Author Topic: Yz490 kick starter  (Read 867 times)

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Offline Big Scotty

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Yz490 kick starter
« on: August 03, 2020, 04:23:25 PM »
Gday,need to replace the kick starter on my 83 490.as these are hard to find what are people using as a replacement,any help appreciated
Cheers scotty
yz400d yz125d yz490k

Offline rocketfrog

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Re: Yz490 kick starter
« Reply #1 on: August 04, 2020, 01:30:42 PM »
Well Scotty, you have a YZ490K 1983, and the Partzilla parts diagram shows me that the starter (based on the knuckle part number 23x-15621-02-00) will fit a stack of bikes up to and including the last 490's and the wr500. The interesting part is that the list also includes the YZ250U (1988). The starter assembly from the YZ250U subs to fit most YZ250/WR250 2 stokes throughout the 90's. The short YZ250 Alloy lever would be terrible on a 490, but this is where it gets interesting.......


The funky bendy (and longer) alloy lever that was first used on the YZ400F and subsequent YZ426F uses the very same knuckle as the 90's 2 stroke YZ/WR's.


My rationale is thus that the kick start lever from a YZ400/426 should match the splines on a 1983 YZ490. The actual bend and function of the lever might not be suitable but for a few bucks on a second hand lever or better yet borrowed lever to verify if it will work you could be a life saver for everyone in the same boat as you. I cant help any further than that as I do not own or have access to a 490 nor a YZ400F.


So there you go, YZ400/426 Kickers would have to be easy to find (still available new from Partzilla for the princely sum of $122 USD or from Trooper Lu's @ $220 AUD). Please let us know if you have a win.

Cheers Jason
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Offline Big Scotty

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Re: Yz490 kick starter
« Reply #2 on: August 04, 2020, 03:45:25 PM »
Thanks rocket frog,I have heard that the 400/426 fits the spline but there's some modification to do,and that the 426 lever fits the 490 knuckle,I will,start my search at my local wreckers and go from there, I have fitted a decompression valve so a shorter lever may not be such an issue
Cheers scotty
yz400d yz125d yz490k

Offline ARN

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Re: Yz490 kick starter
« Reply #3 on: August 09, 2020, 11:53:41 AM »
try the one of your ktm380 if you still have they fit yz250h not ideal for 490 as just suitable for 250

Offline Big Scotty

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Re: Yz490 kick starter
« Reply #4 on: August 09, 2020, 06:35:37 PM »
try the one of your ktm380 if you still have they fit yz250h not ideal for 490 as just suitable for 250
Bit late the 380 went to fund the 490 engine rebuild but that's interesting to know,my 380 had a shorter kick starter and a hole drilled in the barrel to lower compression,apparently the broke the cases starting them,it would be way to short for the 490
Cheers scotty
yz400d yz125d yz490k

Offline Big Scotty

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Re: Yz490 kick starter
« Reply #5 on: August 19, 2020, 08:14:51 PM »
Picked up a new 426 kick starter today,there a bit shorter than the 490 but should be ok,the knuckle fits the spline but just needs a small mod because the lever hits the nut when folded out,but the lever fits the 490 knuckle so can make one from two if needed,hope this helps
Cheers scotty
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Offline rocketfrog

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Re: Yz490 kick starter
« Reply #6 on: September 29, 2020, 10:39:52 AM »
The alloy lever strikes the knuckle retaining nut? Is that right?
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Offline Big Scotty

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Re: Yz490 kick starter
« Reply #7 on: September 29, 2020, 06:01:18 PM »
The alloy lever strikes the knuckle retaining nut? Is that right?
Yes that's right,i just had to grind a small piece out of the lever to get it to clear the retaining nut and also grind a small amount off the back of the lever ba cause it hit the casing where the seal sits in,really both minor mods and can't be seen basically.i have rode it a couple of times since fitting and it is actually much easier to use than the original
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Offline rocketfrog

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Re: Yz490 kick starter
« Reply #8 on: September 30, 2020, 11:57:00 AM »
Yes the bend on the later model YZ levers is far better than the "straight " lever. Its good to know that an easily procured part can be simply adapted to the older engine without too much trouble and at a reasonable cost too. Thanks Scotty, well done you.
Political correctness is a doctrine,fostered by journalists and politicians, which holds forth the proposition that it is entirely possible to pick up a turd by the clean end."