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General Category => Bike Builds, Rebuilds And Restorations Only => Topic started by: canuck750 on January 22, 2018, 04:49:01 PM

Title: 1978 Moto Morini 500 almost done!
Post by: canuck750 on January 22, 2018, 04:49:01 PM
I picked up this 78' Moto Morini 500 last summer and decided to do some refreshing of tires, brakes and bearings, re-fit the stock carbs and air box and just get it running reliably. The previous owner kept it on good shape having saved it from a past life where it been turned into some sort of chopper for a certain lady to ride alongside her husband on his HD. This bike came with a full extra set of body work so I removed the faded grey set and had the second set painted to the factory red scheme.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2552_zpselrnxqh4.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2552_zpselrnxqh4.jpg.html)

North Leicster Motors in the UK sent new brake rotors and rebuild kits for the calipers and master cylinders and a few rubber bits, cables and other pieces.

I sent the brake caliper and MC castings off to be anodized, stripped the rims down for powder coating and sent all the fasteners and misc parts that came off for cad plating.

The previous owner told me the engine had been rebuilt, when I removed the right hand engine cover this little surprise stuck its head up

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2777_zpsiq7mi5ib.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2777_zpsiq7mi5ib.jpg.html)

just a slight oil leak :thewife:

I think a quick freshening up just grew a few items on the to do list

The Morini is going to he left hanging for a while, more parts to order and the Le
Mans needs finishing.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2786_zps2dp0gfbb.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2786_zps2dp0gfbb.jpg.html)

Title: Re: Any Morini Fans?
Post by: TRw1 on January 22, 2018, 05:42:33 PM
Jim,

Anxiously awaiting the posts to come documenting the restoration.  I'm sure there will be more surprises.

Ted
Title: Re: Any Morini Fans?
Post by: ITSec on January 22, 2018, 06:55:17 PM
It's not in my top five, but maybe my top ten. I'd love to have one someday, and it looks like the one you have is headed for your usual loving touch.
Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on January 22, 2018, 07:24:57 PM
You know I am!  :grin: Keep it coming.
Title: Re: Any Morini Fans?
Post by: SemperVee on January 23, 2018, 10:13:32 AM
I remember first seeing them at the Ricky Racer shop in Costa Mesa Ca. Then proprietor former European racer Lance Weil loved them and sold them along side his treasured Laverda's.
I remember on a small group breakfast ride in the 1980's around Lake Elsinore when Lance on his red little Morini led the pack.  Him and an old guy on a Guzzi CX100 naturally, were hard to keep up with!  Back then many of us were riding GS1000's, KZ1000's, BMW's and a few Ducati's.  The good old days in memory of many rides up there in San Juan Capistrano to Elsinore and back after hanging out at the Lookout  restaurant near the top.
Title: Re: Any Morini Fans?
Post by: canuck750 on January 23, 2018, 11:45:30 AM
I remember first seeing them at the Ricky Racer shop in Costa Mesa Ca. Then proprietor former European racer Lance Weil loved them and sold them along side his treasured Laverda's.
I remember on a small group breakfast ride in the 1980's around Lake Elsinore when Lance on his red little Morini led the pack.  Him and an old guy on a Guzzi CX100 naturally, were hard to keep up with!  Back then many of us were riding GS1000's, KZ1000's, BMW's and a few Ducati's.  The good old days in memory of many rides up there in San Juan Capistrano to Elsinore and back after hanging out at the Lookout  restaurant near the top.

I took that road from the coast to Indio this fall, talk about motorcycle heaven! I can't recall ever seeing so many sport bikes in one place, the pull overs where full of sport bikes. I bet the little Morini was blast to ride on those tight curves and its ultra light weight must have been a real advantage over the big Japanese fours.

This nice 1975 Strada 3 1/2 arrived this morning via transport from Phoenix AZ. This little bike has travelled all across North America in the past year, previous owner shipped it from Pennsylvania to AZ and then sold it to me. Next it went by truck to Blain Washington then back across the rockies to my place in Western Canada, thousands of miles without ever turning a wheel. Needs some engine work and a paint job, can't get into the star wars paint scheme.

(http://i249.photobucket.com/albums/gg217/canuck750/1975%20Moto%20Morini%203%201-2/IMG_2801_zps6awciirx.jpg) (http://s249.photobucket.com/user/canuck750/media/1975%20Moto%20Morini%203%201-2/IMG_2801_zps6awciirx.jpg.html)
Title: Re: Any Morini Fans?
Post by: brubache on January 24, 2018, 09:36:04 AM
To fun.  I LOVE Morini's!  I swore to own one some day.  Working on that now in fact. 
Title: Re: Any Morini Fans?
Post by: canuck750 on January 24, 2018, 10:46:56 AM
To fun.  I LOVE Morini's!  I swore to own one some day.  Working on that now in fact.

I wanted a 3 1/2 but a 500 came up for sale 1st in B.C. so I grabbed it, now a 3 1/2 found me and I have not decided if I will keep the 500. Going to get the 500 refurbished and running and then decide.
Title: Re: Any Morini Fans?
Post by: brubache on January 24, 2018, 12:01:57 PM
Is that a Strada converted to Sport?  I love Morini's.  Drool.
Title: Re: Any Morini Fans?
Post by: canuck750 on January 24, 2018, 12:24:21 PM
Is that a Strada converted to Sport?  I love Morini's.  Drool.

Yes, all of the 1st series (1978) where a 'W' model, STRADA, the 'SPORT 500' came out a few years later and was mechanically the same bike with just minor cosmetic changes. The later 500's got a six speed. The previous owner added the aftermarket clip-ons, the 'Sport' badge on the triple tree and the DIY rear sets. The pod filters and the Mikuni carbs where another sacrilegious 'improvement' added by the previous owner. Stuart Mayhew of NLM in the UK claims keeping the stock dual air filter air box and stock Dellorto carbs is the best thing you can do for these Wee Vees.

I have the stock Dellorto carbs and air box for this bike and I have found the stock foot rests and foot controls to go back on. I have not been able to find the stock upper triple clamp and bars, NLM tells me most of the 500 Strada where converted to clip-ons over time and finding the stock 'W' series upper triple and bars is very tough ... I will keep looking.

There has been a later model 500 Sport for sale on Vancouver Island for a couple years, asking around $10K CDN, all stock. Its advertised on Seattle Craigslist form time to time.
Title: Re: Any Morini Fans?
Post by: brubache on January 24, 2018, 05:27:57 PM
Ah thought so.  I new there were details that were not quite on point.  Glad you have the stock carbs etc.  I have heard that as well.  How is the parts situation?

Title: Re: Any Morini Fans?
Post by: canuck750 on January 24, 2018, 09:29:54 PM
Ah thought so.  I new there were details that were not quite on point.  Glad you have the stock carbs etc.  I have heard that as well.  How is the parts situation?

North Leicester Motors (NLM) in England has most of the arts available, a bit pricey but he has what you will need.

http://www.northleicestermotorcycles.com/

Stuart has a great selection of Moto Morini's to drool over and lots of other Italian eye candy!
Title: Re: Any Morini Fans?
Post by: huub on January 28, 2018, 12:27:51 PM
nice bike! amazingly good condition.
if the stainless mudguards are standard it is a very early one.
not sure what they were thinking at the  morini factory when they designed the gearbox,
basically the 5 speed box has the same ratio's as the  six speed box , without the first gear.
interesting.
considering the dry clutch is temperamental at best.
be prepared for some typical italian weirdness working on these bikes.
the ignition is a nightmare,
the original seating position is weird, with footrests very far forward.
the current rearsets are a huge improvement
the rest of the bike is remarkably reliable

i've been running a bunch of morini's since the early eighties,  they are seriously  addictive.
( think i've got seven of them in the shed right now....long story)
my favorite is the early 350 sport, because it is lighter , has a shorter wheelbase and its revvy engine)  .
this is my current ride

(http://thumb.ibb.co/hSmhKG/20170816_180433.jpg) (http://ibb.co/hSmhKG)

image upload (http://nl.imgbb.com/)
Title: Re: Any Morini Fans?
Post by: canuck750 on January 28, 2018, 03:52:45 PM
Thanks Huub! Your 3 1/2 Sport is gorgeous, I would sure like to find one with the 4LS front brake like yours.

What started out as tracing an oil leak has turned into this. The engine has been apart before and there is remnants of red silicone everywhere, this stuff should be banned.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2835_zpsan1czgdz.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2835_zpsan1czgdz.jpg.html)

I don't know if this moving forward or backwards

(http://i249.photobucket.com/albums/gg217/canuck750/IMG_2886_zpsuhkfch2c.jpg) (http://s249.photobucket.com/user/canuck750/media/IMG_2886_zpsuhkfch2c.jpg.html)

Motor mostly stripped down parts vapour blasted as they come off, ready to split the cases.

Cylinders and pistons look good but there was a lot of metal swarf in the oil, need to pull the bearings and have a good look.

