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Differences between 1976 and 1978 dt400 cases and gears (bottom end)

  • DT400FRANK
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My case is messed up on my 1978 dt400 . Will the bottom end parts like cases and gears, crank and all that interchange with the 1975 and 1976 dt400 onto the 77 and 78 dt400? Also is it wise to take two different case halves from unknown history and marry them together or is it best to find case halves that came together from the factory?  Thanks
I know the cylinders and head are different 
18 Jul 2021 22:50 #1

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Totally different cases  not sure about gears and shafts.
doug
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19 Jul 2021 08:19 #2

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How are your cases messed up? if the sealing surface is scored or marred that can be fixed with JB weld. they can also be heli arc welded if they are broken, Rich can do those repairs and you would be hard pressed to tell if they were ever broken. there is also looking on Ebay for cases for your bike. the 1975-76 400s are completely different than the 1977-78 cases and do not interchange unless you mod the frame of your bike and plug a complete 75-76 DT400 engine into your bike which I would never do, the 1977-78 DT400 is to me a better engine.
2 1968 DT1s,1970 RT1M,1970 DT1C,1971 RT1B,1971 Honda Z50K2,1974 DT100A 1974DT250A,1974 Honda MT250,2 1975 DT400Bs,1975 Honda CR250M1,1978 DT175E,1979 Honda CR250R.
Dave
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19 Jul 2021 16:00 #3

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  • DT400FRANK
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Thanks all.   My right hand case is messed up in the area right in front of the crank. It cracked the tachometer gear pin perch. It looks like it could be fixed. Looks to me like the oil pump gear or something came loose. My oil pump and shaft is missing when I got the bike. One of the perches for the engine side cover bolt mount is broke off also

Last edit: 20 Jul 2021 23:20 by DT400FRANK.
20 Jul 2021 23:18 #4

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does the gear pin fit in there sloppy with a lot of play there?
or does it fit tight in the hole? you want to fit tight so it won't back out while the engine is running.
2 1968 DT1s,1970 RT1M,1970 DT1C,1971 RT1B,1971 Honda Z50K2,1974 DT100A 1974DT250A,1974 Honda MT250,2 1975 DT400Bs,1975 Honda CR250M1,1978 DT175E,1979 Honda CR250R.
Dave
Jesus is Lord!
Last edit: 21 Jul 2021 12:14 by Bigdog302.
21 Jul 2021 03:59 #5

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