Well done Spotty, I saw a reel on FB of a guy with a Supertrapp muffler on a bike, that had a screw on cap on the end of the muffler that he could take off to allow for less restriction when racing, which I thought was a pretty cool idea.
Speaking of mufflers, the DT expert I’ve been chatting with said that the end baffle/spark arrestor on my DT250 is a very restrictive design and to think about replacing it with something less restrictive. I did a search on EBay and the only one listed for a DT250 was $269. I contacted the seller to see if it’d fit my bike and he didn’t know. Bugger.
I did another generic search and found a very similar muffler (without the joining pipe) for $31 with free shipping. There’s only a small amount of bending required to make the joining pipe, and so I’ll see what I can knock up to make the cheapo muffler fit. Should be a fun project.
Terry,there's a place that specializes in exhaust systems for motorcycles in NZ? called Musket Muffler. Have you ever called them to see what they offer ?
No Bill, never heard of them. We have folks here in Oz who I could pay to make me a piece of pipe, but where's the fun in that? Expansion chambers are great Jim, I love the ones on my T500, but I'm not building a Motocross bike, I still have little kids living next door that I don't want to wake up at 5am, I just want to make something that's still quiet, just less restrictive, as I want to keep the bike to look as original as possible, with some nice touches.
Anyway, today I got home and there was a box waiting for me from a great guy in the US called Ian Stevenson. It contained a filthy, but complete-ish oil tank that Ian went to the trouble of buying for me on Ebay USA, and mailing to me, before I'd even sent him a dime.
DT250 Wednesday 13 March 2024 by
Terry Prendergast, on Flickr
I gave it a good clean.
DT250 Wednesday 13 March 2024 1 by
Terry Prendergast, on Flickr
I then spent the next two hours installing it. Isn't it funny how what you originally think will be a simple job can become quite time consuming? I initially thought I'd only need to remove the side cover, but ended up removing the sidecovers, seat, fuel tank, battery, battery box and various other bits and pieces, but finally got it installed.
DT250 Wednesday 13 March 2024 2 by
Terry Prendergast, on Flickr
I don't need no stinking workshop manuals (but if anyone has a factory manual for a DT250, please send it to me... ) but I did remember that I needed to bleed the air from the oil pump, so removed the oil pump cover and was happy that a., there was an oil pump under the cover, it's common for them to be blanked off by Yamaha guys, and b., all the screws holding the cover on were only finger tight, so I was lucky that it hadn't already fallen off. The main reason I took the cover off in the first place was because a previous owner had just cut the feed hose from the tank to the pump, so it was too short, but luckily they hadn't removed the oil tank breather hose from the frame under the fuel tank which was the same ID/OD hose, but longer, so I swapped them around. Anyway, I removed the bleed screw (the little JIS screw right there) and nothing came out, so I went for a piss, and when I came back there was 2 stroke oil all over the concrete, so I was happy to confirm that I'd bled all the air out of the oil line and pump.
DT250 Wednesday 13 March 2024 3 by
Terry Prendergast, on Flickr
Now I can't remember if I ever used the tool kit on my previous DT250MX that I owned in 80/81, but it must have been tiny (probably a plug wrench and a hex key) because the kit that I stole from my Suzuki T350 wouldn't fit in the tiny space provided. On my previous ride I wore my big winter jacket with big pockets, but we had a 4 day heat wave from Friday thru Monday (my hottest birthday that I can remember) so I wore my ventilated "Joe Rocket" jacket with not enough pocket space for tools. Hmmnn, OK, using two "Stubby Coolers" a couple of zip ties and some gaffer tape I mounted the tool kit on the cross bar of the handlebars.
DT250 Wednesday 13 March 2024 4 by
Terry Prendergast, on Flickr
When I got home I ordered a cheap Ebay "Pleather" tool bag, and it arrived today as well, so I removed my home made tool bag, and zip tied the new one in place.
DT250 Wednesday 13 March 2024 5 by
Terry Prendergast, on Flickr
Not as pretty as my previous effort, but it'll do the job. All in all, it was a good way to spend a couple of hours. I just need to drain the 2 stroke premix from the DT tank and fill it with normal fuel, before I fog the neighbourhood in a blue mist. It'll be so nice not having to worry about where I'll find my next little bottle of 2 stroke oil while out on a ride, most of the "Gas Stations" here will sell you food, coffee, ice cream, toilet paper, feminine hygiene products, but fcuk-all oil, especially two stroke oil, the arse-hats.