Timing belt was so brittle it broke just pulling it off the sprockets.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2866_zpsqkm87qeh.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2866_zpsqkm87qeh.jpg.html)
Title: Re: Any Morini Fans?
Post by: twowings on January 28, 2018, 07:20:19 PM
Hang in there...it will come together... :thumb:
Title: Re: Any Morini Fans?
Post by: canuck750 on January 28, 2018, 09:30:14 PM
It seems a little daunting right now, more red silicone

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2905_zpsmnei7dho.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2905_zpsmnei7dho.jpg.html)

the big end shells are toast and the white metal crank case bush doesn't look great, so much for the previous owners claim that the engine had been rebuilt.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2945_zpsx4i3adw8.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2945_zpsx4i3adw8.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2946_zps38wtjxor.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2946_zps38wtjxor.jpg.html)

Rest of it looks OK,

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2949_zpsuoobgv7v.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2949_zpsuoobgv7v.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2948_zpssmryypam.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2948_zpssmryypam.jpg.html)
Title: Re: Any Morini Fans?
Post by: huub on January 29, 2018, 08:51:38 AM
i dont know how the availability is for the plain main bearing , they used to be unavailable.
i used to make them from mitsubishi camshaft bearings 
it is pretty common to fit a roller bearing instead. but the crankshaft needs to be modified.
the red stuff might be original, these engines were assembled without crankcase gasket , just gasket cement.
i use dirko HT, but any good gasket cement should do the trick.
also use some gasket cement on the cylinder base gasket, if you dont they tend to leak.
if it still has a base gasket you can remove it , looking at the pistons the squish is large enough to have deposits on the piston.

 i vaguely remember the main crank bearing being a special, the  rest of the bearings are stock , i would change those if you are in there.
oh , and clean the sludge trap in the crankshaft
 
good thing you removed the belt , they are a stupidly cheap (less than 10 dollar?) industrial part, i change them once a year.
no need to reuse one when you removed it.

the vapor blasting is brilliant! i'm jealous!
Title: Re: Any Morini Fans?
Post by: canuck750 on January 29, 2018, 09:25:32 AM
i dont know how the availability is for the plain main bearing , they used to be unavailable.
i used to make them from mitsubishi camshaft bearings 
it is pretty common to fit a roller bearing instead. but the crankshaft needs to be modified.
the red stuff might be original, these engines were assembled without crankcase gasket , just gasket cement.
i use dirko HT, but any good gasket cement should do the trick.
also use some gasket cement on the cylinder base gasket, if you dont they tend to leak.
if it still has a base gasket you can remove it , looking at the pistons the squish is large enough to have deposits on the piston.

 i vaguely remember the main crank bearing being a special, the  rest of the bearings are stock , i would change those if you are in there.
oh , and clean the sludge trap in the crankshaft
 
good thing you removed the belt , they are a stupidly cheap (less than 10 dollar?) industrial part, i change them once a year.
no need to reuse one when you removed it.

the vapor blasting is brilliant! i'm jealous!

Thanks Huub, great information

As for Vapour blasting .. its amazing

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2950_zpssjaott1b.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2950_zpssjaott1b.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2951_zpsyclq97he.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2951_zpsyclq97he.jpg.html)
Title: Re: Any Morini Fans?
Post by: brubache on January 29, 2018, 10:26:23 PM
I have a pile of Benelli parts I need to blast.... gotta get that done!

Looking solid.  Hopefully you can find the needed parts to get it back in order. 

PS... update on your Bene?
Title: Re: Any Morini Fans?
Post by: canuck750 on January 29, 2018, 10:57:39 PM
I have a pile of Benelli parts I need to blast.... gotta get that done!

Looking solid.  Hopefully you can find the needed parts to get it back in order. 

PS... update on your Bene?

The Benelli is still slowly coming together, gathering up parts, cleaning, polishing getting some misc parts powder coated. I will get onto the Benelli after the Moto Morini is done, I had thought the Morini would be a two week project, rapidly turning into a much bigger job.
Title: Re: Any Morini Fans?
Post by: Bluerobotz on January 30, 2018, 05:28:33 AM
I'm glad you didn't post any "chopper" pics, I need to sleep tonight!
Keep it up! I love your builds, very impressive. I wish I had 10% of the time you put into this.
Title: Re: Any Morini Fans?
Post by: Steph on January 30, 2018, 05:28:00 PM
Nice 500.

I enquired about this 350 Sport in South Africa, then the owner changed his mind and is now keeping it due to sentimental value:

(http://thumb.ibb.co/b7zFDm/9_C06_B290_5_C59_4_CC9_B52_F_239_DCB294_B3_E.jpg) (http://ibb.co/b7zFDm)


Do not know a lot about working on these, watch a complete clutch rebuild last night that I found enjoyable:
https://youtu.be/yNxVQ4JLmjo

Title: Re: Any Morini Fans?
Post by: canuck750 on January 30, 2018, 07:31:27 PM
Nice 500.

I enquired about this 350 Sport in South Africa, then the owner changed his mind and is now keeping it due to sentimental value:

(http://thumb.ibb.co/b7zFDm/9_C06_B290_5_C59_4_CC9_B52_F_239_DCB294_B3_E.jpg) (http://ibb.co/b7zFDm)


Do not know a lot about working on these, watch a complete clutch rebuild last night that I found enjoyable:
https://youtu.be/yNxVQ4JLmjo

That is the Moto Moirini 3 1/2 to have! Keep on the owner, it would be a great find.

So far I have found the Morini 500 to be very basic, jewel like little heads and rockers, fine quality castings, very good components throughout. |I was able tp source all the oil seals and most of the case bearings locally. The case bearings and cam bearings where notched, probably a result of running dirty oil. After measuring the crank rod journal I find it is out of round with a center line ridge at one rod, it will need a new set of oversize shells and a crank grind. Crank sludge trap was gummed up. I need to really clean and inspect the transmission gears, on a quick inspection they look good. Clutch is multi-plate dry and after a lot of cleaning it all looks to be serviceable.

This is the ball side of the crank, white metal collars that slide over the crank and grasp the ball bearing on each side of the cage

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2941_zpsbew45pk0.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2941_zpsbew45pk0.jpg.html)

This side of the crank rides in a  white metal bush

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2905_zpsmnei7dho.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2905_zpsmnei7dho.jpg.html)

These are cam followers, push rods sit in them on the top side of the case and drive the rockers

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2910_zpsu7qklue0.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2910_zpsu7qklue0.jpg.html)

Clutch side large ball bearing with loose collars like the large crank bearing

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2920_zpsehcx17y0.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2920_zpsehcx17y0.jpg.html)

Stuart Mayhew at NLM in the UK has been great supplying parts.
Title: Re: Any Morini Fans?
Post by: brubache on January 31, 2018, 08:20:37 PM
Looks quite nicely machined actually. 
Title: Re: Any Morini Fans?
Post by: Psychopasta on January 31, 2018, 11:40:16 PM
I love Morinis. Never owned one, but I fell in love with the 3 1/2 back in the day and it's never left me.
Title: Re: Any Morini Fans?
Post by: canuck750 on February 01, 2018, 12:37:27 PM
Looks quite nicely machined actually.

The castings are very nice but being such a small motor the parts have a delicate look. I am impressed with the engine internals, big heavyweight bearings throughout, shells on the con rods, bush on the small end and bush to the rocker shaft making everything serviceable, designed for longevity. In my limited experience with other Italian brands the Laverda twin is the most over designed beast I have seen, the casting fit on the Benelli twin cases is dead accurate but for all around ease of service, durability and dare I say elegance the Guzzi big twin has them all beat.
Title: Re: Any Morini Fans?
Post by: canuck750 on February 03, 2018, 08:46:19 PM
Well I hate half measures so I broke down and just stripped the rest of the bike back to the frame, sending the frame and frame brackets off to be powder coated in Carbon Black.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3016_zps7plstdko.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3016_zps7plstdko.jpg.html)

In a couple weeks all the plating and painting bits should be done and if the motor parts arrive by then I will get back to assembling it. I need to remake the wire harness and clean up the rest of the electrical but from here on its working with clean and / or new parts.

There is so little chrome, only the lift handle and the turn signal stems. The chain guard and fenders are stainless so they will polish up nice.

Title: Re: Any Morini Fans?
Post by: Steph on February 04, 2018, 09:16:21 AM
As these motorcycle are unlikely to be used until they rust away in the future, wouldn’t painting the frame the traditional way be more original than powder coating/ thermoplastic coating? Just thinking outside the box.
Title: Re: Any Morini Fans?
Post by: canuck750 on February 04, 2018, 09:44:02 AM
As these motorcycle are unlikely to be used until they rust away in the future, wouldn�t painting the frame the traditional way be more original than powder coating/ thermoplastic coating? Just thinking outside the box.

A couple reasons I go for a full powder coat, I don’t have to do the prep, the prep process with the baking off process prior to coating removed all residue oils, the cured powder is so durable that during assembly there is less chance of damage. For the Laverda 750 SF1 I rebuilt last year I did not powder the frame, I removed all the paint with sanding discs and brush applied POR 15, very durable but it was a lot of work, messy and toxic paint and not as nice a finish as powder.

I have been riding my 860 Eldorado for five years, including a couple hour long rides on gravel roads and the powder coated frame is still looking good. I have about 1000 miles on my V7  Sport and the frame still looks sharp.

