My Dualsport to Cafe Project Yamaha DT250

Yeahbro

New Member
Hey guys, I am new to this site and just want to say I love what I see so Far. I have been into Cars and Bikes my whole life and have been building custom cars since I was a teenager. More recently I have found that mopeds can be pretty fun as well and I love the idea of tuning two strokes. I cant really afford to buy an RD as they are super pricey in my area so I am building something out of an old street legal dirt bike. Its a 75 Yamaha DT250 I picked up for a couple hundred bucks.
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And a couple of the mopeds I have built
1978 Puch Magnum not my fastest but it did around 50mph
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1978 puch cobra with a Tomos motor 55mph
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my Favorite so far 1978 J.C. Penney pinto 72MPH with an 80cc cylinder
before paint
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After Paint
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I am planning to build the DT as a complete running streetable bike then tear it down for powder and paint. I have tried building from the ground up and always get side tracked so on piece at a time here. Got the motor fired yesterday and just bought a XS500 front end and wheels with disc front drum rear and the rear swing arm(dont know if i can use it or not yet) that should be here this weekend. I will post pics as I go and probably ask alot of questions.
Thanks for any help in advance
Eric
 
Thanks for the kind words. I should have a big chunk of the new parts this weekend so I will post some pics after I get things started.
 
Huzzah!

I love a good two-stroke. There are quite a few DT builds going on right now. Welcome to the site, and I look forward to seeing what you do to that Dual sport.
 
Got my XS500 Front end on today, the steering tube is a bit longer so it looks like I will have to make a spacer for it. I am going to try to swap swing arms tomorrow. I will post pics after if all goes well.
 
update pic. I put the front end and swing arm on over the weekend. i need to make a spacer for the steering tube still. It also looks like the swing arm and rear wheel are not going to work because of chain alignment issues. I guess i will use the stock swing arm and hub with the 500 rear hoop. Any way here is an update pic.
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:eek: mopeds are sick!!!
this is gonna be so good man, i'm hopping on.

if you need anything, www.yamahaenduro.com is a fantastic place
 
Re: forks, I would look at swapping the steering stems. Probably require grinding off the welds as they are cast iron (or maybe cast steel?) and pressing out each one, then press the DT stem into the XS clamp and either weld it yourself or have it welded at a reputable shop. If the lower bearings of each unit are the same it should work? Best of luck.
Cheers, 50gary
 
That may be the route I go with the front end. I am going to try to press the one out of the the dt forks first and see how it goes.
 
I decided to go this way also, my first bike bike was a 75 dt250. Im looking for one in running shape complete and am going to go dirty cafe stule on it. Ive drawn up plans. Cant wait to see yours complete. Good luck
 
So I got a little side tracked with work, kids,a Jeep, and moving halfway across the country. But I am finally back to working on this turd. I got my suspension and tires worked out, front end all mounted correctly. I started trying to figure out what to do with the seat and made some cardboard mockups. In the end I hated all of them so I bought a ready to go seat from dime city. Just waiting on that and my clubmans to show up in the mail and this bike will be moving full steam.

 
Do more please, I like this type of bike. I just bought an '87 YZ250 water cooled motor to put in my 73 Rt frame. It fits easily because it actually smaller than the air cooled motor. New motor mounts required though.
Cheers, 50gary
 
So I got my bars all set up. Mocked up the front brake set up. I either need to rebuild the master or buy an after market set up. I think this set up looks kind of crappy so I might change it just based on esthetics. My seat should be here this week sometime and I'm sending my gas tank out to get cleaned. Once that stuff is done its time to fire this turd and take it for a test ride.

 
So I got really tired of the ugly yellow on the tank. I decided to strip it and throw some rattle can clear on it for the time being. Look so much in my opinion.

 
So it runs. Probably needs some new seals and a tune. But running none the less.

http://youtu.be/HUhX6Snr9Bk
 
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