Dealing with the DT

[stinkwheel]

[Easy-X]

[trevor saxe-coburg-gotha]

[Easy-X]

Not so bad with the single seat + rear rack option but good shout though, I can easily re-route if I get hold of one of those trials brake lights.

I'm looking at the moment for a number plate mount. The trials ones are just big rubber flaps. I did find a US version of "feked" that had one but it was $60 or so Might have to make one.
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Easy-X]

So I've deliberately held off on diving into the bike until the weather was perfect: the sort of hot, sunny day where you regret working outside for any length of time

Tail Tidy. Along with "Slip-On" probably the most common mods anyone does to a bike. Certainly never thought I'd be doing either of those to an old '70s bike but hey-ho

So this is what we have:

https://i.imgur.com/nOtFP88.jpg?1

As mentioned previously, a bone-stock, Euro-spec tail light and number plate arrangement. Including that wire.

Ah! Lovely: my mate (who previously painted the fenders black) didn't leave the spot underneath:

https://i.imgur.com/hAQ44ND.jpg?1

Drill some holes for the new light, bonus! If one were to put the old arrangement back it would totally cover the holes

https://i.imgur.com/E4F1DWc.jpg?1

Looking better already:

https://i.imgur.com/WvCS26i.jpg?1

It was at this point I paused to try and work out which wire was which. And then did a "while you're down there..." This had been nagging at me a while:

https://i.imgur.com/pMpIvJ0.jpg?1

Like an idiot for some reason I'd run the loom between the frame and the exhaust

While half the back-end wiring was out, may as well do a proper job:

https://i.imgur.com/F8j3sDu.jpg?1

Of course, the new lamp just had to have the wrong sized bullet connectors so had to crimp some new ones on:

https://i.imgur.com/b1hSbia.jpg?2

Now for a little bodgery for the number plate:

https://i.imgur.com/Avnyqd0.jpg?1

I have some tin cable tidy stuff, a roll of holes, if you will. It's not sturdy stuff even under tension but it'll do for now. I'll get one of those smaller style number plates made up and make some permanent brackets.

Rubber bung in the cable hole, original dome-nuts still serve a function; turned out well, if I may be so bold

Now the indicators look a bit lanky Have have a different style in the spares box:

https://i.imgur.com/zrzNr3G.jpg?1

The chrome's starting to peel in places but they'd be passable. Roughly these would lose about half a lens diameter. Not sure whether it's worth the effort

Anyhoo, the finished article (for now!)

https://i.imgur.com/QpPcaHj.jpg?1

A few other minor things. Fitted side reflectors mainly as there was a space on the frame for them:

https://i.imgur.com/Nw968DT.jpg?1

And got some wingnuts for rear seat mounts as occasionally I'll need to top up the oil or check the battery:

https://i.imgur.com/B5cCS0Y.jpg?1

Happy side effect: seat seems to line up better!

https://i.imgur.com/JIQ7umb.jpg?1

Note the Gorilla tape on top of the oil tank. The petrol tank is a wee bit bigger than the original and there's not much clearance so that's just a bodge to slow down any hole being ground into the tank

Finally, as mentioned on Mr. sickpup's thread, I spotted this little area of "corrosion-catching"

https://i.imgur.com/OJV3sF8.jpg?1

Little squirt of Dinitrol

Just some more carb fettling left. Can be a big time-sink so maybe tomorrow
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Easy-X]

If you've seen my posts elsewhere tinkering with the carb didn't take as long as I thought it would.

The air screw was about 1 3/4 turns out. Specs on the carb say 1 1/2 to 3 is the working range. Past 3 the screw isn't really letting more air in so that says too rich. I tried the next size up on pilot jet and now the screw is at 2 1/2 which hints at heading towards too rich. The rule of thumb being "better too rich than too lean" I think it's at the ideal spot.

I was also getting rev hangs around 4k. "Oh noes! Main crank case seal!" thankfully not, I tried the largest main jet I have in my assortment and it runs fine now. I've ordered up some larger jets. Short of a dyno I shall try going up jet sizes till the performance suffers and then go one jet down. Later on that one.

