Mels 500e Engine Rebuild

[Minter]

Gary your a star, it was in an MZ before so yep very slow. I am amased its in such good order, do you think its been in bits before?

Mel

Yep defo to a very high standard too or its a new unit no way its done 60k I've got a new oil return valve as the oil in the sump was above the clutch insp cover! I found out when I went to un hook the clutch cable for Mark! I take it had been sat a while!

[ellrider]

I take it had been sat a while!

Can't have been idle that long, it's still MOT'd til the end on March.

[Minter]

I take it had been sat a while!

Can't have been idle that long, it's still MOT'd til the end on March.

Good job ive got a new one way valve kit then! there must have been 2 litres in the sump!

[Roy W]

Interestingly the clutch cover is the same as the MT. My MZ engine had the round cover like the 604 and the 2 piece belt cover.

Or did you change them Mel?

[StackerMel]

No thats how it was.

Mel

[Minter]

Interestingly the clutch cover is the same as the MT. My MZ engine had the round cover like the 604 and the 2 piece belt cover.

Or did you change them Mel?

Ive come to the conclusion its a new (ish) bottom end high engine number, maybe bought from KLM/force and then the original MZ head has been put on it - head was only thing to show any wear, had to get new bearing for camshaft. Then it seems to have got v hot!

Good motor tho...

[Minter]

Manged to get a bit more done to Mels motor today.. Just need a few more bits and peices but its been a good exercise in finding out what bits to keep in stock!



New type clutch frictions fitted old ones were ok wear wise but bits cracked off the shoulders..



New lock tab, locktited and torqued to 120Nm!





Piston polished, good as new!



Cylinder honed and refitted



Valves polished and relapped..



Head sanded on 600 grit wet and dry ready for refitting with new O rings





Should be finished this week Mel!

[Minter]

Heres some pics of Mels motor all finished and sat on the test bed waiting for some oil!



New Bearing for camshaft and timing gear all back on..



New NRV fitted, old rubber tip gone hard, probably due to excessive heat..



Right hand side all done..



Test rig ready to go - when i get some oil! Plastic hose used to make sure oil is doin what it should.. There is a good spark off the plug.



Hopefully be test ran soon......

[worz]

That test bed set up looks great

[fredd]

Looks a nice set up, make sure you'll wear ear defenders and to open a door...
Hope it will run as clean as it looks!
Good luck.