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Yamaha IT 400-Part 2

By Rick Sieman


By 1978 Rick Sieman

Here are the specs for the Project Bike:


Make model …  Yamaha IT 400

Year … 1977 – 1978

Engine … Two-stroke single, reed valve

Capacity … 396 cc /24.1 cubic inches

Bore and stroke …  85Χ70 mm

Cooling system …  Air cooled

Compression ratio … 7.6:1

Induction … VM 38 SS Mikuni carburetor

Ignition … CDI

Starting  …  Kick

Max power …  40 BHP at 7000 RPM

Max torque …  3.9 LB. FT. At 6000 RPM

Transmission …  Five speed

Final drive … Chain

Front suspension … 43 mm telescopic

Front wheel travel … 300 mm/11.8 inches

Rear suspension … Mono shock, spring preload and rebound damping

Rear wheel travel … 300 mm/11.8 inches

Front brake  … Drum

Rear brake … Drum

Ftire … 300 x 21

Rear tire … 150/80 x 18

Rake … 31.5°

Trail  … 142 mm / 5.5 inches

Wheelbase … 56.2 inches

Ground clearance … 9.4 inches

Dry weight … 253.5 pounds

Fuel capacity … 3.4 US gallons

  Now we start taking the bike apart all the way to the frame. 

We finally got the completed bike rolled into the garage and are now ready to work on it.
Here’s the shift side of the bike.
First thing to really be removed was the handlebars. Restoration hint: whenever you take the bars off, leave the bar clamps in place and also the nuts and bolts. That way, when you paint the triple clamps, you’ll make sure that he painted the bar clamps and the fasteners, too.
Next came the exhaust pipe. All of the mounts holding the body of the pipe in place were cracked and broken.
The muffler had to be taken off before the body of the pipe was removed. It was a bogus set up with a whole bunch of needless nuts and bolts.
The muffler was removed. It turned out to be quite heavy and will probably replace it with another muffler that weighs a lot less.
Here’s the complete exhaust pipe. Luckily, it turned out to have no dents or rust in it. 
The front fender was badly cracked and had to be removed and thrown away. Luckily, we have a whole bunch of good used fenders in stock and one of them should do the trick. Of course, it’ll have to be painted the proper blue color.
The gas tank was next. Again fortunately, there were no leaks or cracks in it.
The carburetor would be removed next. In order to do this, the top of the carb was unscrewed and the throttle cable removed.


That bogus tool holder on the rear fender was removed. It only got in the way when you tried to get on the bike.
Rear section in the first half of the bike removal is done.