Finished up the seat for the DT2 250 today. What a nightmare. Purchased both foam and seat covers from e-bay selles KDI and Pobit which is the Ryder68 cover. Foam from Pobit was to stiff and thick. couldn't get it to work. Seat foam from KDI was closer to what the original feels like and fit the base better "but" doesn't look good at the rear of the seat. It puffs out around the rear bottom edge of the seat and the upper side is rounded making the Yamaha logo look funny and not on a flat surface like a stock seat? terrible looking!
The KDI seat cover ripped at the seam when installing it so its no good! So i used the KDI foam with the Ryder68 cover. I am going to have to take it back apart and somehow cut or countor the rear foam to fit better so the cover looks right. Don't feel like doing it right now so i might wait until spring or after the new year. Below is a picture of the stock seat (RT360) and the KDI seat foam on the DT250! Not even close.
Anyone have these problems? Any tips on cutting or forming the foam?

I wish i could remember where i got the new foam i used on the RT3 restoration bike 1971dt250 has? i am pretty sure it was a ryder68 cover on it.

I've heard that you can use an angle grinder to shape the foam but it makes a mess. I'll be trying it soon myself.

I thought about that. Great, let me know how it works out.

Anyone know where to get one of these? very small cotter pin. Number 17. hardware stores don't have them this small. discountiued from yamaha.

www.partzilla.com/catalog/yamaha/motorcy...1972/dt2/handle-wire

I always search Ebay for the discontinued parts. There are several of those cotter pins listed right now. I always use Yamaha cotter pins on my bikes...never anything from a hardware store

A guy in my general area flagged me down this summer while riding my 400. He showed me his old bikes and he was restoring some old seat foam. He was using old couch cushion foam, some type of glue and then using an angle grinder to contour. He was doing it outside because it makes a mess. It looked pretty good but he said you to be very careful of the disc grabbing to much foam and wisking more away than you want. Use very light pressure and secure the foam or seat base to minimize grabbing.

Yes i usually don't mind paying top dollar for hard to get parts but paying $10.00 for a .16 cent cotter pin that you can't even see is a little overboard. . besides it's only going on the DT2 250 beater! Looks like i might have to resort to it if i don't find one. I have checked 5 stores already!

I've been successful making my own tiny cotter pins using my wife's craft wire. It's green in color so I assume she bought it for making Xmas decorations. I wrapped a small finish nail to obtain the bulb shape on the closed end. Don't tell anybody.....but that spool of craft wire has been in my toolbox ever since.

This is what I've used to reshape seat foam when I need to make a cover fit correctly. 2" angle sander, works good with 80 grit pad.

I use small cheese graters to shape seat foam. It is somewhat difficult to assemble the pan, foam and cover. I would pay extra for a repopped pan with foam and cover already assembled.