And then, just as I was enjoying the thing the clutch cable went Hindsight is a wonderful thing and now I look at the cable it's obviously crap quality. Here's the original (the adjuster is rusted to f*ck and the cable barely moves) above and the busted replacement below:

https://i.imgur.com/owfhQsy.jpg?2

Oh dear, so not even the correct length! That actually doesn't matter too much as it's the available cable travel that's important. Let's line up one end:

https://i.imgur.com/Bt4SHMO.jpg?1

...and then look at the other:

https://i.imgur.com/F11rq7f.jpg?2

Dammit, way out. I was thinking I had a problem with the clutch given I had all the adjusters wound all the way out but obviously not.

At this point I could have bought a cable from a decent source (~£15 from Yambits) and left it at that but given the age of the bike it's still a bit pot luck as to quality. All due respect to Yambits but not everything they sell is 100% matching the OEM parts.

Nope, I got an end of the right size (£2) and whacked on the flux and lead solder:

https://i.imgur.com/NrC8ZY0.jpg?2

I fully expect the clutch end will give next but one step at a time. At least the travel matches now
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Easy-X]

If you've read elsewhere I suspect an air leak (lean condition) and prime suspect is the magneto side crank seal. Let's take a look...

https://i.imgur.com/msAaRgC.jpg?1

A slight cough of the impact wrench (only on no.1 setting) and that's the main nut off:

https://i.imgur.com/NS2OjdG.jpg?1

With the right tools this should be a trivial job:

https://i.imgur.com/R8zihWO.jpg?1

BTW reverse thread on the outside, normal thread on the inside of this extractor. I did fish about looking for a 22mm spanner but in the end I just used a pipe wrench - it came off without too much effort. Much harder is to lift the flywheel off 'cos of the magnets

Bit grubby, some surface rust but really not bad for >30yo:

https://i.imgur.com/4jlf6hR.jpg?1

Again, coils, points, condenser - in a lot better condition than I expected:

https://i.imgur.com/kkXAI1f.jpg?1

I did try a JIS screwdriver but no go. Impact wrench again but this time on setting no.2, eeek!

And here's the old seal:

https://i.imgur.com/BOIjiiw.jpg?1

Took a bit of wrestling to get it out. I was careful not to prise against the soft alloy of the crank case. Although not completely shot the out rubber had pretty much disintegrated on the air side. The interior side has the spring lip; intact but the seal is definitely old so here's hoping this is the source of the air leak.

Replacement tapped in with the help of a large socket from my impact wrench's set:

https://i.imgur.com/uByAJgZ.jpg?1

Bit of a clean-up and, well the assembly photo's would just be the same Obviously take care with the woodruff key

Few more bits to do tomorrow and then we'll see how it runs.

<addendum> oh, and I gave the points a light buffing while I was there
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[A100man]

Interesting.. I might have expected to see some signs of the seal letting by - a weep of petroil maybe.

Have you run her back up yet?
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600

[Easy-X]

[wr6133]

That stock tail light looks identical to the one I had on a 1975 V75A. Indicators look the same too.

[A100man]

[WD Forte]

Not to be an know all arse about it, but Ida stuck a new set of points
and a condenser in while I was in there.
Once you have to start buffing them they're usually on the way out
and if the condenser/cap is shot, that'll make em arc
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bikers smell of wee

[Easy-X]

And in the spirit of not leaving well enough alone...

The rear indicators always annoyed me - the "out on stalks" look. They are stock, of a sort, quite a lot of variations between models, years and countries.

Taking a lead from the front lights:

https://i.imgur.com/eWMvKqn.jpg?1

The rears just look weird to me:

https://i.imgur.com/iKoni6n.jpg?1

So I found these:

https://i.imgur.com/KLkFXLc.jpg?1

Which match the style of the fronts I think. The only downside is the lenses don't match:

https://i.imgur.com/foFDAve.jpg?1

Anyhoo, I've already gone a bit nuts with the brake light. I think it's an improvement:

https://i.imgur.com/DBxHR3c.jpg?1

The mudguard has some rubber v-grommets much like you'd have on suspension ends. The metal collars needed taking out from 8mm to 10mm ID. The frame holes were ~9mm so barely needed the paint knocking off. (Most of these "hollow bolt" type indicators are 10mm. The originals seem a bit weak for the job and were already wonky.) Some minor rewiring to extend the nearside cable and job done.

