Mega 2 Stunner: Maico 490 Custom Motocross Bike

From Donzzilla: A Legendary Motocrosser, Reborn… 

The legendary 1981 Maico 490 is widely considered one of the greatest motocross bikes of all time. None other than the late, great Rick “Super Hunky” Sieman, original editor of Dirt Bike magazine, penned an ode to the German fire-breather.

“It has all the subtlety of a safe falling on a cricket. All the finesse of a cannon being fired in a handball court. The bike leaves you stunned rocked, wide-eyed and weak-kneed. In other words, it does what every other machine has been promising, but has never delivered.” -Super Hunky, Off-Road.com

The Maico 490 boasted 53 horsepower while weighing just 235 pounds with one gallon of gas. For comparison, a new Honda CRF450R, built nearly 50 years later, makes ~55 horsepower and weighs 244 pounds wet — a nearly identical power-to-weight ratio.

Of course, the Maico came right at the end of the twin-shock era, and tires and suspension weren’t nearly what they are today. That made the 490 even more of a beast in the dirt — though it handled superbly for the era. In 2023, test rider Jody Weisel of Motocross Action magazine, who’s ridden and tested just about every dirt bike for the last 50 years, named the ’81 Maico 490 his favorite MX-er of all time:

“If I could only pick one bike to race (in its time), it would have to be the 1981 Maico 490 Mega 2…this bike was luscious to ride. It cornered like a 125, ran like the Super Chief, and oozed cottage industry charm.” -Jody Weisel, MXA

Unfortunately, the 490 marked the beginning of the end for Maico. There were problems with the transition to a single-shock design in 1982, and failing transmissions and rear hubs the following year. The brand was forced into receivership and problems would continue for the brand. Of course, that makes the 490 even more special — the pinnacle of the Maico’s glory days. Today, the brand’s bikes maintain a strong cult following among builders, collectors, and racers.

This ’81 490 comes from our new friend Don “Donzzilla” Miller. Don and his wife, Peg, share a love for vintage bikes — particularly trackers and motocrossers — which they’ve turned into a vocation.

“We have a passion for vintage motorcycles that can sometimes be mistaken for an obsession.  We consider ourselves so very lucky that we get to go to work each day surrounded by things that we love, working together happily after 30 years of marriage, being friends with some awesome people with the same interests, having friendships with some of our motorcycling heroes, and all while being able to make a living selling some cool vintage motorcycle gear.”

Don works out of a 5000 square-foot shop while Peg runs Metro Racing, an apparel company dedicated to vintage bikes. Dream team! This Maico was built for customer Dave McGraw, who “wanted custom with a lot of bling.” Don was only too happy to deliver. The custom work here is stunning:

“Every piece of stainless hardware was made to fit, detailed and polished. Everything that could be made out of aluminum was hand-crafted, frame plugs, air box, tank, brackets, levers, covers, number plates, I polished everything else made of aluminum from the factory. Removed parts that weren’t needed… Custom graphics with the customer’s name incorporated.”

The result is one of the most striking vintage motocrossers we’ve ever seen — a rolling work of art. Alas, Don delivered the bike dry to the customer, so he can’t tell us what it’s like to ride, but luckily Super Hunky left us some definite words on the subject:

“The 490 Maico Mega 2 delivers more stark-raving horsepower than any other motocrosser we’ve ever tested, including the factory jobs we’ve ridden here and there… the finest, fastest, best handling open class motocrosser we’ve ever ridden, to date.” –Super Hunky

Below is our full interview with Donzzilla on the subject. Make sure to follow Don on Instagram (@donzzilla_don_miller) and check out the very cool wear at www.metroracing.com!

Maico 490 Custom: Builder Interview

• Please tell us a bit about yourself, your history with motorcycles, and your workshop.

I have been around cars and motorcycles my whole life. I have been self-employed most of my life too, all in the car and motorcycle industry. My workshop now is in a 5,000 sq ft building that we live and work in, I do the bikes and my wife, Peg does www.metroracing.com — it’s a vintage motorcycle logo’d clothing company.

• What’s the make, model, and year of the donor bike?

1981 Maico 490.

• Why was this bike built?

Customer request. He wanted custom with a lot of bling.

• What was the design concept and what influenced the build?

I pretty much come up with the ideas on my own.

• What custom work was done to the bike?

Attention to detail on every part. Hardware polished stainless, custom made pieces, etc.

Every piece of stainless hardware was made to fit, detailed and polished. Everything that could be made out of aluminum was hand crafted, frame plugs, air box, tank, brackets, levers, covers, number plates, I polished everything else made of aluminum from the factory. Removed parts that weren’t needed, sanded smooth, then. Polished. Custom graphics with the customer’s name incorporated.

• Any idea of horsepower, weight, and/or performance numbers?

Stock motor rebuild. I believe they were in the 50 HP range.

• Can you tell us what it’s like to ride this bike?

Sorry, no, delivered to the customer, dry and not started.

• Was there anything done during this build that you are particularly proud of?

I take pride in all the steps, soon, nothing particular stands out.

• Is there anyone you’d like to thank?

The customer, Dave McGraw for putting his trust in me to build these kind of bikes.

Follow the Builder

Web: www.metroracing.com
Instagram: @donzzilla_don_miller
Photos by Peg Miller