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1977 DT250 light restoration

20 Apr 2020 06:48 20 Apr 2020 07:13 by eight0.
eight0
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1977 DT250 light restoration #1
Thanks again for the kind replies to my introduction post.

Here is the bike I bought again. It didn't come with the side panels pictured.



The bike arrived on Friday and first impressions are that the plastics are in worse condition than they are in the photo supplied above. I also noticed signs of black rattle can coverups. On Sunday we had some nice weather so I dug into the bike.

I was right about the rattle-can spray job. Looks like someone went at it without taking anything off it. Over the rust and all.

the tank has a pin hole on the right rear corner which had been 'fixed' with silicone. The inside of the tank had a small amount of visible rust but after a couple of days soaking with Evapo-rust it's now pretty clean. I love that stuff.





The wiring has been messed about with quite a bit. I think there is supposed to be a Rectifier mounted next to the coil but its been 'deleted' and the white and red wires have been twisted together. I think the previous owner ran the bike without a battery. The regulator is still there but wasn't wired in.



Looking at the engine, the gear lever and shaft no longer has any splines. Luckily a bit of research tells me this can be replaced without splitting the case.
The oil pump and reservoir is not connected at all. Maybe its been ran as pre-mix only.

I Thought I would see if I could get it to run. Cleaned out the carb and jets. Tested for spark, seems ok if a little weak. Rigged up an external fuel tank with premix but I could not get it to go.
It definitely low in compression. I could turn it over easily with my hand just using the magnito.

I Wasn't planning to go too mad with this bike but as I dug into it, the more I wanted to sort and then I got a bit carried away.

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20 Apr 2020 06:51 20 Apr 2020 07:47 by eight0.
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1977 DT250 light restoration #2


The piston showed signs of ware with lateral scoring.

I took the barrel down to a local engine shop today which is a 5 minute walk from my house. He measured the barrel and said it's still standard sized and that a re-bore wouldn't be needed so I've asked him to just give it a hone.

Looks like this bike is going to be a bit more of a project than I anticipated.

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20 Apr 2020 08:50
SlowPoke
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1977 DT250 light restoration #3
They always are.........sigh.

2018 Suzuki Vstrom 1000XT
2014 Yamaha Bolt
2009 Yamaha XT250
1977 Yamaha DT250
Hammond Organ
Fender Bass

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20 Apr 2020 09:47
Mothersbaugh
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1977 DT250 light restoration #4

eight0 wrote:

Looks like this bike is going to be a bit more of a project than I anticipated.


A chance to learn more that you thought you were going to learn...

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21 Apr 2020 03:31
eight0
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1977 DT250 light restoration #5
Tackling some lunchtime tasks. The Speedometer works but the tachometer doesn't.

Any advice on how to separate the housings?

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21 Apr 2020 07:00
eight0
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1977 DT250 light restoration #6
Still wondering what to do about the plastics. I've found some blue side panels in Germany but they are painted white and he wants 150 Euros for them. I can get a whole set from DC for not a huge amount more.

Which looks better, sky blue or White? (excuse my photoshop skills)



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21 Apr 2020 08:10
Schu
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1977 DT250 light restoration #7
I vote for WHITE.
It looks good with the tank graphics.

Schu

70 Yamaha CT175
71 Yamaha CT175
71 Yamaha JT60
72 Yamaha JT60 (2)
74 Yamaha DT360
75 Yamaha GT80
75 Yamaha DT100
75 Yamaha DT125
75 Yamaha DT175
76 Yamaha DT175
75 Yamaha DT250 (2)
75 Yamaha DT400
76 Honda Z50
17 Yamaha SCR950

"Someday, you'll own some Yamahas"
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21 Apr 2020 11:03
FrankC
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1977 DT250 light restoration #8
If they are like my 78 dt400 the backing plate at least for my model is glued on so I took the tip of an exacto blade and sort of went around the case pryiing in the groove. Care must be taken so as not to split the case. A couple drops crazy glue had it back together. I did not glue the whole perimeter because if I had to get in there again.

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21 Apr 2020 11:11 21 Apr 2020 11:14 by Lizeec.
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1977 DT250 light restoration #9

eight0 wrote: Still wondering what to do about the plastics. I've found some blue side panels in Germany but they are painted white and he wants 150 Euros for them. I can get a whole set from DC for not a huge amount more.

Which looks better, sky blue or White? (excuse my photoshop skills)




Both aftermarket colors don’t look right, I would give it a little more time for some used ones to pop up for sale, with my luck as soon as I buy the aftermarket ones a nice set pop up for sale. Also your tank graphics look incorrect, shouldn’t they be light blue, dark blue, darker blue? Yours look white, light blue, darker blue or is it just the camera angle or flash?

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23 Apr 2020 01:43
eight0
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1977 DT250 light restoration #10
I've come across a blue front mudguard listed for a DT175 3R9-21511-10

It looks slightly different but not that far off. Anyone know if it would fit/not look odd?

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