Cheers

Jim
Title: Re: Any Morini Fans?
Post by: huub on February 05, 2018, 03:26:06 PM

In a couple weeks all the plating and painting bits should be done and if the motor parts arrive by then I will get back to assembling it. I need to remake the wire harness and clean up the rest of the electrical but from here on its working with clean and / or new parts.


take your time looking at the wiring diagram ,
the stock wiring looks like a mess ( they are all like that!)
but it is well thought out. there is some method in this madness
basically all the parts have their own wiring harness, and everything connects at the fuse box.
so any electrical problem can be found by removing the side cover, and measuring at the fuse box.

no sparks? measure the green wire from the generator. still no sparks? measure the green wire from the emergency stop.
still nothing? check the contact switch. ( you guessed , another green wire in the fuse box).

pretty brilliant if you are used to guzzi electrics , where they tend to connect everything inside the headlight/ fuse box or even halfway down the harness etc.....
Title: Re: Any Morini Fans?
Post by: canuck750 on February 05, 2018, 04:59:36 PM
take your time looking at the wiring diagram ,
the stock wiring looks like a mess ( they are all like that!)
but it is well thought out. there is some method in this madness
basically all the parts have their own wiring harness, and everything connects at the fuse box.
so any electrical problem can be found by removing the side cover, and measuring at the fuse box.

no sparks? measure the green wire from the generator. still no sparks? measure the green wire from the emergency stop.
still nothing? check the contact switch. ( you guessed , another green wire in the fuse box).

pretty brilliant if you are used to guzzi electrics , where they tend to connect everything inside the headlight/ fuse box or even halfway down the harness etc.....


Spaghetti !

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2781_zpszp7mi6cs.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2781_zpszp7mi6cs.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2741_zpsydp6g65m.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2741_zpsydp6g65m.jpg.html)

and more spaghetti

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2735_zps95zcsz6r.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2735_zps95zcsz6r.jpg.html)
As I took the wire harness sections apart it did start to make sense, and I can rebuild / copy each segment one step at a time. Same fuse box and solenoid as a V7 Sport.
Title: Re: Any Morini Fans?
Post by: brubache on February 05, 2018, 06:43:41 PM
I love this... so much.
Title: Re: Any Morini Fans?
Post by: Steph on February 05, 2018, 06:58:58 PM

Spaghetti !

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_2781_zpszp7mi6cs.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_2781_zpszp7mi6cs.jpg.html)


As I took the wire harness sections apart it did start to make sense, and I can rebuild / copy each segment one step at a time. Same fuse box and solenoid as a V7 Sport.

Art!
A bit like an old telephone operator
Title: Re: Any Morini Fans?
Post by: canuck750 on February 05, 2018, 08:53:24 PM
I threw the bundle of wiring onto the ultrasonic cleaner, filled er up with a degreaser and set it at 50C for an hour. The wires come out clean and soft and the glue residue from the bits of sticky tape are gone. Dried off and laid out they make quite a display, as mentioned, this is not so much a wire harness as a bundle of individual or paired wires each with a separate function all terminating at the switchboard called a fuse box.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3025_zpstldlckug.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3025_zpstldlckug.jpg.html)

Classic Bike's Steve Cooper wrote a nice article on making a new harness for a Suzuki Stinger where he strings out each section of the old harness on a sheet of cardboard held sown with wire ties and then copies the new harness directly below attaching each terminal cap and insulator jacket. Looks like a good way to approach this, I have spools and spools of different coloured automotive wire and the right terminals ends to match so it should just be an issue of time.

First order came back from the powder coaters, frame and exhaust still to be done.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3022_zpslvtgje7g.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3022_zpslvtgje7g.jpg.html)

I don't love the dull grey wheels but that's the way they came in 78' so that's how they will go back on.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3024_zpsgh84rvqg.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3024_zpsgh84rvqg.jpg.html)

This bike came with an odd assortment of extra parts, spare foot controls, extra exhaust, side covers, gas tank, seat cowl, once done there will be an Ebay sale of unused extras.
Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on February 05, 2018, 10:53:07 PM
 :thumb:

My friend Jarl might need some of your surplus, let me know when you're ready to sell it.
Title: Re: Any Morini Fans?
Post by: tetarabra on February 06, 2018, 03:34:06 PM
If it helps :
http://www.hofmann-andi.de/MoriniWebsite/Downloads.html
Title: Re: Any Morini Fans?
Post by: canuck750 on February 06, 2018, 06:30:49 PM
If it helps :
http://www.hofmann-andi.de/MoriniWebsite/Downloads.html

Thanks!
Title: Re: Any Morini Fans?
Post by: canuck750 on February 24, 2018, 07:57:53 PM
I have made new wire harness components matching the original fittings and colours, British Wiring Supply has all kinds of gauge and colour of PVC wire, plastic end covers, connectors and PVC tube harness covers. I need a few piggy back crimp connectors and few more dual colour wires to finish the rest of it but it's mostly done. I found a new CEV left hand light / horn switch on Italian Ebay for cheap so I swapped the molex ends and connectors to the new switch.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3057_zpsjhpy4tyq.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3057_zpsjhpy4tyq.jpg.html)

Fitted new wheel bearings to the powder coated rims, NLM supplied new stainless steel rotors that match the OEM rotors.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3061_zpsfmjemjic.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3061_zpsfmjemjic.jpg.html)

Dropped the rims and new Pirelli Sport Demon tires off at the bike shop to get mounted

I assembled the rear cush drive, new sprocket from NLM, replated the axle carrier and spacers

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3064_zpsyy59grhg.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3064_zpsyy59grhg.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3065_zpsoljq9nhy.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3065_zpsoljq9nhy.jpg.html)

I polished up the stainless steel fenders, repainted the front fender brackets

The powder cater finished the rest of the coatings including the ceramic coated exhaust

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3067_zpsinvjxlsm.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3067_zpsinvjxlsm.jpg.html)

All hung up awaiting to go back together

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3068_zpsehszrou1.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3068_zpsehszrou1.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3069_zpscawc9hed.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3069_zpscawc9hed.jpg.html)

Crank to be sent out for grinding Monday, engine case bearings arrived Friday so I can start on the engine.

Next job is to mask and powder coat the engines side covers and related access plates.





Title: Re: Any Morini Fans?
Post by: brubache on February 25, 2018, 10:16:14 AM
WANT. IT. PERIOD.  :thumb:
Title: Re: Any Morini Fans?
Post by: twowings on February 25, 2018, 02:44:28 PM
Where did you source that most excellent Moto Guzzi print on the left with the different models?

Everything is looking great! This will be a gem... :bow:
Title: Re: Any Morini Fans?
Post by: canuck750 on February 25, 2018, 03:22:19 PM
Where did you source that most excellent Moto Guzzi print on the left with the different models?

Everything is looking great! This will be a gem... :bow:

I found the Guzzi poster on UK Ebay, had it for years.

Powder coated the engine case covers with satin black

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3074_zpsne6vtgtc.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3074_zpsne6vtgtc.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3076_zpsww5i9pgn.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3076_zpsww5i9pgn.jpg.html)

stripped the horn down to repaint the steel frame and reseal the air chamber

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3078_zps0waaneyu.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3078_zps0waaneyu.jpg.html)

new harness and fasteners

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3079_zpsquqlmwqs.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3079_zpsquqlmwqs.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3080_zpsrbizucor.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3080_zpsrbizucor.jpg.html)
Title: Re: Any Morini Fans?
Post by: canuck750 on February 27, 2018, 10:07:15 PM
I took a few more bites out of finishing the elephant, the tail light assembly, powder coated the CEV light and plate hanger, cad plated the cup that holds the rubber damper and replaced the hardware

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3081_zpseucr8ndb.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3081_zpseucr8ndb.jpg.html)

Original tail light cleaned up nice just had to glue the gasket back into the body

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3082_zps5yexqga0.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3082_zps5yexqga0.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3083_zpsgn8zzmny.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3083_zpsgn8zzmny.jpg.html)

To the brakes, these are Grimeca, I stripped off the original anodizing and sent the caliper bodies and master cylinder parts off to get anodized, very cheap, about $4.00 a part
The bolts, washers, lock plates and bleeders were cad plated, new seals fitted

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3085_zpsxsikqqdw.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3085_zpsxsikqqdw.jpg.html)

Grimeca use a ball bearing between the caliper casting and the bleeder

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3086_zpsu5og7c3v.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3086_zpsu5og7c3v.jpg.html)

The front master cylinder is new

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3087_zps93u7cb6i.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3087_zps93u7cb6i.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3088_zps7u6g0m36.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3088_zps7u6g0m36.jpg.html)

I had new rubber brake lines made to match the original ones and had the steel brake lines cad plated, just need to fit the new brake shoes and install the rear master cylinder rebuild kit.

Now to dig into the boxes and decide what component to do next.
Title: Re: Any Morini Fans?
Post by: Rick4003 on February 28, 2018, 09:16:08 PM
 :popcorn:

Spectacular as always Jim! Good job on the horn, I have to see if I can do the same on my Alfa, it got two horns on it and they sound like they have a cold :grin:

-Ulrik
Title: Re: Any Morini Fans?
Post by: canuck750 on February 28, 2018, 10:22:13 PM
:popcorn:

Spectacular as always Jim! Good job on the horn, I have to see if I can do the same on my Alfa, it got two horns on it and they sound like they have a cold :grin:

-Ulrik

The plastic sound box, built like a nautilus shell, is glued to the steel body, on this horn the glue had dried out and the plastic body was loose to the steel plate, silicone sealant between the two should solve it.



