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Makotosun
Yet another DT400 project,the Super DT400.
- bluntz465
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Replied by bluntz465 on topic Yet another DT400 project,the Super DT400.
Don't melt it!
I have been thinking of experimenting for a way to increase piston cooling.I wonder if anyone has tried to cross drill their piston like a brake rotor? I know it will not help for combustion temps,but should reduce the friction significantly You could of course run methanol for chemical cooling of the combustion.
I have been thinking of experimenting for a way to increase piston cooling.I wonder if anyone has tried to cross drill their piston like a brake rotor? I know it will not help for combustion temps,but should reduce the friction significantly You could of course run methanol for chemical cooling of the combustion.
1957 Cushman Eagle 1969 Honda 90 ATC 1969 Honda CB250
1973 Yamaha AT3 1974 Kawasaki KH440 1974 Honda XR75
1975 Suzuki TS75 1975 Kawasaki GreenStreak 90 1975 Suzuki GT550
1975 Suzuki TS250 1976 Suzuki GT550 1976 Indian Chief
1976 Yamaha YZ80 1978 Yamaha IT175 1980 Suzuki GS550
1982 Yamaha IT465J
1973 Yamaha AT3 1974 Kawasaki KH440 1974 Honda XR75
1975 Suzuki TS75 1975 Kawasaki GreenStreak 90 1975 Suzuki GT550
1975 Suzuki TS250 1976 Suzuki GT550 1976 Indian Chief
1976 Yamaha YZ80 1978 Yamaha IT175 1980 Suzuki GS550
1982 Yamaha IT465J
04 Sep 2015 16:44
#121
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- Bigdog302
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Replied by Bigdog302 on topic Yet another DT400 project,the Super DT400.
I don't plan on it. BTW I think I found the reason for the ticking noise. the nut for the primary side drive pinion was backing off. the threads are weak in that area. it backed off to the point it locked the engine up!
inside the engine otherwise was great. I did torque the nut but had the impression the threads were weak to begin with.
not sure if I will hunt for another engine to rob the crank out of or get this one rebuilt. I found a NOS crank half with what I need but it is not cheap! I found a whole 1975 DT400 engine for much less.
for now I got it back together but I am leery of that crankshaft. the torque spec was 50-65 ft lbs. I got it to hold at 40 Ft lbs of torque on the nut.
when the nut backed off and it stripped the threads on the crank as the nut butted up to the side cover a little at the end. I was majorly bummed out by this. pulling the head and inspecting the top end still looks beautiful and it is getting plenty of oil.
it got really noisy as it was idling then quit. glad I was not out riding it or anything,I was testing a silencer I put on it. need to weld a stinger back on the pipe to use the silencer.
for now I got the engine back together but have not run it yet. everything else in the engine is fine,main bearings,piston and cylinder still look great and it looks like it was burning nice and fat,plenty of oil and nothing at all burned up.
when the engine stuck I was freaking about it to say the least. the engine now since the nut was addressed turns over well and very smooth.
sorry I did not take pictures and I was a most unhappy man when I tore it down to look at it.
as far as temps when running,it did not get hot but it does run a little warm. of course it was hot and nasty humid as weather goes.
BTW,I did some more reading up on the MX400B. they confirmed my findings on power pretty much,lots of power and torque and it makes mucho torque at low rpm.
scroll down the page and you will find 2 MX400B tests there. the dyno tests confirmed what another test said in their dyno test. 38 HP at 8,000 rpm. for a engine that winds like this one does. it makes
excellent bottom end power. if you scroll up the page there is a 1976 YZ400C test and in the MX400B test,the MX400 actually made more power! the YZ only had 34 hp and the MX400B made 38. the test on the YZ400C actually blamed the silencer for the power loss and they mentioned piston life in a MX400B was pretty short. the tests in question is in the link.
