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Old 03-11-2012, 09:22 PM   #1
FJ_Kevin OP
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Building a 1981 Yamaha YZ465 Factory Replica plus Husqvarna & vintage racing...

*** Thread now expanded to include vintage Husqvarna's (around pg 23), vintage motocross (Unadilla) and cross country racing! ****

Hello Gents,

My interest in vintage motocross and enduro bike has really taken off the last couple of years. Right now I am rebuilding a Yamaha YZ465 with the ideal of participating in some VMX events this spring. My goal is to build a OW replica bike.

This is what I started with...



That plus some other junkers got me to this point...



Plus a lot more work to get to here...


I hope to have a completed motor installed next weekend.

Finally, here's Bob Hannah at Southwick riding a factory OW

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Old 03-11-2012, 11:17 PM   #2
D.T.
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Sweet! Did they come with gold rims in 81'?
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Old 03-12-2012, 04:05 PM   #3
Euromad
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Nice! Looking forward to seeing the end result. Big motor in that one.
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Old 03-14-2012, 10:46 AM   #4
FJ_Kevin OP
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D.T., you are correct. The 1980 model came with silver rims and the '81 with gold. You have a sharp eye there!

In fact, the 1st bike I bought was a 1980 model. It was in such terrible shape that it has more or less morphed into a 1981 model as I have replaced so much of it.

In reworking the wheels I chose to stay with the silver as I am going with the earlier look overall.

One thing I have found it that 30+ years is a long time for these old motocrossers. The insides of most of the motors I have are screwed up in one way or another. Some are just plain worn out, others have been assembled incorrectly or hacked up in some way by previous owners.

Thanks too Euromad... it's been a lot of work but I have been enjoying it.
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Old 03-19-2012, 08:44 AM   #5
Donkey Hotey
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Quote:
Originally Posted by FJ_Kevin View Post
D.T., you are correct. The 1980 model came with silver rims and the '81 with gold. You have a sharp eye there!
There was more than that. IIRC, they changed at least the rear axle diameter in '81 and very possibly the front as well. Rear axles were known to bend and get stuck in the wheel on the G..
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Old 03-19-2012, 09:07 AM   #6
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Nah the front axle is the same. I'm using the '80 axle in my '82 490 forks on my 465.
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Old 04-09-2013, 04:25 AM   #7
Retro boy
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Loved your posts on your 465.
Found it extremely helpful in setting mine up
( still got a long way to go).
I read your post on jetting with great interest.
What jetting did you end up going with?
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Old 04-11-2013, 06:58 PM   #8
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Originally Posted by Retro boy View Post
Loved your posts on your 465.
Found it extremely helpful in setting mine up
( still got a long way to go).
I read your post on jetting with great interest.
What jetting did you end up going with?

Retro: Thanks for the note and glad the posts are helpful to you on your own 465. Please feel free to share some pictures.

I am still running the following jetting

Pilot Jet= 50
Main Jet = 380
Slide = 3.5 (also a hand cut 3.0 slide)
Needle = 6DH3
Needle Jet = Q8, 247 series
Premix = 40:1

It seemed to run very well two weeks ago at Budds Creek in 45-50 weather, good throttle response and clean throught the rpm range. I thought it felt slightly lean when riding at 30F.

It has warmed up a lot in Maryland these last few days, closer to the temp when I was setting up the jetting initially. I plan to ride it a bit tomorrow so it will be interesting if it runs any differently.

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My '81 YZ465 Factory Race Replica
http://www.advrider.com/forums/showthread.php?t=772033

My Vintage Husqvarna/Motocross Restoration Extravaganza Thread
http://www.advrider.com/forums/showthread.php?t=964670
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Old 03-14-2012, 11:24 AM   #9
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As I have a pretty complete photographic record of my work to this point, I thought I would share a little more of the details for those who might be interested.

It turned out that the 1980 bike I started with was in far rougher shape than 1st thought. I found a considerable amount of frame corrosion under the tank and the seat rails were bent up pretty good from loop outs. One of the frame rails had cracked and someone did a pretty crappy job of welding it up.

