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Makotosun

1975 DT400 Oil Leak Help Needed

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Replied by RT325 on topic 1975 DT400 Oil Leak Help Needed

The Plot thickens. Here's a pic of ebay. Looks like its blanked off in its casting & no plug. So if that's the end of the shaft i hope it's not been hit hard enough from the other end to pop the C-clip--but doubt 'that'. Bugger--two pot mix stuff like Araldite if that's a thing in the US. Trouble is shaft will moves a little--wriggle. Hope something like that will work.
www.selleys.co.nz/products/adhesives/hea...dite-super-strength/  
18 May 2023 15:31 #11

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Replied by MarkT on topic 1975 DT400 Oil Leak Help Needed

I wonder if the shaft popping a hole in the casting was an issue...  I found pictures of cases with the solid casting over the end of the shaft and pictures with the plug over the end of the shaft...  seems to be a later update as the 77 had that plug over the end of the shaft too. 

I'd be worried a little that the shaft clips might have given way...  testing the shifting through the gears while watching should determine that...  if shaft comes out of hole in case while shifting gears there could be an internal issue.
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
18 May 2023 17:00 #12

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Replied by Maxwell on topic 1975 DT400 Oil Leak Help Needed

Yeah, good point. The bike had been in storage for a long time (20 to 30 years) and I just got it running before winter when it started leaking oil from the clutch actuator shaft. Then it sat all winter, until now when I just recently changed the actuator seal then I found this oil leak. But before I found this oil leak it ran good and shifted well so, I feel like the internals are O.K.

I took a small wood dowel and lightly pushed on what looks to be (to me) the the (selector or shifter) shaft. It did not move, so I think (and hope) everything is O.K. I know I could only try pushing the shaft in one direction only but it felt pretty stationary. No telling if the damage was caused from the inside or outside to me.

But I will look at the shaft while shifting gears before I work on covering-up the hole with something.
18 May 2023 18:59 #13

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Replied by RT325 on topic 1975 DT400 Oil Leak Help Needed

Wonder if its dropped a chain sometime & broke the end off. Doesn't look like it though--no other chain damage.
18 May 2023 19:30 #14

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Replied by Clegg on topic 1975 DT400 Oil Leak Help Needed

I just came across this posting. I have a 75 DT400. I will take a pic of that area tomorrow.
1971 SL350, 1973 Bultaco Matador, 1978 XS650, 1979 MX175, 1982 XT250, 1982 GS650, 1982 CB450T HAWK, 1979 IT175, 1977 Suzuki TS185
01 Jun 2023 13:43 #15

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Replied by Clegg on topic 1975 DT400 Oil Leak Help Needed

Here is a pic of mine. Def looks like your casting has damage.

 
1971 SL350, 1973 Bultaco Matador, 1978 XS650, 1979 MX175, 1982 XT250, 1982 GS650, 1982 CB450T HAWK, 1979 IT175, 1977 Suzuki TS185
02 Jun 2023 18:44 #16

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Replied by Maxwell on topic 1975 DT400 Oil Leak Help Needed

Thanks for the close-up shot, Clegg. Something definitely happened and I have no idea or indication of what it was.
Everything else seems to be OK, though. The bike runs and shifts normally. It just leaks oil. I have several ideas on how to go about fixing it, but I'm just thinking it through right now. JB WELD is going to be involved somehow ........ I'm sure.
02 Jun 2023 19:45 #17

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Replied by Ht1kid on topic 1975 DT400 Oil Leak Help Needed

Maxwell can you take a picture from back to front so I can see the depth of the plug and how close is it to your sprocket didn’t know if you could put a rubber or plastic cap over it of course you would have to notch it to fit over the hole for it to fit flush with the case. Maybe I’m crazy lol
Last edit: 02 Jun 2023 22:12 by Ht1kid.
02 Jun 2023 22:11 #18

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Replied by Ht1kid on topic 1975 DT400 Oil Leak Help Needed

 
   Something like this? 
The following user(s) Liked this Post: MarkT, RT325
03 Jun 2023 08:07 #19

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Replied by MarkT on topic 1975 DT400 Oil Leak Help Needed

I like that idea HT1Kid.... it seems like epoxying a cap over the end of the shaft would be better than trying to use epoxy or sealer directly on the end of the shaft?
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
03 Jun 2023 08:45 #20

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