I was scratching my head on the YZ400C test,awfully weak power,especially considering the YZ360 made around 39 hp but it was a lot harder to ride due to it's light switch power.
vintageyzinfo.tripod.com/

not sure if I will hunt for another engine to rob the crank out of or get this one rebuilt. I found a NOS crank half with what I need but it is not cheap! I found a whole 1975 DT400 engine for much less.
for now I got it back together but I am leery of that crankshaft. the torque spec was 50-65 ft lbs. I got it to hold at 40 Ft lbs of torque on the nut.
when the nut backed off and it stripped the threads on the crank as the nut butted up to the side cover a little at the end. I was majorly bummed out by this. pulling the head and inspecting the top end still looks beautiful and it is getting plenty of oil.
it got really noisy as it was idling then quit. glad I was not out riding it or anything,I was testing a silencer I put on it. need to weld a stinger back on the pipe to use the silencer.
for now I got the engine back together but have not run it yet. everything else in the engine is fine,main bearings,piston and cylinder still look great and it looks like it was burning nice and fat,plenty of oil and nothing at all burned up.
when the engine stuck I was freaking about it to say the least. the engine now since the nut was addressed turns over well and very smooth.
sorry I did not take pictures and I was a most unhappy man when I tore it down to look at it.
as far as temps when running,it did not get hot but it does run a little warm. of course it was hot and nasty humid as weather goes.
BTW,I did some more reading up on the MX400B. they confirmed my findings on power pretty much,lots of power and torque and it makes mucho torque at low rpm.
scroll down the page and you will find 2 MX400B tests there. the dyno tests confirmed what another test said in their dyno test. 38 HP at 8,000 rpm. for a engine that winds like this one does. it makes
excellent bottom end power. if you scroll up the page there is a 1976 YZ400C test and in the MX400B test,the MX400 actually made more power! the YZ only had 34 hp and the MX400B made 38. the test on the YZ400C actually blamed the silencer for the power loss and they mentioned piston life in a MX400B was pretty short. the tests in question is in the link.
I was scratching my head on the YZ400C test,awfully weak power,especially considering the YZ360 made around 39 hp but it was a lot harder to ride due to it's light switch power.
vintageyzinfo.tripod.com/
2 1968 DT1s,1970 RT1M,1970 DT1C,1971 RT1B,1971 Honda Z50K2,1974 DT100A 1974DT250A,1974 Honda MT250,2 1975 DT400Bs,1975 Honda CR250M1,1978 DT175E,1979 Honda CR250R.
Dave
Jesus is Lord!
Dave
Jesus is Lord!
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- bluntz465
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Replied by bluntz465 on topic Yet another DT400 project,the Super DT400.
Glad you at least saved most of it,When we raced these things we usually did a teardown and inspection after every event sometimes we raced one sat and another sunday so may just do a slight inspect after sat night.There was always something to be tightened even though we used Locktite on almost everything,turning 8-9k will loosen anything.
1957 Cushman Eagle 1969 Honda 90 ATC 1969 Honda CB250
1973 Yamaha AT3 1974 Kawasaki KH440 1974 Honda XR75
1975 Suzuki TS75 1975 Kawasaki GreenStreak 90 1975 Suzuki GT550
1975 Suzuki TS250 1976 Suzuki GT550 1976 Indian Chief
1976 Yamaha YZ80 1978 Yamaha IT175 1980 Suzuki GS550
1982 Yamaha IT465J
1973 Yamaha AT3 1974 Kawasaki KH440 1974 Honda XR75
1975 Suzuki TS75 1975 Kawasaki GreenStreak 90 1975 Suzuki GT550
1975 Suzuki TS250 1976 Suzuki GT550 1976 Indian Chief
1976 Yamaha YZ80 1978 Yamaha IT175 1980 Suzuki GS550
1982 Yamaha IT465J
06 Sep 2015 14:43
#123
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- Bigdog302
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Replied by Bigdog302 on topic Yet another DT400 project,the Super DT400.
I got some more parts trickling in. I got the air filter,a vent for the magneto cover and the locking plate washer for the countershaft sprocket.
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I also got the gauge face decals.
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I also got the gauge face decals.
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2 1968 DT1s,1970 RT1M,1970 DT1C,1971 RT1B,1971 Honda Z50K2,1974 DT100A 1974DT250A,1974 Honda MT250,2 1975 DT400Bs,1975 Honda CR250M1,1978 DT175E,1979 Honda CR250R.
Dave
Jesus is Lord!
Dave
Jesus is Lord!
10 Sep 2015 14:37
#124
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- Bigdog302
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Replied by Bigdog302 on topic Yet another DT400 project,the Super DT400.
first we open up the instrument we are putting the new gauge face on. I wrap some abrasion proof electrical tape to protect the chrome on the instrument then work it open with a straight blade screwdriver.
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then remove the needle carefully then the gauge face.
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then remove the old gauge face decal. I used a wire wheel very lightly on it.
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then remove the needle carefully then the gauge face.
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then remove the old gauge face decal. I used a wire wheel very lightly on it.
