Day 20: Ingniting Perfection

Turning on the gas, watching it drip into the clear line, like blood that keeps precious life from slipping away. Cycling the kick start to get the piston at top dead center. Maybe even using the tickler to coax her a little! Checking for neutral, winding up and giving her what for! When you are constantly met with nothing for all your efforts and you have a good, solid spark; there is only one thing left. Yes, I am talking about the points. I have now split the case on the other side from the kick start and will be digging in to the points. Fortunately the manual has good testing procedures for checking and timing them. The only problem is the mystery tool used to hold the reverse threaded balance flywheel is just that, a mystery. It feels like the nut was put on with more than the reccommended 72 ft/lbs of torque as well. A little T&E (minus the E) will follow. I will let you all know how it goes, wish me luck!

Day 19: Kick Starter Shaft Repaired!

Karl's dad, John, comes through again! This is a $166.00 part that he was able to straighten and repair. Thanks John!

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.

Day 14: Let-Down's and Laments; Trying To Start

Well as you can see by the video, she is not going to start without push starting. I went to Western Cycle Salvage on N. Vancouver Way in Portland, but nothing. No master link, no clutch cable, no bulk foam for an air filter.

Next I went to Johnny's Motorcycle Repair and was able to find out that the chain I have is a 428. Does not say that in either the Clymer's or the stock manual I have. They are at 1510 Washington St, Vancouver, WA. Their website is: www.johnnysmotorcyclerepair.com. I was able to order the master link for $4.28 (including tax). He said within a couple of days. So... I will soak the chain and get it all cleaned up, same with the clutch cable.

Before the test starting above, the top end did not have a gasket so I manufactured one out of a Lucky Charms box and a hole punch. Worked pretty darn good.

Now there is spark, compression, and fuel flow. We are one master link away folks!

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.