Day 18: Carburetor, Air Filter etc.

I have been trying to find somewhere to get foam to make a replacement filter. I was tempted to shave some off an existing cushion. Then it hit me, I have this love seat I am trying to haul off to the dump. I started cutting the covering off and was able to harvest enough foam to last another twenty years! In lieu of the spring, I will just use aluminum tape for doing duct work. Problem solved! We also took the carburetor apart and verified that the current jet is in fact a "U" like the manual specifies. The replacement part for the kick start is $166.00. We are going to explore some other options and see if that works. Thanks John Haberbosch at http://rmmontesa.com/ for giving the proper fuel to oil mix! This seems to be one of those closely guarded secrets! 28:1 to as low as 20:1! Otherwise we will be constantly replacing pistons! This little tip will probably save us plenty of heartbreak since we were recommended 40:1 to as low as 30:1! Quite a disparity there! Well even though the piston is easy to replace, I still would not like to do it every week. This was probably what originally killed this bike. Again John, THANKS!

Day 17: Parts Supplier Found!

Well I got an email back from John at Rocky Mountain Montesa. Below is my whole wish list I am getting pricing for: Serial # on engine: 28M1448 Foot peg spring: 2820.326 Front Fender and hardware: 0090.0620, 0093.106, 0093.506 and 0092.06 Chain Guard: 2820.306 Rt side case gasket: 2860.113 Exhaust clamps: 3362.063 and 0096.1026028 Air cleaner: 2162.067, 3462.057 and 2862.321 Clutch parts: 0263.107, D5518, 2155.020 (amal 18/838-m) and 2155.021 ( amal 18/839) Kick Starter parts: 2865.007, 2865.005 and 2865.010.1T

Then lets see about making it street legal while we are at it!

Accessories

Light switch: 2170.065.2J Tail light: 0070.170152 and 2170.025 Wire harness: 2870.0345J Fuse box and pin: 0270.203 and 0070.2210204 Mounts: 2835.004 and 2835.005 Head light: 2170.0011J, 0070.2208003 and 0070.140267

Day 16: Back To Basics

The decision has been made to go back to basics. Since this is a trials bike it took me all of about nine minutes to get the engine free of the frame. The oil drained while some yard work was attended to.

Once the side cover was removed, the kick starter assembly was visible. It appears that the end of the shaft is bent.

It took two to loosen this nut. Further inspection showed some loose screws but for the most part, this side of the engine looks beautiful.

Once the clutch is out, the kick starter shaft is easily removed. A spring must be removed from the shaft of the kick starter pin, but it is not under much tension.

Here is the whole assembly once it is removed. It is difficult to tell from the picture but the broken end of the shaft is also bent at an angle far exceeding optimal.

The inside looks like it just came off the factory floor! Perfection!

Here is the layout of the kick starter shaft in order. Now that the pesky shaft has been removed. That did not take long.

I have exhausted my other supplier of parts and he has referred me to a new supplier. I guess I will be getting a list and checking it twice. Here is his website:

www.rmmontesa.com

Very nice site!

Day 15: Kick Start Kaput!

Well... what can one say?! We are still unable to kick start the old girl. We have spark, we have compression, we even have the spark plug gapped correctly. After gapping the spark plug it started to have another cycle when kicking it. So we started giving her what for. As you can see from the pictures above, the post that the kick starter mounts to, broke off. In the end of the post is a bolt, and that snapped off as well. This will be needed to have an easy out used on it and the end of the post welded. The case also needs some tig work for filler and polished on a spot. The kick starter will also need some work with a grinder.