Day 13: Exhaust, Fuel Tank and Starting

Well after last night's monumental success, starting is now imminent! The exhaust, as shown here, is now mounted and finalized!

The only thing keeping her from starting now is the drying out of the fuel tank and mixing the fuel. There was some difficulty removing a pine cone from the inside of the fuel tank but all is good now. I am also informed by Karl, as per Southwest Montesa, the fuel mixture is 42:1. A bit odd of a mixture but what should one expect for 1972?! Other input that we have had say as high as 30:1. I guess we will have to dink with it a bit. Update: mix is 20:1.

The only thing holding us back from starting is the master link on the chain so we can push start her.

I had to manufacture the exhaust gasket. Here is the video:

Day 12: WE HAVE SPARK!

After a solid effort by Karl and myself checking the electrical system, WE HAVE SPARK! She lives! Today has been a monumental success! More to follow...

Day 12b: Electrical System

This is the entire fuse box and electrical system. The only part not shown is the kill switch on the handlebars. As per the manual, the left side is: green/black/red/yellow and the right side (without optional lights) is: Empty/coil/kill switch/empty. It is a very simple system without a battery. The plan is to add lights later and make it street legal.

Day 12a: Brakes and Throttle

It is my opinion that before going, one must ensure the ability to stop. To facilitate that I have completed the front and rear brake. This included replacing the rear break wing nut, which broke in half and shot across the room. Talk about dodging a bullet! That was two at once! The front brake just needed the cable rehabilitated and some cleaning. It still sticks a little but this bike hasn't been ridden in a long time and I believe some use will get it working good.

The throttle assembly, including the carburetor and cable, needed some extensive rehabilitation to get it to work properly, but all is well now!

Day 11: Fuel System

The fuel system is next. As you can see it is very simple on a trials bike. The only part not included here is the carburetor, which is already mounted on the engine. Notice how the gas tank is integrated into the seat to conserve weight and materials. I decided to use brand new tubing after cleaning the fuel filters. Ridgefield True Value Hardware had exactly what I needed on hand and they are always helpful.

Now after the cleaning and rehab of the existing parts, we have a finished product. Beautiful!

Day 10: Continue the Build

Now that most of the problems have been ironed out, the build continues. Aside from a few hiccups, everything is starting to come together. I believe the only things that are needed to actually start the motorcycle are: Clean out the tank, purchase some tubing for a fuel line and connect the electrical. Once those three happen the motorcycle can be started.