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Makotosun

74 DT360 project.... broke the pulser already

  • shopgrant
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I got this bike a few years ago and got it running right when right when I got it. It shot tons of oil out of the exhaust so I figured the crank seals were bad.

Then let it sit and worked on other projects. Finally got back to it over the weekend. actually looked really clean inside and the crank seals seemed flexible
imgur.com/vL0mfZc

Didn't know that I need to inspect the mag cover FIRST. Broke my pulser, so now my first order of business is figuring out an ignition.
imgur.com/COS02vE
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after searching the forum all day yesterday, it looks like I have 3 options. 

1. find another pulser (risky)

2. 74-78 DT 250 stator and flywheel conversion for points (best option)

3. new magneto assembly from vape or rex. ($$$)


I want to do the points conversion because that seems the most reliable but doesn't seem like there are any for sale now. So is there any other bikes that have the same pulser part#? DT400s look like the stators are extremely similar to the dt360 stator plate I have. 
02 Apr 2024 18:27 #1

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  • Schu
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I didn't know the 250 parts option was good thru 78. I thought it was only 74 and 76.
Schu

CT1B, CT1C, JT1, JT2, DT360A, GT80B, DT100B, DT125B,
DT175B, DT175C, DT250B, DT400B, Z50, SCR950

Someday, you'll own some Yamahas
Last edit: 03 Apr 2024 03:19 by Schu.
03 Apr 2024 02:37 #2

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Pretty sure the "79 dt250 went to the good cdi stator & pulser like the 400 but would need the box too--& flywheel of course.
Sorry i see you're DT360A "but same applies all should fit "79 250 & "77 400 onwards.
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Last edit: 03 Apr 2024 03:26 by RT325.
03 Apr 2024 03:21 #3

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I'm fairly certain the 74 DT360 and 75-76 DT400 had the same pulser coil.

US 77-78 DT250 points systems can also work as a replacement...  but might take a little more work to accomplish correctly.

If I remember correctly, the 77 on bikes were wired differently and lost the "day/night" battery charge selection in the headlight switch...  Yamaha wired the voltage regulator into the battery charge system so some creative thinking and/or additional parts and wiring might be required when installing 77-78 points on an earlier model.  Not impossible, but not as "plug and play" as using a 74-76 points magneto.

Also, if buying a system, always best to get a "matched set". 

Last note is that the challenge with the earlier (pre-74) points magnetos is that the flywheel was bigger.  The new engine design that came out in 1974 has a smaller opening for the ignition system and the earlier flywheel will rub the case if it fits at all.  Some have reportedly done some machining to get the earlier magneto system to fit in the later case.  I'm not sure this is wise or how difficult it is...  but it might be an option.

 
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
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03 Apr 2024 07:31 #4

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Replied by shopgrant on topic 74 DT360 project.... broke the pulser already

Awesome good to know! The early magneto sounds pretty tempting... I'm a machinist so it would be fun to figure it out and I have a line on an early set. From my reading I too saw that the early kit would work with modification but assumed it was the tapers were different which didn't seem cost effective to recut the taper and the tapered slot. However If its just the size of the fly wheel then I think ill give it a go! 
03 Apr 2024 16:04 #5

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Just curious. Would you machine the flywheel or would you modify the side case? I would assume the flywheel would go out of balance if you did any machining on it.
Schu

CT1B, CT1C, JT1, JT2, DT360A, GT80B, DT100B, DT125B,
DT175B, DT175C, DT250B, DT400B, Z50, SCR950

Someday, you'll own some Yamahas
03 Apr 2024 16:23 #6

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On my useless phone so hope it posts. Tapers will be the same all the way through the years on those from “68 to “79 or so. But advantage of the later cdi is you have electronic retard for starting. Early one did too although different pulses & how it did ‘that’—performed that duty. Be sure the decomp is clear if carbon in the cylinder drilling & also the drilling going down to the exhaust outlet from the valve. Has to be cleaned from bottom to top where valve sits as can’t get at it from the top above the valve as will be blanked off in the top fin.
03 Apr 2024 16:28 #7

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Replied by shopgrant on topic 74 DT360 project.... broke the pulser already

I'm not sure what Ill machine yet. I just placed an ebay order so once it comes and its in my hands ill have a better idea. But right now I'm thinking the same as you. Seems like I'm less likely to encounter problems if I clearance the case.

RT thanks for the tips ill start there while im waiting for parts to come in.
Last edit: 03 Apr 2024 16:33 by shopgrant.
03 Apr 2024 16:31 #8

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I have a couple of NOS pulsars available. Both have the correct resistance to prove they are good.
Since there are not to be found anywhere for sale, they are not cheap.
Just an option for you should you decide to go back stock.
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Where the Yamaha Enduro is still a current model...
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04 Apr 2024 10:21 #9

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