my winter DT400 project

[crag antler]

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.

[spyug]

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

[850 Combat]

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.

[crag antler]

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

[GSX1000E]

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

[crag antler]

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.

[hjfisk]

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.

[tkent02]

Anyone who knows two strokes can make them fast enough.

[Morrison]

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

[amxsteve]

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.

[crag antler]

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

[jwhelan65]

Nice, what system did you use?

[crag antler]

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.

http://home.comcast.net/~rt66tbird/website/zincplating.html

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

[tas850g]

Those look very nice Doug.