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TOPIC: '78 IT175 build. Gotta use up the parts!

'78 IT175 build. Gotta use up the parts! 04 Apr 2016 17:10 #1

  • Kurt Flash
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Over the past few years, I've gathered a pile of '77-'79 IT175 stuff. Last month I posted pics of the '79 DG equipped IT175 that I built over the winter. Well, since I had most of this month off, I decided to go through all the junk, use the best of what I had to work with and possibly build another IT175. Three weeks later, here we are. Anything worn on the chassis was refurbished or replaced with new. The motor got all new bearings and seals, crank rebuild and fresh bore/piston etc. Used up some of the spare plastic I had hanging from the rafters and topped it off with a custom set of Moto-X Fox tank decals from 2guysmxgraphics.com



Here's some pics of what I started with for parts. Sometimes what appears to be pure trash can yield some really good parts!



































Hope you enjoyed the pics!
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Last Edit: by Kurt Flash. Reason: Added pictures

'78 IT175 build. Gotta use up the parts! 04 Apr 2016 17:20 #2

  • MarkT
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Nice work!!! Love those bikes!

:OnFire :OnFire :OnFire
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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

'78 IT175 build. Gotta use up the parts! 04 Apr 2016 17:23 #3

  • mike1995
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Nice job, both bikes look great! I had a 79 IT 175, easy bike to ride and a lot of fun!
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'78 IT175 build. Gotta use up the parts! 04 Apr 2016 20:34 #4

  • Biknflyfisher
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Looks like your ready for the Jackpine Enduro :likey

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1983 IT490K; 2007 Yamaha FJR 1300,
2003 KTM 450exc
Too many fly rods,,,

'78 IT175 build. Gotta use up the parts! 04 Apr 2016 21:55 #5

  • Steve F
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Great work...nice looking bikes! :OnFire

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1974 DT250A, his
1974 DT250A, hers
1974 GT80A
1978 IT175E
1978 IT175E No. 332 -SOLD
"Is everything connected properly?"

'78 IT175 build. Gotta use up the parts! 05 Apr 2016 03:00 #6

  • yorarider
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Kurt Flash wrote:


Very nice!
Hey I see the case half in the photo above appears to be from a '79, but maybe it's a '77/78 (hard to tell from the photos). I also see the center punch markings around the main bearing insert (only on one side of the cases). Can you comment on that? I know the '77-78 had problems with the epoxy beating out of them and then they'd come loose, leak trans oil into the bottom end, wear out primary gears, beat-up the ignition stator,... etc., but the '79 was an improved design. Just curious what's the purpose of those punch marks are? They look eerily similar to the repair I made on my '77 after the epoxy was beat out of them.

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'78 IT175 build. Gotta use up the parts! 05 Apr 2016 03:39 #7

  • Kurt Flash
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You hit the mail on the head. This was a '78 case. The biggest issue I've found when waking up the '77/'79 IT175's are the steel main bearing inserts getting loose and wallowing out the case. This one was not too bad with .006" slop. I injected Loctite 620 Green "Slip Fit" into the gap then used a large center punch with a 48 oz ball peen hammer. Each hit, the green would ooze out so I knew it was helping to tighten it up.

We use Loctite 620 in several assembly processes at work and it can handle up to a '015" gap so it worked perfectly for this application. Once cured, the stuff hardens like iron. Very tough to remove. I also re-sealed the insert locating pins on the back side of the cases.

As for the '79 model having this issue rectified, I have not seen this, maybe later '79 models did. -This is an issue on the same years YZ125's also.

Thanks for the interest!

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'78 IT175 build. Gotta use up the parts! 05 Apr 2016 07:07 #8

  • MarkT
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Nice repair. Thanks for the mention on the loctite. This is also a problem on the early DT125/175 monoshocks.

The 79 cases did get changed. Most obvious, the "locating nubs" on the outside of the cases that had dabs of sealer on the earlier models are solid aluminum on the 79 version... no sealer needed or used.

The 125/175 DT, IT, YZ cases from that era are sister castings (but the IT175 had much bigger transfers) and all got the insert update... not sure exactly when in the year... but I have 79 cases with the updated insert design.
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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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'78 IT175 build. Gotta use up the parts! 07 Jan 2019 14:27 #9

  • magee16701@gmail.com
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I have a 77 175 with both inserts loose got so bad flywheel was spinning out of round pretty bad. Pretty sure crank prob junk to can I just buy another one on ebay or whatever and put in or gotta get one made. It's been sitting 2 years because don't know what to do about the inserts may have machinist at work try this punch and silicone for me. If I can find cases what years will work and if I am able to get a complete engine what years will bolt right up. Really miss riding this beast. When I tore engine apart found someone had plugged the crank case vent with silicone. Why would someone do that probably why it's junk now besides guy before me rebuild it and left it outside uncovered for few years clutch plates were rusted together so it definitely had water in there for awhile but was able to get it going for year then started knocking so thought it needed crank bearings and be good to go but no such luck.

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'78 IT175 build. Gotta use up the parts! 07 Jan 2019 14:43 #10

  • MarkT
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1977-79 IT175 cases will work if you can't fix the inserts.

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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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