MT500 - Rebuild

[wessex4291]

I bought a running mt500 but the engine ocassionaly sounded as though the piston was hitting something, and it stank of petrol when it was turned off, altough te tap was turned off. I had been looking for a project anyway so decided to rebuild it and sort out these issues at the same time!

As is probably to be expected nothing has been striaght forward! Almost every bolt has been seized, or damaged, with the engine being the worst.

I'm geting through it and now have my frame back from the powdercoaters, and will be trying to get the crank pressed out of the lefthand case tomorrow as its not moving!

Anyway some picutres;

Before work started, looks better here than it was!










That weld might be why the piston was knocking!


Frame off to the powdercoaters!

[wessex4291]

Frame back from powdercoaters, still under wraps !


Rebuild commences, chainring bolts will be replaced before it goes on the bike.
I know I should sort the engine first but I'm now like a kid at christmas with my shiny new frame!

Will

[nick]

Looks like you may be busy for a while
Know what you mean about having a shiney frame to play with - just like getting a grown up meccano set - like the colour...
Good luck with the rest of it - when you're done we'll have the shiniest 500's in the South West

[ZIP TIE]

Frame is looking nice.
That oil pump doesn't look at all well have you found the rest of it? Had they really tried to weld it back together? (can't quite tell from the pic)

[wessex4291]

Thanks! I spent a shile with the guys from RPA Powdercoating matching what looked like original paint on the forks to their colour charts. I'm not sure how long it will stay shiny though once its built!

They haven't welded the oil pump back together, but have welded the nozzle that sprays oil onto the piston, its the rough area in bottom right of the picture. I need to compare whats there with what should be, its on my list of things to do this weekend!

Will

[ZIP TIE]

They haven't welded the oil pump back together, but have welded the nozzle that sprays oil onto the piston
Will

I did think that's what they may have done but didn't want to confuse the question.

I need to compare whats there with what should be, its on my list of things to do this weekend!

It should be about another inch to an inch and a half longer. It looks like you may need another pump body/complete pump (they should really be checked for wear on a rebuild anyway as it can't be done without splitting the crankcases).
HTH

[mtt.tr]

If you need a pump i have one pm if you are interested

[wessex4291]

A quick update pictures to follow.

The frame is now back together, swingarm assembled but separate, awaiting engine rebuild, before its fitted.

Forks built up and fitted, front wheel on and chassis on the floor as I need the bench space for my engine rebuild.

Loom is mostly cut to length and terminals fitted to one end, conduits offered up this evening before I got too cold. New connectors sourced from Apophis, great service.

I'm due to pick up the engine cases from the powder coaters tomorrow! Oil pump sourced. Gaskets on order. Should be able to start rebuilding it on Saturday, can't wait!

Will

[morpheus]

Well done Will - coming along nicely. Keep up the good work!

Morpheus

[wessex4291]

The pictures I mentioned before!






Since these were taken I've fitted the front wheel, controls and spent a long time making up a new loom. I’ve also fitted the battery, airbox, rectifier and brake light in order to make the loom.

Finally it now seems that all the work on my new loom is paying off; it feels like I've spent weeks on it! It’s not quite finished yet as I'm waiting on a few more connectors.

I'm happy with it for my first ever foray into electrics!

I now have a small stock of parts waiting to be fitted. I was let down with my engine cases, but should be picking them up tomorrow or Tuesday.