What seems like years ago was actually March or April. Gravel Guy was selling his DT250 and I got to it first.
I'm a fan of projects and old 2-strokes so this one was perfect. It was mostly complete, partially disassembled, and potentially only needed a clutch push rod.
Over the past few months I've worked on different parts of the bike here and there. I've grown to like the aged metal. I have no plans of painting it and making it pretty. What does matter to me is functionality.
THe first time I laid eyes on it over the internet, here's how it looked:
And the first night it came home-
Parts wise it's almost all there which is a huge benefit. I powerwashed the frame, cleaned up the years of grease, dirt, and oil. And then the engine came out of the frame to find out what was wrong.
I also did some carb work. I tried out the pine sol method for the first time. Worked amazingly well.
24 hour, unagitated, 100% pinesol soak. I would go on to put the carb in chem-dip to get off the powder coating. I'd leave the carb in there too long and ruin it. That stuff ate the aluminum almost to the point of unrecognition.
Engine plan was- put in good push rod from ebay. Replace main seals. Run.
As i got further in, i realized something else was going on. When i'd move the engine, I'd hear rattling. I could shift in to different gears, but non of them engaged the output shaft....hmm. Decided a splitting of the cases was in order. So i'd wait for time and money to buy the proper tools. In the mean time, i rebuilt the front forks and rear swing arm.
these "collars" were hard to find. but better than the old ones.
New tires, rebuilt forks, steering head, rear swing arm. Put in brand new brake shoes. ordered brake cables that I needed.
And by that time, it was case-splitting time. For perspective, I bought this in April I think. Suspension was rebuilt and done by June. Cases were split in July or so.
You can barley see the problem sitting next to the oil drainplug. It's a gear tooth. I'd suspected as much. And i ordered a replacement trans on ebay before opening the engine up.
Here's the problem-
So in more pieces than ever, i put everything in boxes and went hiking in california for a month to do the John Muir Trail. I got back, moved in to an apartment with an actual garage instead of a porch (which had been my workshop prior til now) And i've been working.
I decided that i want the engine to be the only thing that looks "new." So I decided to powder coat it.
Engine got all new bearings. The new used trans was taken down to component level and checked and then rebuilt.
Today the cases were bonded together, sealing the new transmission inside. I had a scare with the shift drum (i could only get first and second after pressing on the cases and tightening them up) but it was a simple linkage fix.
Right now i've got a bottom end sitting in the garage waiting for an oil pump.
I'm waiting on some small things like rings, an oil pump (ruined the old one in the b12 chem tool, as well) and a couple of gaskets. Other than that, it's ready to go back together and sit in the frame for the first time in almost 9 months. It's like having a baby! kind of. maybe. Never had one...
I'll keep this thread updated as I go along. Just wanted to share.
I'm a fan of projects and old 2-strokes so this one was perfect. It was mostly complete, partially disassembled, and potentially only needed a clutch push rod.
Over the past few months I've worked on different parts of the bike here and there. I've grown to like the aged metal. I have no plans of painting it and making it pretty. What does matter to me is functionality.
THe first time I laid eyes on it over the internet, here's how it looked:
And the first night it came home-
Parts wise it's almost all there which is a huge benefit. I powerwashed the frame, cleaned up the years of grease, dirt, and oil. And then the engine came out of the frame to find out what was wrong.
I also did some carb work. I tried out the pine sol method for the first time. Worked amazingly well.
24 hour, unagitated, 100% pinesol soak. I would go on to put the carb in chem-dip to get off the powder coating. I'd leave the carb in there too long and ruin it. That stuff ate the aluminum almost to the point of unrecognition.
Engine plan was- put in good push rod from ebay. Replace main seals. Run.
As i got further in, i realized something else was going on. When i'd move the engine, I'd hear rattling. I could shift in to different gears, but non of them engaged the output shaft....hmm. Decided a splitting of the cases was in order. So i'd wait for time and money to buy the proper tools. In the mean time, i rebuilt the front forks and rear swing arm.
these "collars" were hard to find. but better than the old ones.
New tires, rebuilt forks, steering head, rear swing arm. Put in brand new brake shoes. ordered brake cables that I needed.
And by that time, it was case-splitting time. For perspective, I bought this in April I think. Suspension was rebuilt and done by June. Cases were split in July or so.
You can barley see the problem sitting next to the oil drainplug. It's a gear tooth. I'd suspected as much. And i ordered a replacement trans on ebay before opening the engine up.
Here's the problem-
So in more pieces than ever, i put everything in boxes and went hiking in california for a month to do the John Muir Trail. I got back, moved in to an apartment with an actual garage instead of a porch (which had been my workshop prior til now) And i've been working.
I decided that i want the engine to be the only thing that looks "new." So I decided to powder coat it.
Engine got all new bearings. The new used trans was taken down to component level and checked and then rebuilt.
Today the cases were bonded together, sealing the new transmission inside. I had a scare with the shift drum (i could only get first and second after pressing on the cases and tightening them up) but it was a simple linkage fix.
Right now i've got a bottom end sitting in the garage waiting for an oil pump.
I'm waiting on some small things like rings, an oil pump (ruined the old one in the b12 chem tool, as well) and a couple of gaskets. Other than that, it's ready to go back together and sit in the frame for the first time in almost 9 months. It's like having a baby! kind of. maybe. Never had one...
I'll keep this thread updated as I go along. Just wanted to share.