I cleaned up the forks, polished the fork lowers and fitted new dual lip seals,

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3099_zpsm3uszrzm.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3099_zpsm3uszrzm.jpg.html)

Fitted new aluminum sealing washers to the bottom bolts

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3101_zpsydq8qxox.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3101_zpsydq8qxox.jpg.html)

filled the fork tubes with 200cc of 10 weight fork oil.

repro decals finish them off

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3103_zps6wsotohi.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3103_zps6wsotohi.jpg.html)

the dust caps and retainer clips were in good shape so they go back on

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3102_zpsagt9g1x9.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3102_zpsagt9g1x9.jpg.html)

Replacing the transmission and cam bearings and the crank white metal bushing, heat the cases up to 300F, set the bearings outside on a cookie sheet on the snow bank

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3104_zpsllemil2f.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3104_zpsllemil2f.jpg.html)

Pull the hot case out of the oven, drop the ice cold bearings into the hot case and they bearings drop right down, then fit the main roller bearing retainer plates

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3105_zpsu1lacirz.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3105_zpsu1lacirz.jpg.html)

the crank white metal bush sits in a steel ring, got the ring real hot and the old bush was driven out, then reheat the steel retainer and push the new cold bush into place. The white bush retainer ring is held to the crankcase with three 3mm bolts, uses 3mm studs threaded into the retainer to guide the retainer / bush into the hot case, once cool removed the guide studs and then fitted the 3mm bolts.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3106_zpsfxzgptfq.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3106_zpsfxzgptfq.jpg.html)

Now I need to get the crank ground to fit the oversize shells and fit the new con rod small end bushes


Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on February 28, 2018, 11:13:38 PM
...the crank white metal bush sits in a steel ring, got the ring real hot and the old bush was driven out, then reheat the steel retainer and push the new cold bush into place. The white bush retainer ring is held to the crankcase with three 3mm bolts, uses 3mm studs threaded into the retainer to guide the retainer / bush into the hot case, once cool removed the guide studs and then fitted the 3mm bolts.

Did you remember to put the copper washers on the 3 mm bolts?  :wink: I couldn't for the life of me figure out where those three tiny copper washers that Stuart sent me went. One of the guys on the Morini Facebook group set me right eventually. They're not used on early 3 1/2 Sport engines like I was building, since it has ball-bearings on both ends of the crank.

Enjoying this build more than the Guzzi ones.  :thumb:
Title: Re: Any Morini Fans?
Post by: canuck750 on February 28, 2018, 11:55:17 PM
Did you remember to put the copper washers on the 3 mm bolts?  :wink: I couldn't for the life of me figure out where those three tiny copper washers that Stuart sent me went. One of the guys on the Morini Facebook group set me right eventually. They're not used on early 3 1/2 Sport engines like I was building, since it has ball-bearings on both ends of the crank.

Enjoying this build more than the Guzzi ones.  :thumb:

Yep, are they there as an oil seal?
Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on March 01, 2018, 08:42:15 AM
Yep, are they there as an oil seal?

Yes, crush washers to prevent oil leakage.
Title: Re: Any Morini Fans?
Post by: canuck750 on March 01, 2018, 11:40:00 AM
Yes, crush washers to prevent oil leakage.

Thanks Charlie!

The Moto Morini repair manual talks about making sleeved covers to go over the shafts to protect the oil seals during assembly of the bottom end, never done this before.

What are your thoughts / recommendations for fitting the gear clusters and crank through the oil seals during assembly?
Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on March 01, 2018, 12:12:00 PM
Thanks Charlie!

The Moto Morini repair manual talks about making sleeved covers to go over the shafts to protect the oil seals during assembly of the bottom end, never done this before.

What are your thoughts / recommendations for fitting the gear clusters and crank through the oil seals during assembly?

I wasn't taking a chance on boogering up a seal, so made them for the crank, cam and countershaft:

(https://scontent-iad3-1.xx.fbcdn.net/v/t31.0-8/20017442_1269113769877418_2625437408640093957_o.jpg?oh=bb32c4daa6e6550f85e78ed12161edd4&oe=5B4947F3)

(https://scontent-iad3-1.xx.fbcdn.net/v/t31.0-8/20116985_1269113763210752_5729097832566553575_o.jpg?oh=a236a751496c0dc0f91107db89e7b2e3&oe=5B0A3AFD)
Title: Re: Any Morini Fans?
Post by: canuck750 on March 01, 2018, 12:55:50 PM
Very nice, I will spark up the lathe this weekend.
Title: Re: Any Morini Fans?
Post by: canuck750 on March 01, 2018, 03:28:36 PM
I got the wheels back from the shop today, I went for Pirelli Sport Demons, they look pretty handsome with the fresh powder coated rims and new rotors.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3109_zpsigrgbakv.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3109_zpsigrgbakv.jpg.html)

The shop manager came out to tell me the trouble they had getting the Pirelli's to sit into the rims, apparently they spent hours messing with them, eventually fitted tire heaters to the tires, installed the tubes and pumped up pressure, then deflated the tubes and installed tire / tube. The shop had the same trouble fitting the same Pirelli tires to my 1977 Le Mans ..... they are not happy with me.

Both of these bikes have Italian mag wheels, the Moto Morini wheels are made by Grimeca, not sure who made the Guzzi LeMans wheels. I wonder if trouble is with the profile of the Pirelli tire or is the profile of the Italian rims?
Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on March 01, 2018, 04:28:08 PM
I always have "fun" trying to get the beads to seat on Guzzi cast wheels, but don't remember any issue with the K2's Grimeca rims. But then, the tires I run (Shinko 712s) are likely a bit less stiff than the Pirellis.
Title: Re: Any Morini Fans?
Post by: canuck750 on March 02, 2018, 09:53:27 AM
I stripped the Ikon shocks that came on the Morini, seals and O rings looks good but the fluid was brown and milky, threw the lot into the ultrasonic cleaner for an hour, powder coated the shock bodies. The ultrasonic cleaner along with a blast of compressed air cleans out the valves, really just thin wafer discs of steel center fastened to a machined disc with tiny holes to control the flow of fluid. These Ikon shock seals were not partially dissolved like all of the KONI shocks I have rebuilt for the V7 Sport / 750S series of bike. Ikon must be using a modern compound O ring and seal that is resistant to hydraulic fluid.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3112_zpsmemtlvxx.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3112_zpsmemtlvxx.jpg.html)

Wolfgang Haerter in B.C. Canada distributes Ikon shocks and tells me that this particular model of Ikon take 71cc of fluid, and as they are older shocks he recommends 15 weight fluid. How Ikon came up with 71cc and not 70 or 75 is strange.
Title: Re: Any Morini Fans?
Post by: Psychopasta on March 02, 2018, 02:32:06 PM
I do love the results you get with ultrasonic cleaning Jim. What gear do you use?
Title: Re: Any Morini Fans?
Post by: canuck750 on March 02, 2018, 03:44:06 PM
I do love the results you get with ultrasonic cleaning Jim. What gear do you use?

To clean the shock parts I just used some ZEP concrete floor degreaser / cleaner I had in the garage, seemed to get the fluid residue out of the parts.
Title: Re: Any Morini Fans?
Post by: Psychopasta on March 03, 2018, 10:51:30 AM
Thanks. HarborFreight do a little ultrasonic cleaner unit, I think one may appear in my mancave soon...
Title: Re: Any Morini Fans?
Post by: brubache on March 03, 2018, 11:12:19 AM
So tasty.  Looking amazing.
Title: Re: Any Morini Fans?
Post by: canuck750 on March 03, 2018, 04:23:37 PM
Started to hang the parts back onto the frame. I always enjoy working on fresh parts and fasteners, the work goes quickly with clean and fresh parts.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3113_zpsxrlgbngb.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3113_zpsxrlgbngb.jpg.html)

Having a parts manual makes the assembly so much easier, knowing where rubber washers go, flat washers, etc. and having taken a couple hundred pictures before and during the disassembly is invaluable. Like the manual says reassembly is the opposite of disassembly.  :laugh:

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3116_zpsfvnwq1mk.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3116_zpsfvnwq1mk.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3114_zpsicxipxfh.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3114_zpsicxipxfh.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3115_zpsgm0ej1xs.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3115_zpsgm0ej1xs.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3117_zpsum7htchm.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3117_zpsum7htchm.jpg.html)

The stainless steel fenders polish up nicely with green polish and a buffing wheel

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3118_zpsrnvhhwrf.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3118_zpsrnvhhwrf.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3119_zpsmzpwwlsd.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3119_zpsmzpwwlsd.jpg.html)

I am going to get the bike standing on its tires before I assemble the engine, machine work getting done next week.

Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on March 03, 2018, 04:37:39 PM
 :thumb:
Title: Re: Any Morini Fans?
Post by: Rick4003 on March 04, 2018, 04:16:23 AM
 :thumb: :1: :popcorn:
Title: Re: Any Morini Fans?
Post by: BikeMike on March 04, 2018, 10:52:46 AM
Nice work Jim!  Are you in a new shop?

-Mike
Title: Re: Any Morini Fans?
Post by: canuck750 on March 04, 2018, 06:05:20 PM
Nice work Jim!  Are you in a new shop?

-Mike

Not really, I just moved most of my bigger tools and welding to a space I have open at my office, loading dock and some extra unleased space.

