Hey guys
I bought a YZ465 -81 from a friend a couple of years ago, as a restoration project. I just started to take the engine apart and I found a lot of problems.
Former owner told me the cylinder head was “planed” (don’t know the English word - Material was taken of the height of the cylinder head for higher compression). This resulted in a bike almost impossible to kick start. The bike made a backfire 15 years ago and the kick idler gear broke and punched a hole in the right crank case (see photos).
The question I have - is it so difficult to find spare parts for this model as I think? I’ve been searching everywhere but I can’t find the parts I need, and as a Swede eBay is my trusted friend. But not even there I find what I need. I also called a Yamaha store here in Sweden specializing on NOS parts, and they had nothing..
I need a new clutch basket, a new cylinder head, a new kick shaft, a new kick idler gear, a new piston in OD (.025, 0.50 etc), depending on what bore size it will need, a new exhaust chamber/pipe and so on…
Anyone know where to find parts?
Please help this newbie with any tips or information I can use restoring this bike.
Looks more like a reservdelshoj than a project to me
Have you tried CMNSl.com in Holland for the parts? They have NOS parts for many Japanese bikes and are near you. Keep us posted on the build, Peter
Haha, reservdelshoj! 🤣 ja, kanske… but! The bike somehow in the 80’s got registered as a road legal bike with lights, turn signals and speedometer. So it’s one of a kind bike! I really need to get it back on the road! 😎
Thank you, I did try this, I checked all the parts I need, but all of them were out of stock.. 😖
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Many parts are common to the YZ250, YZ465 and IT465...
Cylinder head 3R5-11111-00-00...
https://www.ebay.com/itm/256502653859
Kick shaft 56A-15661-01-00...
https://www.ebay.com/itm/146333097421
Kick idler gear 3R4-15651-00-00...
https://www.ebay.com/itm/267130278238
You may have to go aftermarket with the exhaust...
https://www.ebay.com/itm/186783731036
and the piston...
https://www.ebay.com/itm/305718580761
https://www.ebay.com/itm/126616163417
Wow! You made my day! Thank you!!
I bought the cylinder head, the kick idler gear and sent a message to the kick shaft seller. The exhaust was perfect, but that one will have to wait for next month salary 😃
Pistons will be great, they seemed available. Next thing is having the cylinder bore measured.
The thing I need now is the basket... I really don't know why I have troubles finding parts on eBay, even though I'm using p/n.
Anyone having a clucth basket for sale maybe?
Some sellers don't list the part number, or don't include "-" between the numbers in the part number.
The same clutch was used on the 1980-1981 YZ250, 1981-1982 IT250, 1980-1981 YZ465 and 1981-1982 IT465
There are some complete used ones on eBay...
https://www.ebay.com/itm/284737226844
https://www.ebay.com/itm/205170701847
https://www.ebay.com/itm/256777894405
Thank you once again 🙏🏻 I’m very grateful!
But you said the yz250 basket will fit yz465… I can notice thinner/smaller fins on the 250 compared to the 465. I guess my 465 lamell and metal plates don’t fit in a 250 basket?
Shouldn’t this be a problem with torque etc?
The 3 eBay links I posted show different clutch baskets, two with straight cut gears...
One has an angle cut gear...
Some of the eBay sellers maybe mistaken in their descriptions!
Microfich shows the clutch basket, clutch boss and pressure plates are the same part numbers, CMS is shows compatibility under the description...
https://www.cmsnl.com/products/driven-gear-comp_3r41615000/
Friction plates have the same part numbers, but metal plates have different part numbers, I'm guessing some may be steel, some maybe aluminum.
Clutch springs are the same for the 1980 YZ250 and the 1981 YZ465, but 1982 YZ250's springs have a different part number.
Hello! as already mentioned above (great work finding parts Mr. Last2stroke!!) many parts are common between YZ250 / YZ465 and IT250 / IT465.
Vmxservice has a dg exhaust for your yz:
https://www.vmx-service.eu/en/341-465cc-490cc
Is your yz road legal? check the chassis/engine number...maybe it's an IT.
Cheers!
Fun project! I built and raced a 81 YZ465 in our vintage harescramble series. It was a fun bike but the dead engine starts use to kill me. LOL
Find a YZ490 clutch basket setup and kick starter shaft. The clutch plates are still available and the main gear is one piece with the kick starter gear, the older ones would spin as it was just a press fit. The kick starter shaft has a welded on stop, the older ones would crack and spin.
You can weld that case up if you don't want to find a new one. The YZ465 and YZ490 cases all work as replacements.
Make sure you have the head cut, some folks call it the Eric Gorr mod but most old school tuners know what needs to be done to keep it from knocking.
The carb needs attention here are my notes from my setup.
Jetting VM38
Main 410
Pilot 40
Needle 6DH3 (clip position 3)
Needle Jet 247 Q8
Cut Slide 3.5 (7/32 gap at peak radius on slide)
Forks respond well to Race Tech emulators
Rear shock can be setup with the Race Tech gold valve and modern seal head. I added a Fox reservoir with compression valve to mine.
Have fun!
Thank you! But what clutch basket is the correct one for the YZ465? What’s the specific difference between angled or straight cut gears? Do both of them work?
