choke. Rattles a bit but they do that anyway. You can hear the reedvalves "brooop" sound when slowly stroking. Very little sun damage. A few dents in the pipe. Subframe pretty straight. Complete airbox and side covers. No evidence of ever throwing the chain. Engine sprocket cover still there installed! Guy now 63 bought it new from our local Ogden dealer and says he never raced it just trail ride. Original title and MSO. Original tires. Front brake cable guides still there. Wheels straight and true front and rear. Amaizing shape but looks like it's 40 years old as you could only expect.

I'll post pictures when I get that figured out. An extremely good starting point for a restored racer!
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86 YZ250S, 84 RZ350L KR, 82 IT465J, 81 YZ465H X 2, 81 ZIT465H, 79 DT250F, 78 DT400E X 2, 78 YZ400E, 78 DT175E, 77 YZ400D X 2, 77 YZ250D, 76 Bultaco 250 Pursang Mk 9, 75 DT250B, 74 Suzuki TM250L, 72 DT2 MX X 2
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Old 08-25-2017, 10:47 PM   #34
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Now I'm motivated to move forward with the project. I think I'll start pulling parts tomorrow and see what lies within. Might just send the shock off to Steve Sage first of the week. We'll see if the swingarm pivot come out easy. I need to make a welding jig fixture to weld on a lower chain roller mount as seen on the 78 models. I will copy the positioning off my 78 400. Chain control is so critical on these bikes. I'm going to have to eradicate a few wasp nests before I can get at the 78. The shed I have that bike in is full of them. There's enough in there to fly off with the shed!

PS, adding to my previous, the clutch seems to be in good order as well. Who knows, I might can change the main seals and put on a new intake manifold and just run it for now. I'll play with removing the few dents in the pipe. We'll see. This old bike is not that thrashed out!
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86 YZ250S, 84 RZ350L KR, 82 IT465J, 81 YZ465H X 2, 81 ZIT465H, 79 DT250F, 78 DT400E X 2, 78 YZ400E, 78 DT175E, 77 YZ400D X 2, 77 YZ250D, 76 Bultaco 250 Pursang Mk 9, 75 DT250B, 74 Suzuki TM250L, 72 DT2 MX X 2
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Old 10-12-2017, 06:38 PM   #35
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Default Project Revised! 77 YZ250D into 78 YZ400E Chassis

Now that we have a way to post pics again, here are a few!

Full steam ahead with this project! This one I've been working on over the last few weeks.

I've torn down the 78 400 chassis and rolling toward fixing all the problems.

I found this when I pulled the swingarm! Some people should not own dirt bikes! Off to my my most trusted local welder friend!

https://lh3.googleusercontent.com/Z_...=w1211-h909-no

Now I have to whittle this back down to serviceable condition.

https://lh3.googleusercontent.com/sw...=w1211-h909-no

Found these tabs broken off for the center brace.

https://lh3.googleusercontent.com/G1...=w1211-h909-no

Back from the welder all fixed up!

https://lh3.googleusercontent.com/Ft...g=w681-h908-no
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86 YZ250S, 84 RZ350L KR, 82 IT465J, 81 YZ465H X 2, 81 ZIT465H, 79 DT250F, 78 DT400E X 2, 78 YZ400E, 78 DT175E, 77 YZ400D X 2, 77 YZ250D, 76 Bultaco 250 Pursang Mk 9, 75 DT250B, 74 Suzuki TM250L, 72 DT2 MX X 2
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Old 10-12-2017, 06:49 PM   #36
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Alright I messed that last one all up! Forgot that one step!

Here is a picture of the 250 motor going in the 400 chassis

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86 YZ250S, 84 RZ350L KR, 82 IT465J, 81 YZ465H X 2, 81 ZIT465H, 79 DT250F, 78 DT400E X 2, 78 YZ400E, 78 DT175E, 77 YZ400D X 2, 77 YZ250D, 76 Bultaco 250 Pursang Mk 9, 75 DT250B, 74 Suzuki TM250L, 72 DT2 MX X 2
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