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2 1968 DT1s,1970 RT1M,1970 DT1C,1971 RT1B,1971 Honda Z50K2,1974 DT100A 1974DT250A,1974 Honda MT250,2 1975 DT400Bs,1975 Honda CR250M1,1978 DT175E,1979 Honda CR250R.
Dave
Jesus is Lord!
Dave
Jesus is Lord!
10 Sep 2015 14:45
#125
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- Bigdog302
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Replied by Bigdog302 on topic Yet another DT400 project,the Super DT400.
then spray some soapy water on the gauge face backing and align the decal then used something to squeegee the water out once you got the decal where you want it.
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then take a exacto knife and trim out the holes for the light bezels to go into. do it from the back and use the gauge face backing as a template.
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once the holes are trimmed then you can glue the light bezels back into place followed by the rubber cups around the light bezels on the backside of the gauge face. then you can install it back into the gauge can.
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I got some 12 volt LED bulbs to go into the instruments.
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then take a exacto knife and trim out the holes for the light bezels to go into. do it from the back and use the gauge face backing as a template.
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once the holes are trimmed then you can glue the light bezels back into place followed by the rubber cups around the light bezels on the backside of the gauge face. then you can install it back into the gauge can.
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I got some 12 volt LED bulbs to go into the instruments.
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2 1968 DT1s,1970 RT1M,1970 DT1C,1971 RT1B,1971 Honda Z50K2,1974 DT100A 1974DT250A,1974 Honda MT250,2 1975 DT400Bs,1975 Honda CR250M1,1978 DT175E,1979 Honda CR250R.
Dave
Jesus is Lord!
Dave
Jesus is Lord!
10 Sep 2015 14:54
#126
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- Bigdog302
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Replied by Bigdog302 on topic Yet another DT400 project,the Super DT400.
this is where I got them.
inside the box....
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they overpower the bezels a bit. these work on 6 volts and 12 volts but due to the nature of LED lights they require D/C current to work.
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inside the box....
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they overpower the bezels a bit. these work on 6 volts and 12 volts but due to the nature of LED lights they require D/C current to work.
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2 1968 DT1s,1970 RT1M,1970 DT1C,1971 RT1B,1971 Honda Z50K2,1974 DT100A 1974DT250A,1974 Honda MT250,2 1975 DT400Bs,1975 Honda CR250M1,1978 DT175E,1979 Honda CR250R.
Dave
Jesus is Lord!
Dave
Jesus is Lord!
10 Sep 2015 14:58
#127
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- Bigdog302
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Replied by Bigdog302 on topic Yet another DT400 project,the Super DT400.
I got to tone them down a bit. where the bulb is it overpowers the area a bit but it does illuminate the entire gauge face but it really lights up the area where the bulb is. the light is too focused in that area.
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I repeated the same procedure on the speedometer. this area is easier than the tach. I also got a gas cap,seat latch and ignition switch that shares the same key.
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also got the speedometer cable. it came from Rusty riders on Ebay.
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I repeated the same procedure on the speedometer. this area is easier than the tach. I also got a gas cap,seat latch and ignition switch that shares the same key.
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also got the speedometer cable. it came from Rusty riders on Ebay.
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2 1968 DT1s,1970 RT1M,1970 DT1C,1971 RT1B,1971 Honda Z50K2,1974 DT100A 1974DT250A,1974 Honda MT250,2 1975 DT400Bs,1975 Honda CR250M1,1978 DT175E,1979 Honda CR250R.
Dave
Jesus is Lord!
Dave
Jesus is Lord!
10 Sep 2015 15:04
#128
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- FrankC
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Replied by FrankC on topic Yet another DT400 project,the Super DT400.
You might be able to spray paint a light blocking hood on the ends of the bulb so the light won't be so pronounced at the tips.
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11 Sep 2015 10:42
#129
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- Bigdog302
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Replied by Bigdog302 on topic Yet another DT400 project,the Super DT400.
I may need to do what you suggested to all the bulbs. it overpowers the indicator light bezels too. thanks for the suggestion!

2 1968 DT1s,1970 RT1M,1970 DT1C,1971 RT1B,1971 Honda Z50K2,1974 DT100A 1974DT250A,1974 Honda MT250,2 1975 DT400Bs,1975 Honda CR250M1,1978 DT175E,1979 Honda CR250R.
Dave
Jesus is Lord!
Dave
Jesus is Lord!
11 Sep 2015 11:32
#130
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