Assembled the front end, I miss the tapered steering bearings pf the Guzzi, these ball bearings are a messy job

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3120_zpsyogalc7t.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3120_zpsyogalc7t.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3121_zpsw8vqzoyi.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3121_zpsw8vqzoyi.jpg.html)

Fitted the rebuilt calipers, cad plated steel brake lines and the new rubber brake hoses I had made, had to let the air out of the tire to get it to fit past the fender mounts then reflate it

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3135_zpswenhcg2l.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3135_zpswenhcg2l.jpg.html)

the anodized splitter and I replated the pressure switch

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3134_zpshmwcd9ry.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3134_zpshmwcd9ry.jpg.html)

Fitted the steering damper and the speedo cable guide

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3133_zpsrdvffman.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3133_zpsrdvffman.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3132_zpsh9tc3kvt.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3132_zpsh9tc3kvt.jpg.html)

side stand back on

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3137_zps8xk8bwrm.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3137_zps8xk8bwrm.jpg.html)

and the center stand

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3138_zpskyn9tlx3.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3138_zpskyn9tlx3.jpg.html)

headlight shell and the front signal lights

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3140_zps4obpobnj.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3140_zps4obpobnj.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3141_zpssbcrm9t7.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3141_zpssbcrm9t7.jpg.html)

Fitted the rear master cylinder rebuild kit, new hose to the caliper

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3142_zpsorllnbte.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3142_zpsorllnbte.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3143_zpshfkqi8vp.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3143_zpshfkqi8vp.jpg.html)

the Griemca caliper uses cotter pins rather than sprung pins like on the Brembo, I much prefer to Brembo

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3144_zps1k5hkrd3.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3144_zps1k5hkrd3.jpg.html)

Emptied a lot of boxes this weekend, and I painted over the ceramic coat matt black with very high heat exhaust paint, the ceramic just marks too easily, it will make a good primer coat though for the top coat. I am going to repaint my Le Mans exhaust with the same paint, I really like the look of the satin black.


(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3147_zpsr0vx2pmu.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3147_zpsr0vx2pmu.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3146_zps9azinvpz.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3146_zps9azinvpz.jpg.html)

Title: Re: Any Morini Fans?
Post by: Rick4003 on March 05, 2018, 08:24:48 AM
immaculate Jim! It just looks great. I am with you on those ball bearing headstocks. Our small 150cc bikes have the same kind. Much prefer the tapered roller bearings instead. Honestly I hate those loose ball bearing types, not that they are so hard to fit if you pack them with enough grease, but they just don't feel as good as the tapered roller bearings when you riding the bike in my opinion.

Can't wait to see the engine back together!

Love your threads Jim, I can live a little through your builds while I wait for a change for continue on my own. :grin:

-Ulrik
Title: Re: Any Morini Fans?
Post by: canuck750 on March 05, 2018, 09:03:50 AM
Thanks Ulrik!

I had to scrounge through old parts bins to find a couple ball bearings on the weekend, somewhere on the shop floor two of them are hiding out of sight.
Title: Re: Any Morini Fans?
Post by: canuck750 on March 11, 2018, 11:12:15 AM
Fiddling with the electric starter, I spoke to Stuart in the UK about them and he tells me that most failed due to lack of service, oil needs to be replaced in the drive unit and most owners didn't even know service was required.
On this bike the previous owner removed the electric motor and blanked it off from the drive mechanism with a lid from a tin can, the right hand stop / start button / throttle was removed and replaced with a Tomasseli, the wire4s from the switch where cut off and the remains of the harness to the motor wrapped around the frame.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3155_zpsfi5zmd6n.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3155_zpsfi5zmd6n.jpg.html)

This is the start / stop button that also holds the throttle, thankfully a previous owner left enough wires to join new leads to

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3152_zpsjta31ilc.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3152_zpsjta31ilc.jpg.html)

This is the motor with drive (a spare)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3156_zpsie7a58qt.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3156_zpsie7a58qt.jpg.html)

Dirty inside but the motor looks ok, will clean and test it

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3159_zpshn41ujgs.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3159_zpshn41ujgs.jpg.html)

Fill oil here, or not...

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3162_zps1um2bzna.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3162_zps1um2bzna.jpg.html)

worm gear and bearing

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3171_zpsv4176kqo.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3171_zpsv4176kqo.jpg.html)

and the other half of the drive gear assembly

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3172_zpsvtn6cygg.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3172_zpsvtn6cygg.jpg.html)

yech...

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3174_zpspmaqdai6.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3174_zpspmaqdai6.jpg.html)

time to clean it all up, lube and bench test it, brushes and armature look good, I think the gear mechanism was so gummed up it hardly turned 

Title: Re: Any Morini Fans?
Post by: canuck750 on March 12, 2018, 10:16:13 AM
Correction to the brake hose fitting on the rear master cylinder

I think this is now on the correct way

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3178_zpsyvonrspv.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3178_zpsyvonrspv.jpg.html)

The low pressure feed line from the rear master cylinder reservoir to the master cylinder is fitted, I used a black EPDM line rather than saving the old brittle clear line,

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3179_zpszwunco2i.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3179_zpszwunco2i.jpg.html)


Title: Re: Any Morini Fans?
Post by: canuck750 on March 12, 2018, 10:16:00 PM
The painter I use finished the Morini 3 1/2 paint work, painted white stripe with black pin stripe edge, he looked at the original 1975 Moto Morini brochure and a lot of pictures on the internet to try and match the paint, still its a guess but I like it.

(http://i249.photobucket.com/albums/gg217/canuck750/1975%20Moto%20Morini%203%201-2/IMG_3180_zpspbl0jhzx.jpg) (http://s249.photobucket.com/user/canuck750/media/1975%20Moto%20Morini%203%201-2/IMG_3180_zpspbl0jhzx.jpg.html)

I need to pick up some clips to hold the repro side cover emblems on

(http://i249.photobucket.com/albums/gg217/canuck750/1975%20Moto%20Morini%203%201-2/IMG_3182_zpszmxbe5ag.jpg) (http://s249.photobucket.com/user/canuck750/media/1975%20Moto%20Morini%203%201-2/IMG_3182_zpszmxbe5ag.jpg.html)

Its such a 70's colour, reminds me of the blue on the 1970 Mustang.
Title: Re: Any Morini Fans?
Post by: TRw1 on March 13, 2018, 06:35:31 AM
Enjoying all 3 of the builds going on.  Very cool stuff. :bow:
Title: Re: Any Morini Fans?
Post by: brubache on March 13, 2018, 10:05:14 AM
WAYYYYYY better than when you got the 3 1/2!  Looks great!  Nice choice as there are really not many that color.
Title: Re: Any Morini Fans?
Post by: twowings on March 13, 2018, 04:26:11 PM
Even if the color isn't an exact match, it's still bitchin'! Looking forward to more... :thumb:
Title: Re: Any Morini Fans?
Post by: canuck750 on March 18, 2018, 05:44:22 PM
Safest place to store the freshly painted parts is on the bike, the 3 1/2 will sit for a while before I can rebuild the motor

(http://i249.photobucket.com/albums/gg217/canuck750/1975%20Moto%20Morini%203%201-2/IMG_3193_zpsbyphued9.jpg) (http://s249.photobucket.com/user/canuck750/media/1975%20Moto%20Morini%203%201-2/IMG_3193_zpsbyphued9.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1975%20Moto%20Morini%203%201-2/IMG_3194_zpsahs6aw29.jpg) (http://s249.photobucket.com/user/canuck750/media/1975%20Moto%20Morini%203%201-2/IMG_3194_zpsahs6aw29.jpg.html)
Title: Re: Any Morini Fans?
Post by: twowings on March 18, 2018, 05:46:04 PM
I wish I could be your apprentice!  :bow:
Title: Re: Any Morini Fans?
Post by: canuck750 on March 18, 2018, 06:00:20 PM
I wish I could be your apprentice!  :bow:

And I wish I had a real mechanic that I could apprentice under to properly learn the ins and outs of motorcycle electronics and carburation, two things I need to learn a lot more about!
Title: Re: Any Morini Fans?
Post by: huub on March 19, 2018, 03:29:10 AM
try and find a original airbox for the 350,  K&N filters on a morini are a pain,
at speed the forward facing filter gets lots of wind, leaning out the mixture.
leaning out the rear cylinder is not a good idea, it is the hottest of the two to begin with.
in serious rainshowers the K&N soaks up enough rain to drown the engine.
the original airbox is fiddly, but K&N filters are worse.
Title: Re: Any Morini Fans?
Post by: canuck750 on March 19, 2018, 09:19:30 AM
try and find a original airbox for the 350,  K&N filters on a morini are a pain,
at speed the forward facing filter gets lots of wind, leaning out the mixture.
leaning out the rear cylinder is not a good idea, it is the hottest of the two to begin with.
in serious rainshowers the K&N soaks up enough rain to drown the engine.
the original airbox is fiddly, but K&N filters are worse.

The K & N's are going in the bin! I talked to Stuart Mayhew about my 500 and he set me straight on using the stock air box and filters, the 3 1/2 will be reverted back to stock carbs and air box.
Title: Re: Any Morini Fans?
Post by: canuck750 on March 21, 2018, 03:05:11 PM
A package from England!

