At age 62, I finally got a DT! Oh, I have had many other bikes but it all began in the 70's for me as a young boy. One friend, actually several had JT's and one let me use it for delivering papers, the other had a purple 90 (or was it a 100cc bike?- lucky kid!) around '69 - later in my teens, the bigger bikes popped up including a few YZ's -those were the days! This 360 is very complete, a little rough and currently not running but piston moves. No key for bike and need to find the proper 6 volt battery - pulled a Yuasa 6N4B-2A-3, Batteries and Bulbs had no batteries that would fit, same for Napa and O'Reilly's - anyone know a good AGM style battery that fits our tiny battery tray? Will need to order key blanks off EBay and try my hand at cutting a key once I remove ignition tumbler -I was able to pick gas tank lock and in spite of a fair amount of rust here and there on bike, I was surprised to see a good looking internal tank with very minimal rust-yay! Will rinse with hot soapy water and then a good vinergar soak, rinse with two stoke gas, etc. Carb was a mess, took it apart, pulled float needle, jets, etc and put it in my ultrasonic cleaner with a little heat - a ton of varnish and dirt was liberated - the slide looked a little hammered, should source a new one, bore in carb looks good - good source for slide? Petcock need a good clean, will disassemble, solvent clean. Is there a link to a factory FSM here for the 360? I am also working on a Can Am Outlander at this time and will one day put the Bultaco Alpina 250 back together. Wish me luck! No shortage of fun/disassembling/cleaning etc in my future!

Service manual available in Tech Library here.

You can probably save yourself a lot of hassle by just ordering the key from the number on the lock from one of the many ebay sellers or locksmiths.

Autozone can get you a battery... many other places too.  Not needed for spark so I wouldn't start with a battery.  Just don't turn on the lights when you get engine running until you install a battery...  and preferably a voltage regulator.

Auto parts store sell the acid cheap too if you decide to buy a dry battery online...  some ship with DOT approved acid packs so you can go that route too. 



 

Great info, thank you!

congrats on the new DT360!
the bit about adding a voltage regulator is reallu important as every time you pop a headlight its like $50, plus the tach/speedo bults which are cheap but a pain in the butt to replace.  The voltage output of the coils is way higher than 6V when left unregulated.
I have attached a link to the one I used.  I connected the yellow wire of the regulator to the bright blue wire in the headlight can and then ran a ground for good measure to one of the unused bullet connectors hanging off the black ground wires.  After installation I was able to confirm that voltate to headlight never went above 6V when reving engine, success!

re keys, I was able to get on ebay using number on other key that i had, if number is also on lock then you are set!

one major mistake I made was not verifying the main jet (and others) sizes, which contributed to my unfortuante Xmas meltdown.  So i would make sure that main is #180 and pilot #50.  I use a set of binoculars backwards as a microscope as markings are smaller than flea poo.



 

Thanks so much for that advice! Voltage Reg ordered, done! By the way, in general, best source for ordering oem style stuff? Trying to find a new gasket for my gas tank cap as the old is cracked and I am cleaning out tank.

www.kdirepros.com/category-s/372.htm

fit perfectly, just make sure it it venting once installed.  I think the screw layout is asymetrical to prevent screwing this up, but I still think its possible based on expereince!

 

for waht it is worth, in additon to checking carb jets for proper size, you might want to pressure test the assembled engine too.  The magneto side crank bearing runs hot as hell and a leak there or somewhere else will make tuning impossible and could cause meltdown.  I paid more for a 1OS piston than I did for my first 3 cars! (all under $150)

Just a caution.  Pull the mag cover and have a look.  Its likely a real mess of dirt and rotted magnesium and if you dont clean  it up you will destroy the pulser and then the fun begins findind one of those. Just a observation after 20 restores

on the regulator, for correct wiring instructions, download this Yamaha service bull item. It was a known problem until the 1976 models.

yamaha-enduros.com/index.php/service-bul...e-voltage-regulators