Of course, one has to take it down the road to check it works! Start the engine anyway as you can't see shit in bright sunlight just running from a weedy 6V lead-acid battery.

Initial tests don't show up any of the rev hangs but I only did a quick spin around the town. TBH after pissing about with the lights I wasn't in the right frame plus it was almost tea time All indications (hahaha!) are good
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[WD Forte]

I'd say the rear light is a definite improvement,
the high level one was asking to be kicked.
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bikers smell of wee

[Easy-X]

[Easy-X]

So my local garage sent me an MoT reminder for the Keeway. I know these things are automated but it's an excuse to go round and tell them I sold that bike. Given these are the guys that did the tyres on the DT I had promised them a look once it was finished. Glad I did...

Obviously only a quick visual appraisal but if it had gone for an MoT it'd fail 'cos I haven't got a nylock or split pin nut on the rear torque arm bolt. Gotta love free advice like that! Other than that they were pretty impressed. Engage smug mode

I'm getting a lot more used to the riding style now - I had been pretty negative about it - but I have to wait till the log book comes back with the colour change before I can sell it, nothing the wife can do about it! What a terrible shame
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Easy-X]

Log book is back so final touches. This one?

https://i.imgur.com/BB5O525.jpg?1

Or this one?

https://i.imgur.com/kSqK4TW.jpg?1

I went with the latter:

https://i.imgur.com/ggn4Klz.jpg?1

Too much?

https://i.imgur.com/GheWJlJ.jpg?1

Yeah, too confusing

https://i.imgur.com/C4Nxz4E.jpg?1

If I get some time tomorrow I'm going to buff up all the chrome and the odd steel bolts for surface rust ready for some eBay/Gumtree/Autotrade/FB photos.
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[blurredman]

The original tail lamp I agree is awful, but those cheap e-Bay 'trail' tail lamps like the one you have are also pretty poor. Not good.

I use this myself- I don't actually know what it's from, it's similar, but a lot smaller than the Suzuki DR650 lamp. Either way- can't kick it, and it is sleek- That is.. until you see the number plate.

https://blurredmanswebsite.ddns.net/pictures/bikes/ts/lostback.jpg
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CBT: 12/06/10, Theory: 22/09/10, Module 1: 09/11/10, Module 2: 19/01/11
Past: 1991 Honda CG125BR-J, 1992 (1980) Honda XL125S, 1996 Kawasaki GPZ500S.
Current: 1981 Honda CX500B - 91k, 1987 MZ ETZ250 (bored to 295cc) - 38k, 1990 MZ ETZ251 - 49k, 1979 Suzuki TS185ER - 9k, 1973 MZ ES250/2 - 17k.

[Easy-X]

Thing is it mounts really well in that spot and I believed at the time it was originally intended for the IT175... I suppose it's actually a super generic part?
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[blurredman]

[Easy-X]

[ThunderGuts]

Looks a good project. I wish I had the time/space/money to do this sort of thing, although it'd probably be a Cub. I joined all this biking malarky 10 years too late; I understand Cubs and the like were peanuts to buy then.
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TG.

[Easy-X]

[Easy-X]

Tie a bow on it, it's done:

https://i.imgur.com/orQmWyw.jpg?1

Well, as much as I'm prepared to do anyway

Rode over to the garage to put some fuel in and stopped off to see my mate who originally sold me the bike to show him how it turned out. I think he was most impressed at how the rims cleaned up.
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[ThunderGuts]

Looks fantastic! It also looks quite small, or is that a camera perspective thing?

A newborn has pretty much killed any opportunity I'd have to renovate an old bike sadly . . . I struggle to find the time now to even ride my only bike!
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TG.