North Leister Motors delivers again!, small parts for the restoration, replacement dash indicator lens', rear signal light brackets and dampers, choke lever, a bunch of cables, disc brake nut retainers, stainless steel instrument bezels, handlebars and a rebuilt starter motor.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3198_zps9ujtazjn.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3198_zps9ujtazjn.jpg.html)

NLM has supplied a lot (most) of the parts to rebuild the bike and what is amazing the parts arrive from the UK in a week or less.
Title: Re: Any Morini Fans?
Post by: brubache on March 21, 2018, 05:22:51 PM
That is incredible.  They are about the only people to get parts from. 
Title: Re: Any Morini Fans?
Post by: canuck750 on March 22, 2018, 09:33:13 AM
Got a few more parts out of boxes and back onto the bike,

The low rise Strada type handle bars are the closets thing to stock that Stuart could find for me, The knurling is wider than the clamps but other than that they will work just fine

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3203_zps8grzmjjb.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3203_zps8grzmjjb.jpg.html)

I found a new Grimeca master cylinder on German Ebay months ago and grabbed it for the price it was listed at, complete with lever, a nice find

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3202_zpsyyfoi2gl.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3202_zpsyyfoi2gl.jpg.html)

The stock throttle with the ON/OFF and START buttons, rewired and sheathed

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3200_zpsjtiit44k.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3200_zpsjtiit44k.jpg.html)

A NOS left hand switch, Italian Ebay, cheap, these are also used on the early Ducati Twins and in North America they go for three times the price,

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3199_zpst6oazao1.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3199_zpst6oazao1.jpg.html)

The choke lever locks into the underside of the clutch perch, kind weird but it makes sense when your hand is resting on the clutch, I need to powder coat the clutch lever to match the brake lever matte black

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3201_zpsmtf9inqc.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3201_zpsmtf9inqc.jpg.html)

..... meanwhile the Le Mans carbs were torn apart last night, ultrasonic cleaned again for a couple hours and blown out just to be sure, then the floats re-set, going to try to fire it up again on the weekend if time permits. Doubt it was a carb issue, still think it's the dreaded Guzzi kill switch :thewife:



Title: Re: Any Morini Fans?
Post by: canuck750 on March 22, 2018, 10:45:57 PM
Went to fit the rear signal lights, the stems on the bike are not stock, the end that passes through the frame should be a small diameter, I have a box of signal light parts, reproduction Lucas lights I buy for V7 Sport use have these imperial threaded stems that fit the bill,

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3205_zpstwsyw3ir.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3205_zpstwsyw3ir.jpg.html)

Next problem the CEV signal lights have a metric female threaded nut and the stems are 7/16" x 20 thread, I used a 7/16" x 20 tap and tapped the CEV signal light

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3206_zps4jzonoc5.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3206_zps4jzonoc5.jpg.html)

The new rubber dampers at the rear frame tab provide a little bit of deflection

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3210_zpsi5dgoqi5.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3210_zpsi5dgoqi5.jpg.html)

I fitted water proof disconnects to the signal lights

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3211_zpsx00q5gyz.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3211_zpsx00q5gyz.jpg.html)

Front signal lights are a straight forward fit, the original head light shell wears the road rash from a previous crash, think I will leave it as badge of honour

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3207_zpsugt6y8pe.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3207_zpsugt6y8pe.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3208_zpsekc23seo.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3208_zpsekc23seo.jpg.html)

I replaced the four coloured idiot light lenses in the console

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3209_zpsb4gifjho.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3209_zpsb4gifjho.jpg.html)

The instrument bezel covers are reproduction stainless steel caps that will be glued onto the rubber instrument receivers

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3212_zpsih0nei6j.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3212_zpsih0nei6j.jpg.html)

Title: Re: Any Morini Fans?
Post by: brubache on March 23, 2018, 10:18:03 AM
The headlight rash explains the headlight mounts then.   As always... your work... to be admired!
Title: Re: Any Morini Fans?
Post by: canuck750 on March 23, 2018, 11:25:51 AM
The headlight mounts are actually stock, I thought they were some after market things but the parts manual confirms them to be as they left the factory,

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/SKM_C554e18032310270_zpszjxiynac.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/SKM_C554e18032310270_zpszjxiynac.jpg.html)

Trying to confirm what is factory stock on this Morini has been a bit of head scratcher at times since a lot of little things on the bike were changed over the years by previous owners. I am trying to get it back to as close as stock correct as possible, I like to preserve them as they were when new. Tracking down a stock pair of shock absorbers will probably be a dead end but who knows, maybe NLM can find a pair that could be rebuilt. :smiley:
Title: Re: Any Morini Fans?
Post by: brubache on March 24, 2018, 12:52:24 AM
ha! Thats awesome.  The ikons are probably a decent choice anyway.  Were the originals Marzocchi on that one?
Title: Re: Any Morini Fans?
Post by: canuck750 on March 24, 2018, 09:08:39 AM
ha! Thats awesome.  The ikons are probably a decent choice anyway.  Were the originals Marzocchi on that one?

I am not sure about the rear shocks, they may have been Marzocchi but perhpas Paoli?

The Ikons look 'close enough' and are probably a decent riding shock, but if a stock set did turn up it would be nice to hgave them.
Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on March 24, 2018, 01:00:46 PM
All three of my Morinis ('80 500 Strada bought used, '86 350 K2 bought new and my present '85 K2) had/have Marzocchi rear shocks.
Title: Re: Any Morini Fans?
Post by: canuck750 on March 24, 2018, 10:42:46 PM
All three of my Morinis ('80 500 Strada bought used, '86 350 K2 bought new and my present '85 K2) had/have Marzocchi rear shocks.

Thanks Charlie
Title: Re: Any Morini Fans?
Post by: huub on March 28, 2018, 06:28:14 AM
I am not sure about the rear shocks, they may have been Marzocchi but perhpas Paoli?

The Ikons look 'close enough' and are probably a decent riding shock, but if a stock set did turn up it would be nice to hgave them.

i should have a couple of original morini marzocchi's somewhere in the stash of parts.
if interested i can have a look, but postage from europe might make it impractical
Title: Re: Any Morini Fans?
Post by: gentlemanjim on April 02, 2018, 03:24:59 PM
Very nice workmanship
Title: Re: Any Morini Fans?
Post by: canuck750 on July 06, 2018, 11:11:24 AM
A little bit of progress this summer on the Morini 500, the machinist finished the crank shaft regrind, fitted and trimmed the replacement big end shells NLM provided and fitted new small end bushings as well, and he did a full valve job with new valves and valve guides. Thanks to Charlie for  the simple engine stand idea I copied from a picture on his Morini rebuild post

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3472_zpsisujejs9.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3472_zpsisujejs9.jpg.html)

rods have been balanced

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3473_zpskpwysq5f.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3473_zpskpwysq5f.jpg.html)

The big end shells that NLM sources are too wide for the rods so they need to be trimmed and fitted

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3474_zpsxeygxieb.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3474_zpsxeygxieb.jpg.html)

All of the ball bearings in the cases were replaced with the exception of the one large crank ball bearing

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3477_zpsymrgvkvx.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3477_zpsymrgvkvx.jpg.html)

All the shafts spin so hopefully there won't be any problems with the bottom end

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3480_zpss8ymwpqt.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3480_zpss8ymwpqt.jpg.html)

I used Honda case bond to seal the two crank case halves together
Title: Re: Any Morini Fans?
Post by: canuck750 on July 08, 2018, 08:53:49 PM
More bits and pieces found their way back onto the motor, pistons, rings, cylinders and heads,

The flat Heron head, same design as used on the small block Guzzi's V35 and V50 of the 70's (and I assume carried over into more recent Guzzi small block engines).

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3518_zps5j9mpjcj.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3518_zps5j9mpjcj.jpg.html)

The combustion chamber formed into the top of the piston

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3519_zpstvjsj6xk.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3519_zpstvjsj6xk.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3520_zpsnmgevewo.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3520_zpsnmgevewo.jpg.html)

I have lost one small bag of important parts that I kept out not to be cad plated, go figure I can't for the life of me find it. A small order for woodruf keys, special spacers etc has gone off to NLM. In a couple of months that little plastic bag is going to come out of hiding.
Title: Re: Any Morini Fans?
Post by: Rick4003 on July 09, 2018, 12:21:42 AM
Very lovely job Jim,

Sorry to hear about the missing bag with important parts. Almost happened to me too when rebuilding the Alfa motor, it took a while to find the right box where it was hiding. It will surely come out of hiding the day your new parts arrive. :)

-Ulrik
Title: Re: Any Morini Fans?
Post by: canuck750 on July 09, 2018, 05:41:49 PM
Very lovely job Jim,

Sorry to hear about the missing bag with important parts. Almost happened to me too when rebuilding the Alfa motor, it took a while to find the right box where it was hiding. It will surely come out of hiding the day your new parts arrive. :)

-Ulrik

Yep, in a week or two that zip lock bag is going to rise up out of the corner its been hiding in!
Title: Re: Any Morini Fans?
Post by: canuck750 on July 14, 2018, 11:58:39 AM
Engine is back in the frame. it's so much lighter than a Guzzi big block and though it takes some careful protecting of the painted frame one person can get it into place. I dropped some rubber sheet pads around the bottom of the frame to slide the motor on while I threaded the bolts through the back of the frame to get it into position before fitting the front engine plates.

NLM is shipping me the parts that went 'missing' so I can button up the motor in a week or two.

