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my winter DT400 project

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    my winter DT400 project

    Well, thanks to all the guys @ www.yamahaenduro.com for setting the bar so high, I had to jump in.
    With the issues I was having,idle,with my '76 DT400 and getting it down to the head gasket, I thought why not.
    I got a decent set up in my garage,cars are running great,my 2000 Concours is purring along, why not have a winter project.
    Got into her over the weekend and was surprised that it didn't take me that long to get where I am.
    Took plenty of pics and wrote down wiring colors and pin placements.
    Not my first rodeo.
    Got to say for having on 9874 miles on her, I am quite happy with the shape of things.
    Did not think the head looked bad, the bore was smooth and nothing I could catch with a fingernail and the piston was just dirty.
    If the rest of the motor is like this, I should be in good shape I have seen worse motors in the past, so I am happy she is a Yamaha.






    So far, everything looks great.All the bolts came right out.
    Gonna have to replace some 37 year old rubber bushings but to be expected. Splitting the cases and going thru all the bearings and seals.
    Donna's going to let me bring the engine to the basement to do the work. Alot warmer than the garage.
    Replace these and the motor should be good for another 37 years.
    Imagine me riding this at 87
    Have a buddy at work that does painting on the side,so over the winter give him the frame,fenders,gas and oil tank and assorted parts.
    Want to bring her back to showroom condition.
    Really looking forward to it.
    I'll post more pics as she progresses.
    Look out Edbot, we'll be D/S riding in VT next year.
    Doug aka crag antler

    83GS1100E, gone
    2000 Kawasaki Concours
    Please wear ATGATT

    #2
    This is going to be a very cool project. I'll be following along.

    Comment


      #3
      Cool bike.

      I've got one of those with a monoshock. I'm wanting to find out if it can be easily upgraded using a YZ or IT front end and swing arm. Mine has something wrong in the front axle. A missing or incorrect spacer or something. Not sure.
      sigpic Too old, too many bikes, too many cars, too many things

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        #4
        I know it has been like forever since I've put anything of the rebuild on but I have been busy at it. Split the cases and replaced all bearings and oil seals. Had the crank rebuilt and balanced and now am onto the rebuilding part. Just finished up painting and here are the results



        A little hi temp engine paint and it is becoming a beautiful thing
        A nice blend of both gloss and satin black
        Doug aka crag antler

        83GS1100E, gone
        2000 Kawasaki Concours
        Please wear ATGATT

        Comment


          #5
          A lot of work into an old gutless DT400. The parts look great though. Sentimental value?

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            #6
            Not really too much work. Only about 4 cans of spray. In the end,it will only be about $600 in parts. Purchase price of $400 so for $1000 altogether, I'll have a new bike. My first bike was a 77 DT250, so there is a little sentiment here.
            Doug aka crag antler

            83GS1100E, gone
            2000 Kawasaki Concours
            Please wear ATGATT

            Comment


              #7
              Originally posted by GSX1000E View Post
              A lot of work into an old gutless DT400. The parts look great though. Sentimental value?
              Ya I had one of those in the early eighties, they were gutless. My Husky CR 250 would swallow that Dt. But the DT was still fun and very dependable , it was a very easy bike to ride( user friendly). I wouldn't mind finding one to beat around on.
              1984 GS1100GK newest addition to the heard
              80 GS 1000gt- most favorite ride love this bike
              1978 GS1000E- Known as "RoadKill" , Finished
              83 gs750ed- first new purchase
              85 EX500- vintage track weapon
              1958Ducati 98 Tourismo
              “Remember When in doubt use full throttle, It may not improve the situation ,but it will end the suspense ,
              If it isn't going to make it faster or safer it isn't worth doing

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                #8
                Anyone who knows two strokes can make them fast enough.


                Life is too short to ride an L.

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                  #9
                  Love it! I have a 72' Benelli mini bike was 50cc blew the cylinder out to fit a 125cc piston. Baaad mofo!

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                    #10
                    We have a 76 dt 400 that my son son blasts around on . It fires first kick and has enough power to overcome the chassis anyway. . Looking good.

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                      #11
                      Got into DIY zinc plating and it seems to work out great for this project. So far,here are results

                      Before:


                      After:


                      I know it has a gold tinge,just the lighting,they do polish out to an almost chrome look.
                      Not going for concours but IMHO looks good
                      Doug aka crag antler

                      83GS1100E, gone
                      2000 Kawasaki Concours
                      Please wear ATGATT

                      Comment


                        #12
                        Nice, what system did you use?

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                          #13
                          Used a homemade mix.
                          Epsom salt,vinegar,zinc anodes, and Karo corn syrup.
                          It's a set up I got from the yamaha enduro forum.
                          Here is a link to a website with the info.

                          It's fun and it works out being cheaper than the ones you can buy and don't have the nasty chemicals around.
                          Doug aka crag antler

                          83GS1100E, gone
                          2000 Kawasaki Concours
                          Please wear ATGATT

                          Comment


                            #14
                            Those look very nice Doug.
                            1979 GS850G
                            2004 SV650N track bike
                            2005 TT-R125 pit bike
                            LRRS #246 / Northeast Cycles / Woodcraft / Armour Bodies / Hindle Exhaust / Central Mass Powersport

                            http://s327.photobucket.com/albums/k443/tas850g/

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