Yamaha IT 490 Restoration

Wild_Alaskan · 03-19-2013, 05:53 PM

Picked up a 1983 IT490 a couple days ago to restore, it was pretty rough cosmetically, but was basically complete, only things missing so far are the tail light and kickstand. Was able to start it and it appears to run great.

I am currently working on

recovering the seat
restoring the usable plastics
replacing all the cables
replacing the airfilter
replacing the exhaust
doing some touch up paint and cleaning

FastDoc · 03-19-2013, 06:09 PM

Did that bike run lights originally? Is it a premix or oil injected?

This will be a great project. :P

Wild_Alaskan · 03-19-2013, 06:34 PM

Pre-mix and it did run lights (in some countries it was factory street legal) and I have the head light for it. The ignition system on it is good, i haven't explored the 12v system but will once it is back together.

here are some old magazine reviews for any who are interested

http://www.yamahait.com.au/forum/ind...pic,461.0.html

FastDoc · 03-19-2013, 07:22 PM

That bike would make a great desert sled or vintage racer. I'd dual sport it and kill mosquitos all over Bozeman. 8)

Wild_Alaskan · 03-19-2013, 08:14 PM

Tank and fender are resurfaced

SpudRider · 03-20-2013, 01:04 AM

Thanks for starting the great thread, WA!

That bike is a nice acquisition.

You are certainly off to a good start; the tank and front fender look great!

Spud

FastDoc · 03-20-2013, 11:20 AM

How did you do that they look amazing!

I used Plastic renew on the tank of my XR250 and it worked well but took hours....

Wild_Alaskan · 03-20-2013, 11:44 AM

Basically i scraped all the sun damaged plastic off with a knife. then buffed it.

just like in this video

**quadz** · 03-20-2013, 04:00 PM

Nice pick up! I loved those bikes.. love all the 80's Yamahas actually.

What an amazing job on those plastics, I can't believe those are the same ones! :o

pete · 03-21-2013, 12:38 AM

What a kool rocket...
I had a IT465 in the day...
they are a real beast...
mine colapsed the piston and took out
the barrel.... I found a YZ465 used barrel
put a YZ piston in it...
With the YZ top end & the ITs wide ratio
gear box... Dam could that thing move...

Wild_Alaskan · 03-23-2013, 08:23 PM

recovered the seat and got the head light cleaned up most the way. going to get YAMAHA stenciled on to it when my seat paint comes

SpudRider · 03-24-2013, 01:50 AM

It's remarkable how well that old plastic cleans up.

Spud

Weldangrind · 03-25-2013, 01:55 AM

Great tip! I've used the blade trick, but I never thought of polishing with a buffing wheel. The seat turned out really well.

SpudRider · 03-25-2013, 02:05 AM

Indeed! I forgot to comment; the seat looks great!

Spud

zingshoen · 03-25-2013, 09:23 AM

great bike + good work! some serious 2 stroke power to look forward to?

03-19-2013, 05:53 PM	#1
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	Yamaha IT 490 Restoration Picked up a 1983 IT490 a couple days ago to restore, it was pretty rough cosmetically, but was basically complete, only things missing so far are the tail light and kickstand. Was able to start it and it appears to run great. I am currently working on recovering the seat restoring the usable plastics replacing all the cables replacing the airfilter replacing the exhaust doing some touch up paint and cleaning __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
	0

03-19-2013, 06:09 PM	#2
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Did that bike run lights originally? Is it a premix or oil injected? This will be a great project. :P __________________ Happy to serve.
	0

03-19-2013, 06:34 PM	#3
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	Pre-mix and it did run lights (in some countries it was factory street legal) and I have the head light for it. The ignition system on it is good, i haven't explored the 12v system but will once it is back together. here are some old magazine reviews for any who are interested http://www.yamahait.com.au/forum/ind...pic,461.0.html __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
	0

03-19-2013, 07:22 PM	#4
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	That bike would make a great desert sled or vintage racer. I'd dual sport it and kill mosquitos all over Bozeman. 8) __________________ Happy to serve.
	0

03-19-2013, 08:14 PM	#5
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	Tank and fender are resurfaced __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
	0

03-20-2013, 01:04 AM	#6
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Thanks for starting the great thread, WA! That bike is a nice acquisition. You are certainly off to a good start; the tank and front fender look great! Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

03-20-2013, 11:20 AM	#7
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	How did you do that they look amazing! I used Plastic renew on the tank of my XR250 and it worked well but took hours.... __________________ Happy to serve.
	0

03-20-2013, 11:44 AM	#8
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	Basically i scraped all the sun damaged plastic off with a knife. then buffed it. just like in this video __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
	0

03-20-2013, 04:00 PM	#9
quadz Administrator Join Date: Mar 2013 Posts: 303	! Nice pick up! I loved those bikes.. love all the 80's Yamahas actually. What an amazing job on those plastics, I can't believe those are the same ones! :o
	0

03-21-2013, 12:38 AM	#10
pete Join Date: Jan 2012 Location: ChCh , NZ Posts: 2,261	What a kool rocket... I had a IT465 in the day... they are a real beast... mine colapsed the piston and took out the barrel.... I found a YZ465 used barrel put a YZ piston in it... With the YZ top end & the ITs wide ratio gear box... Dam could that thing move... __________________ 09 XT660R ... 06 TTR250 ... 80 Montesa H6 125 Enduro... 77 Montesa Cota 348 MRR "Malcom Rathnell Replica"... Current resto projects.. 81 Honda CT110... 80 Kawasaki KL250A1... 11 Husaburg TE125 enduro... "sold" along with another 31... Lifan 125 Pitbike.. "stolen" ... KIWI BIKER FORUM...... http://www.kiwibiker.co.nz/forums/content.php All the best offroad rides in NZ... http://www.remotemoto.com/ E-mail... xtpete1@gmail.com
	0

03-23-2013, 08:23 PM	#11
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	recovered the seat and got the head light cleaned up most the way. going to get YAMAHA stenciled on to it when my seat paint comes __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
	0

03-24-2013, 01:50 AM	#12
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	It's remarkable how well that old plastic cleans up. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

03-25-2013, 01:55 AM	#13
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Great tip! I've used the blade trick, but I never thought of polishing with a buffing wheel. The seat turned out really well. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-25-2013, 02:05 AM	#14
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Indeed! I forgot to comment; the seat looks great! Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

03-25-2013, 09:23 AM	#15
zingshoen Join Date: Jun 2009 Location: Brisbane, Queensland, Australia Posts: 648	great bike + good work! some serious 2 stroke power to look forward to? __________________ 1971 Garelli Gulp 50cc with open ports and 16 mm Bing Carbie + 1980 Honda XL 223 ZS + 2007 Zongshen LZX200G + DR400SM
	0