I began to think it would be best to find a cleaner frame rather than repair the 1980 frame. Frames turn up fairly regularly on auction sites. After a little searching, I wound up with a nice straight 1981 465 frame for $100.

There are a few minor differences between the 1980 and '81 frame. The airbox mounts are different and the steering head is 1/2 degree steeper. The '81 model uses a longer shock reservoir and the reservoir mounts on the frame accomodate this diffference. It is also believed that the '81 frame is slightly lighter due to wall thinkness in some frame tubes however I did not weigh them.

Here is another view of this wreck.



Rust in the frame tubes inder the tank...


The '81 frame was stripped, epoxy primered, and painted with top quality Glasurit black paint. The Glasurit was left over from my BMW R100 repaint. Normally I would say this product is too expensive to use on a dirt bike but since I already had it on the shelf...







Hannah again...
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Old 03-15-2012, 08:54 AM   #10
Donkey Hotey
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Originally Posted by FJ_Kevin View Post
Hannah again...
Yer' gonna' buy some of those sweet Scott boots and JT "Hurricane" gloves to wear when you ride it, right?
(I think I've still got those gloves around here somewhere)
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Old 03-15-2012, 08:09 AM   #11
99Bandit
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Looking forward to seeing this come along. Nice work so far. Have you had any problems finding replacement parts for this?
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Old 03-16-2012, 08:45 AM   #12
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Jason,

Parts availabilty is pretty good overall. The yz465 seems to be very popular in vintage racing so there is pretty good aftermarket support. It helps too that the IT enduro bikes are very similar and share most parts. And it turns out that a lot of parts are the same for the 250, even some motor parts like the clutch basket.

Then there is the yz490, basically an evolution of the 465. I am finding that a lot of the 490 parts can be made to work on the 465. Sometimes the parts are directly interchangable sometime some effort is needed to make them work. The 490 has had a production run of ~10 years and so lots of stuff gets listed on ebay. There is still a considerable number of parts available from yamaha as well.

Greg,

Yeah I like those Scott boots too! However I do have a couple of pairs of High Points I still use. And I picked up a new pair of JT gloves... gives me all the protection I need when driving the mouse.

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Old 03-16-2012, 11:38 AM   #13
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Reassembly:

With the frame fleshly painted, the next step was to move it onto the lift where I could start reassembly.

It turns out the airbox from 1980 is not a direct bolt in as some changes were made in the mounting brackets. Instead of changing the brackets I sourced an '81 box off the vmx site vintagemx.us. While the new box was in good shape overall, the rear bracket was missing (seems to be a common problem) so I milled a simple replacement out of aluminum plate.

By this time I had also ordered replacement All Balls brand stearing head, swing arm, wheel and crank bearing kits. I found these kits to be of acceptable quality with the exception of the swing arm bearing kit. I thought that one fell well short of the OEM in terms of fit and quality... more about that later.

Here is a few more photos of the build up...


Fitting airbox and inner rear fender...


Here the steering head bearings and triple clamps are installed. New Yamaha OEM fenders are also bolted up.

I removed the old bearing races out of the frame before painting. This was a bit of a pain as I was unable to catch the edge of the races in order to knock them out with a drift.

I wound up welding a strap across each race and then hammered against that. I am happy to say the ALL BALLs replacement steering bearings fit well and seemed to be of good quality.




Here are the various bearing kits from All Balls



Making the missing airbox bracket.

I used a studded rubber mount together with the new bracket made from 1/4 aluminum. The one stud goes into the box where it is held in place by a large flat washer and nut.

The other stud goes into the bracket which is in turn mounted to the frame. The mounting is sturdy and I like the idea of having the old plastic airbox isolated against vibration and shock.






The next step was to install the swing arm. Before doing that I had some decisions to make regarding rear wheel options...

But first lets take a with Bob Hannah at Unadilla...


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Old 03-16-2012, 08:24 PM   #14
anotherguy
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Excel rims and Buchanons stainless spokes. I oughta take a new photo of the damn thing. This one's getting old.


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Old 03-17-2012, 09:13 AM   #15
Shocktower
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Very nice
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