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Dt100 top end rebuild when and why
- Tunnie
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Dt100 top end rebuild when and why was created by Tunnie
Hello, what would be an indicator that a top end rebuild is needed and is it more age or mileage linked. My bike runs ok but is so noisey it makes it not movie to ride for a long time. Thanks Tunny
29 Aug 2025 07:28
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- Tinkicker
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Replied by Tinkicker on topic Dt100 top end rebuild when and why
Loud rattling from the cylinder area is the best indicator. Apart from that, it is a case of situation and consequence.
Poor air cleaner maintenance, inlet leaks and a lack of engine warming before asking it to produce 50% and upwards power will destroy a piston and cylinder very quickly. Often in as little as 30 or 40 hours.
Piston on the right from my own DT100 restoration is a direct consequence of all of the above problems. Bike has just 2700 miles on the clock.
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Poor air cleaner maintenance, inlet leaks and a lack of engine warming before asking it to produce 50% and upwards power will destroy a piston and cylinder very quickly. Often in as little as 30 or 40 hours.
Piston on the right from my own DT100 restoration is a direct consequence of all of the above problems. Bike has just 2700 miles on the clock.
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- Tunnie
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Replied by Tunnie on topic Dt100 top end rebuild when and why
Great photo, ok I’m going to have a look at a rebuild. I think it will make a huge difference difference. Many thanks for the info
29 Aug 2025 12:27
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- MarkT
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Replied by MarkT on topic Dt100 top end rebuild when and why
If you look in the owner's manual, the maintenance schedule generally says the engine and exhaust should be decarbonized after like the first 1000 miles and then every 2000 miles after that.
This maintenance is rarely done.
If you're pulling the head and exhaust to decarbonize, it's not a whole lot more work to pull the cylinder and have it and the piston assessed by experts like PJME in the UK.
If piston/bore measured out of spec, then recondition. Otherwise you can reassemble and ride it more.
One critical thing to check with cylinder off is the big end rod bearing. If the engine ever sat with moisture in it, just a spec or two of rust on the rod bearing will cause it to fail very quickly and it could be the cause of your noise.
This maintenance is rarely done.
If you're pulling the head and exhaust to decarbonize, it's not a whole lot more work to pull the cylinder and have it and the piston assessed by experts like PJME in the UK.
If piston/bore measured out of spec, then recondition. Otherwise you can reassemble and ride it more.
One critical thing to check with cylinder off is the big end rod bearing. If the engine ever sat with moisture in it, just a spec or two of rust on the rod bearing will cause it to fail very quickly and it could be the cause of your noise.
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
The following user(s) Liked this Post: Snglsmkr, Ht1kid
29 Aug 2025 14:41
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