Meanwhile installing all the electrical harness sections I made. I found the clear plastic caps I fitted are too big to fit into the fuse box or connector block so I had to cut off all the fresh crimped ends, reinstall the black plastic covers and recrimp everything.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3531_zpsw8ecfytt.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3531_zpsw8ecfytt.jpg.html)

Spaghetti junction is coming together. Now that I have started to refit all the wires it's starting to make sense to me why Moto Morini chose all of these independent harness sections terminating at the fuse box. It's all pretty easy to follow. The shop manual wire diagram is hard to read but by snapping a picture on my I Phone then enlarging the picture I could make out the tiny writing of such things as the 6 wire leads on the ignition switch and other multiple connections. As well Scrambler Cycle in the USA has on his web page access to a colour wire diagram for this model of 500cc twin, very helpful!

Many of the harness sections were cut off or bodged, previous owner gave up on the electric starter and the wires for the motor and switch were cut off, the idiot light wires were cut and taped, a few cheap crimp connectors here and there, the usual 'fixes' to wire harnesses these old nails get after a few decades of use.

Looks worse than it is!

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3532_zpszbjlxhat.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3532_zpszbjlxhat.jpg.html)
Title: Re: Any Morini Fans?
Post by: canuck750 on July 15, 2018, 09:39:39 PM
The bike came with a pair of Mikuni carbs, sacrilege!!

NLM recommends fitting the stock air box and filters

Rebuilt the stock Dellortos

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3578_zpsc5kgfozh.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3578_zpsc5kgfozh.jpg.html)

Slide is all corroded, need new ones

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3580_zpsjaf0nea9.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3580_zpsjaf0nea9.jpg.html)

Main jet holder is also the bowl retaining nut, smart!

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3581_zpsrmzoeyps.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3581_zpsrmzoeyps.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3582_zpshpdpxnih.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3582_zpshpdpxnih.jpg.html)

New boots, need more clamps

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3584_zpsd0uosnhn.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3584_zpsd0uosnhn.jpg.html)

can't figure out where the one blue lead goes to near the fuse box??

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3586_zpswlqzbija.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3586_zpswlqzbija.jpg.html)

And the horn is supposed to plug into the main wire harness, the only available wire is a red one but its a thick one??

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3598_zpsn5kkljlt.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3598_zpsn5kkljlt.jpg.html)

The usual sorting out a bike that's been bodged for decades, and trying to get it back to stock.
Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on July 16, 2018, 08:20:48 AM
Blue wires are usually grounded on Morinis. That red could very well be the horn power wire.
Title: Re: Any Morini Fans?
Post by: canuck750 on July 16, 2018, 09:05:43 AM
Blue wires are usually grounded on Morinis. That red could very well be the horn power wire.

Thanks Charlie
Title: Re: Any Morini Fans?
Post by: canuck750 on July 18, 2018, 02:50:19 PM
Blue wires are usually grounded on Morinis. That red could very well be the horn power wire.

Stuart from NLM confirmed the red wire is 'likely' the horn wire and that despite no such information on any of the wire diagrams 'some' Morini rectifier's white wire is a ground and that the stray blue wire coming out of the harness near the fuse box is also a ground. Apparently Moto Morini changed wire colours and patterns regularly

This is what Stuart had to say about the Morini wiring diagrams:

We always imagined that Morini made bikes, and they made wiring diagrams, but they never made one that matched the other; so you have been more fortunate than you know

On another mystery solved item, NLM sent me four new rubber boots for the carbs and these plastic split rings.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3583_zpsztk4a9lz.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3583_zpsztk4a9lz.jpg.html)

Stuart confirmed the plastic split ring goes between the rubber boot and jubilee clamp at the cylinder head intake to carb boot, this prevents splitting of the rubber boot from over tightening the jubilee clamp around the head intake spigot and rubber boot.

Its almost looking like a motorcycle again

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3604_zpselneadlc.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3604_zpselneadlc.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3605_zpszetqjkjl.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3605_zpszetqjkjl.jpg.html)
Title: Re: Any Morini Fans?
Post by: Rick4003 on July 25, 2018, 05:28:27 PM
As always Jim, it looks marvelous, great to see the little bike coming back to life!

-Ulrik 
Title: Re: Any Morini Fans?
Post by: canuck750 on August 05, 2018, 07:52:59 PM
I have found a little  time to keep on with the Moto Morini 500 build, I find I keep needing one more part and getting parts from the UK is slow and pricey compared to getting Guzzi parts.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3677_zpsjxg9erel.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3677_zpsjxg9erel.jpg.html)


I got most of the motor back together but I found I am missing a seal for the clucth basket, I can get that localy

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3683_zpswnpxmnvd.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3683_zpswnpxmnvd.jpg.html)

Exhaust ceramic coated, new head exhaust gaskets, replated the cinch parts that go around the header and is squeezed by the header nut

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3682_zpsk6sstjqf.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3682_zpsk6sstjqf.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3679_zpsvuclac7p.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3679_zpsvuclac7p.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3678_zpslhwbric5.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3678_zpslhwbric5.jpg.html)

                                                 

Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on August 05, 2018, 09:39:04 PM
Looking good! Just an FYI: Herdan Corp., the US importer of Morinis back when, is slowing putting up parts on ebay, username "dellortousa". I needed the exhaust head pipe half-rings and they recently listed them. Four more pieces that I won't have to make, or buy from NLM! 
Title: Re: Any Morini Fans?
Post by: canuck750 on August 06, 2018, 10:58:50 AM
Looking good! Just an FYI: Herdan Corp., the US importer of Morinis back when, is slowing putting up parts on ebay, username "dellortousa". I needed the exhaust head pipe half-rings and they recently listed them. Four more pieces that I won't have to make, or buy from NLM!

Thanks Charlie for the heads up.  Stuart is a great guy but it takes a long time to get stuff and the shipping is not cheap.

I can't find the fine thread nut that goes over the end of the cam to secure the electronic ignition unit, I must have at least 50 metric nuts that look like they should fit but don't. One more small road block.

The two exhaust heat shields that came loose with the bike don't fit, must be off a 3 1/2.

And lastly the bike came with home made rearsets but the pedals that came with the bike (three of them) don't fit this bike. I bought a set of Excalibur 500 brake and shift pedals with linkage off German Ebay last week hoping I can make something work out of the lot.
Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on August 06, 2018, 12:27:51 PM
Thanks Charlie for the heads up.  Stuart is a great guy but it takes a long time to get stuff and the shipping is not cheap.

I can't find the fine thread nut that goes over the end of the cam to secure the electronic ignition unit, I must have at least 50 metric nuts that look like they should fit but don't. One more small road block.

The two exhaust heat shields that came loose with the bike don't fit, must be off a 3 1/2.

And lastly the bike came with home made rearsets but the pedals that came with the bike (three of them) don't fit this bike. I bought a set of Excalibur 500 brake and shift pedals with linkage off German Ebay last week hoping I can make something work out of the lot.

The nut is an M7-1.00 nylock type on the 3 1/2 Sport, is that what you need? If so, I have 9 of them and will send you one (or more). Do you have the special dished washer that goes on first?
Title: Re: Any Morini Fans?
Post by: canuck750 on August 06, 2018, 07:31:56 PM
The nut is an M7-1.00 nylock type on the 3 1/2 Sport, is that what you need? If so, I have 9 of them and will send you one (or more). Do you have the special dished washer that goes on first?

Thanks Charlie that would be great!! ( I have the special washer for it ).

Cheers

Jim
Title: Re: Any Morini Fans?
Post by: canuck750 on August 10, 2018, 10:03:29 AM
I found the 'missing' exhaust heat shield hanging from a wire right above my head in the shop, duh !! :embarrassed:

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3693_zpsbiezckei.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3693_zpsbiezckei.jpg.html)

Fitted the crank case breather hose with new clamps

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3694_zpsoa14kqmy.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3694_zpsoa14kqmy.jpg.html)

The local seal shop had the clutch basket seals I needed to assemble the clutch

Lock tab washer

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3686_zpsuexahswy.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3686_zpsuexahswy.jpg.html)

new nut and oil seal

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3687_zpsdidvxmma.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3687_zpsdidvxmma.jpg.html)

clutch plates looked good so I am reusing them

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3688_zps1k6dtaar.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3688_zps1k6dtaar.jpg.html)

handy clutch bolt tool I got off Ebay, works on the Benelli clutch and the Benelli dash idiot lights as well

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3689_zpsubrazpik.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3689_zpsubrazpik.jpg.html)

The clutch activation rod is in three pieces plus the big fat dowel on the opposite side

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3690_zpsqtyjqfky.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3690_zpsqtyjqfky.jpg.html)

then the clutch cable arm

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3691_zps66akfpbi.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3691_zps66akfpbi.jpg.html)

and the cable, the new rubber boot goes over the stamped steel clutch cable arm

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3696_zpso0zwselg.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3696_zpso0zwselg.jpg.html)

left side cover back on

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3692_zpsnax5ckkm.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3692_zpsnax5ckkm.jpg.html)

It is a dry clutch and it is very stiff! hopefully when I get the cable adjuster fitted on the clutch hand lever, get the bike running and work the clutch cable the plates will feel right

next job is to tackle the right side case cover that holds the starter motor with its drive chain, it is an amazingly complicated little piece of engineering!
Title: Re: Any Morini Fans?
Post by: canuck750 on August 17, 2018, 10:32:48 PM
After installing the air box I noticed a nasty crack in the plastic and found another one after removing it and separating the two halves

The plastic has gotten hard over the years and the plastic tube seal is hard and brittle, clamping the two halves into the deformed seal just stresses the case more

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3782_zpsdhktaujz.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3782_zpsdhktaujz.jpg.html)

I got this plastic welder last year and it works pretty good

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3784_zpse2fkfif6.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3784_zpse2fkfif6.jpg.html)

The welder works like brazing, you get the iron real hot and melt the braising rods into the original plastic and build up the joint

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3783_zpszfo6gmbz.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3783_zpszfo6gmbz.jpg.html)

This plastic tube with a rigid wire in the center is the seal, its past its prime

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3785_zps2fkuze8t.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3785_zps2fkuze8t.jpg.html)

After trying some other rubber tubes and wires the gasket still didn't fit, its a poor design at best

I just bolted the case back together and then sealed the joint with black silicone, when the filters get replaced the silicone will need to be redone, Morini has a nice filter box but changing he air filters required removing the box from the frame (3 nuts) and then separating the case - 1o fine machine screws, not a quick job!