Thank you for your good information! I certainly need it
Thank you for the tip! That exhaust looks perfect! 😁
Yes, that makes everything so fun. The bike is a YZ, vin nr is matching 4v4, and unique in this context. Today this would be impossible in Sweden, but since it was once registered, it’s still in the system. I have all papers from the Swedish traffic agency as well.
Oh, this led me to a lot of new question as the newbie I am! 😅
You say the main gear is one piece with the kick starter gear, I don’t get it. Isn’t the main gear the little gear on the backside of the clutch basket? 🤔 I tried looking at exploded pictures but I couldn’t figure it out.
The crank case will be welded, it’s not a big deal. It’s extra fun to have a matching number engine as welI. I have contact with a guy specialized on tig welding.
I have this kick shaft (see picture below), I guess this one is the one with high risk for cracking as well? I need another kick shaft though, cause the splines is a little twisted at the bottom (see picture). What will the part number be on the 490 kick shaft so I know what I’m looking for? 🙏🏻
The other question is what you mean with “having the head cut”. Are we talking about a decompression valve?
Thank you very very much for the carb info! This will get me started when it’s time setting it in! 🤩
Yamaha's microfich show the angle cut gear for your bike...
cmsnl.com is useful, they have photos for parts they have had in stock, their photo of the primary gear has angled gears...
It looks like straight cut gears were used on later models...
It sounds like the later model clutch baskets will fit, but you will also have to change the primary gear to match.
I understand. So if I go for YZ490 -82 clutch, I’ll need the primary gear straight cut as well, and what more, a different kick shaft assembly with straight teeth there also?
What positive purposes do I get from mounting 490 clutch, changed main gear and a different kick shaft assembly? Is it worth it, or I should just go the easy way out with the 465?
You actually want a 84 and newer clutch basket to get the one piece gear arrangement. Yes you will also need the straight cut primary gear to go with it. The little gear on the back of the clutch is driven by the kick starter to start the bike. It is just pressed in so with a good kick on the big bore it can spin and slip. Once it slips it just gets worse.
Yes that is the older style kick starter shaft with the pressed on stop. If you can't find a newer one then just have someone weld the stop on to the shaft and then grind the area flat again to keep it from breaking. The later year YZ490 clutch case also has a bronze bushing for the kick starter, can't remember what year but 87 sticks in my head as the first year they did it.
The Eric Gorr mod is when you modify the head dome and cut a relief in it. These motors use to ping a bit and this helped a bunch along with the jetting changes.
The same kick start idle gear 3R41565100...
is used on later models, it meshes with the smaller gear on the back of the clutch hub...
which is straight cut.
Parts availability might be a positive fitting a later model clutch basket.
Pit Row
450exc115, are you sure the one unit-basket needs to be 84 or newer? Can you if you have the ability, get me this 84 basket part number so I know what to look for? Or if you may know anybody selling this part?
Very interesting with the cylinder head modification. But why? You say ping, or knock. Why would the engine do this, and why will this mod help not to?
I guess you mean the combustion chamber line as pointed in my picture? Doesn’t this change the compression ratio of the cylinder? 😄
Thank you 🙏🏻 I need the primary gear for the big outer gear on the basket, the small inner one go to the kick idler gear! Time to find these parts! 😅
Post pictures as you rebuild the bike, we need bike porn!
Last2stroke, I definitely will! 😁
I found an exhaust on eBay! But it was for a 84-90 YZ490.
https://www.ebay.com/itm/196932980999?_skw=yz490+exhaust&itmmeta=01JJTH…
The part number for this was 40T-1461000
The part number for my bike 4V4-1461000
It’s only the three first digits. Will this be a perfect fit or that is absolutely not a good idea to try?
It will not fit!
If you are looking for an OEM pipe, you will have to be patient.
If you don't care about an aftermarket, you can try DG, PFR... or the australian Geof Morris.
In Europe, as I said, vmxservice imports DG, or you can also contact some "handmade" manufacturer like JSV.
The finish and the fitting of the DG is not the best, but the performance is very good.
Guys, are there any web sites I can find out more about where my bike is sold new, and what color it had from the beginning via my vin number?
I figured it out like this
Sold in USA - black and yellow
Sold in Europe - white with red seat and red decals on tank
But I’ve seen YZ465 that was white with black seat and red decal in the tank..
Do you guys know the stories? 😎
I think all 465, usa and european had the black seat. The one with the red seat was the euro 490.
Many riders used the 490 seat on the 465 to be able to move better to the tank and not hurt their balls...😁
https://www.motodacross.com/yamaha/500.html
AMS Racing in Arizona USA typically has the lowest cost for the PFR (Pro Form Racing) exhaust in the USA. The only problem is that you must call them as their website is undergoing some changes. I pasted a link where the YZ465 is listed below. Being from Sweden, I would guess your English would be more than good enough for a phone call!
https://amsracing.com/product-category/manufacturer/yamaha/page/2
Robert Fish on Facebook (US) makes billet clutch baskets for the 465. I believe you have to machine or drill the rivets out, similar to using a Hinson basket on a newer bike then you can use your clutch gear.
If you can't find OEM parts, try Tom at DC Plastics in Michigan. They have been involved in vintage dirt bikes for many years. If they don't have your part they can most likely tell you where you can get it.
Very helpful and nice people
Thanks guys, for the tips! 🙏🏻
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