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3786_zpsyctyvxof.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3786_zpsyctyvxof.jpg.html)

Cracks sealed, box sealed

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3789_zpsnpvi9udg.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3789_zpsnpvi9udg.jpg.html)

A friend gave me an original Cycled magazine from 1979 with a detailed road test of the Moto Morini 500, there are lost of nice pictures (B & W) of the chassis with the gas tank off and plenty of detail shots of wire and hose routing.

I had the breather hoses routed incorrectly, this is how they should be placed, at least in 1979  :azn:

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3790_zpshxltnokd.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3790_zpshxltnokd.jpg.html)

That took an evening to get the box off, fixed and back together, just to fix two cracks.
Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on August 18, 2018, 09:05:43 AM
I was advised by the Morini importer (Herdan Corp.) to discard the seal between the upper and lower halves and rejet to suit if needed. That made a huge difference on my first K2 - it went from struggling to rev past 4500 rpms, to shooting up to 9k like a two-stroke (almost).

It was already missing from my present K2 and I left it out on the 3 1/2 Sport restoration project. 
Title: Re: Any Morini Fans?
Post by: canuck750 on August 18, 2018, 12:18:39 PM
I was advised by the Morini importer (Herdan Corp.) to discard the seal between the upper and lower halves and rejet to suit if needed. That made a huge difference on my first K2 - it went from struggling to rev past 4500 rpms, to shooting up to 9k like a two-stroke (almost).

It was already missing from my present K2 and I left it out on the 3 1/2 Sport restoration project.

Well that's interesting!

I will just pull the silicone out of the joint, the gap was surprisingly wide, a lot of air is going to find its way in, probably not a bad thing now that I think about it.

Thanks for the tip
Title: Re: Any Morini Fans?
Post by: Rick4003 on August 20, 2018, 01:41:50 PM
Hi Jim,

Looks spectacular as always, it is going to be a super nice little Morini! I just spotted one of the newer Morini's when I was on holiday in Berlin this week.

Is it just a optical illusion on the picture or isn't there a crack in your crank case breather hose?

-Ulrik
Title: Re: Any Morini Fans?
Post by: canuck750 on August 20, 2018, 03:54:51 PM
Hi Jim,

Looks spectacular as always, it is going to be a super nice little Morini! I just spotted one of the newer Morini's when I was on holiday in Berlin this week.

Is it just a optical illusion on the picture or isn't there a crack in your crank case breather hose?

-Ulrik

Your eyes are better than mine, its a crack and the hose needs to be replaced. I have a new hose from NLM to fit.

Yesterday I played around with fitting the starter motor, the motor is attached to the right hand engine side cover, NLM sent me a rebuilt one. The set up is quite ingenious but overly complex IMHO.

There is a shaft in the side cover that rides in a pair of ball bearings, the starter clutch rides on the shaft. The starter clutch has a sprocket that is joined by a chain to the starter motor.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3809_zpsgazlrn3r.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3809_zpsgazlrn3r.jpg.html)

Drops down as unit like this

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3810_zpso94t0xqc.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3810_zpso94t0xqc.jpg.html)

There is a sheet metal guard and a tensioning lock bolt and tab.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3811_zpsnww6tcah.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3811_zpsnww6tcah.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3812_zpsdkjt2ufr.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3812_zpsdkjt2ufr.jpg.html)

The whole unit then flips over onto the engine and the starter clutch nests into the outside of the rotor.

On another note I am having a heck of a time trying to figure out how to fit brake and shift pedals, the parts manual shows the UK model with right hand shift, the North American model had a left shift and the previous owner had fitted home made rear sets.

I have gathered up several sets of pedal mechanism for a 500 Morini but none seem to fit. From period magazine literature I can see the brake pedal was on the right hand side and a cable was routed to the left hand mounted rear master cylinder, my bike still has the threaded frame tab for the brake cable. On the right hand side of the frame beside the foot peg there is a threaded boss to accept a pedal but there is nothing on the frame to secure a cable to.

I have strong suspicion that the previous owner cut off tabs for the pedal mechanism, there is what appears to be evidence of weld marks on both sides of the frame where some lugs were attached.

The shift shaft exits the right hand side of the engine and I have several sets of shaft sleeve and rods that supposedly work the shift pedal. Attached to the underside of the frame is a hollow tube that appears to accept a shaft, I have several of these shafts, a knurled end on one side and an oblong tab with a hole drilled through it on the other. I am guessing the shift pedal sits on the knurled end of this shaft and somehow the tab end connects to shift linkage on the right hand side. I can not find a shift pedal in my lot of parts that fits on the left side of the engine.

I am considering throwing in the towel and just refitting the rear sets that came with the bike, they are set up for right hand shift, left hand brake.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3814_zps5upywy6z.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3814_zps5upywy6z.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/DSC_0183_zpsmrgfmzyx.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/DSC_0183_zpsmrgfmzyx.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/DSC_0179_zpsxigjo7tn.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/DSC_0179_zpsxigjo7tn.jpg.html)

If anyone has some good pictures of a 78 to 80 Moto Morini 500 brake and shift pedals and linkage to send me I would be indebted.

Thanks

Jim

Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on August 20, 2018, 04:56:04 PM

If anyone has some good pictures of a 78 to 80 Moto Morini 500 brake and shift pedals and linkage to send me I would be indebted.

Thanks

Jim

Check with Kevin Hahn at Scrambler Cycle.
Title: Re: Any Morini Fans?
Post by: canuck750 on August 20, 2018, 05:31:32 PM
Check with Kevin Hahn at Scrambler Cycle.

Thanks Charlie,

I sent Kevin an email
Title: Re: Any Morini Fans?
Post by: canuck750 on August 21, 2018, 10:26:23 PM
Kevin from Scrambler Cycle was kind enough to take pictures of his 78 Moto Morini to identify how the control pedals attach, as I suspected the previous owner did the unspeakable, mutilated the poor Morini frame and cut off the tabs and lugs that held the pedal and linkage, unforgiveable   :sad:

This of Kevin's Morini left side showing the lug that carries the shift lever

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3852_zpszagq8ynz.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3852_zpszagq8ynz.jpg.html)

And this is the same spot on my bike, the remenant of the tube post that carriers the shift pedal remains

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3850_zpsjirklo88.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3850_zpsjirklo88.jpg.html)

same strorey on the otherside of the frame. tabs missing that stop the brake pedal and hold the brake cable.

The original rearsets go back on
Title: Re: Any Morini Fans?
Post by: Antietam Classic Cycle on August 22, 2018, 08:48:24 AM
 :sad:
Title: Re: Any Morini Fans?
Post by: canuck750 on September 03, 2018, 08:54:56 AM
I was setting up the clutch and sitting on the bike trying to row through the gears but the shifter is very stubborn, it seems to hang up at times and not want to move. I stripped out the clutch sied of the motor, no better so I bit the bullet and pulled the motor ( a pretty easy job on the Morini) and put the motor back on the bench. Aftewr getting no where examining the outside of the cases I split th ecases and removed the transmission gear set and selector. Shifting is very reluctant. Thankfully Charlie Mulendore sent me a handy alignm ent tool that grasp ass four tenamsion related hsfats at once to allow for shift adjustment and shifting with the gear set in the left hand engione case.

I think the trouble is down to a worn selector arm pawl.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3889_zpsjt6vr890.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3889_zpsjt6vr890.jpg.html)

This is what the top of the sdelector drum looks like as I move the shift lever through the gears.

Pawels not in position on 1st

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/1st_zps8cek693f.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/1st_zps8cek693f.jpg.html)

Pawls not cenetring in 2nd

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/2nd_zpslebcbwxu.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/2nd_zpslebcbwxu.jpg.html)

Pawls not cenetriung in 3rd

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/3rd_zps7fb4rxqx.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/3rd_zps7fb4rxqx.jpg.html)

The pawls are bot cenetrd in 4th

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/4th_zpsctborc4u.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/4th_zpsctborc4u.jpg.html)

It does not apper tahte 5th is being engaged

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/5th_zpsbectlcpz.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/5th_zpsbectlcpz.jpg.html)
Title: Re: Any Morini Fans?
Post by: canuck750 on September 05, 2018, 06:35:13 PM
Stuart from NLM came through again for me.

I ordered a new selector arm but Stuart consulted his mechanics and felt that I had misplaced a shim on one side of a shaft, sure enough asfter striping down the parts I was missing a thin shim between a shaft and the ball bearing in the engine case.

Once I fitted a shim I could shift up and down all 5 speeds and neutral. I am surprised the difference this thin shim made.

I fitted each shaft or drum one a a time in the crank cases, bolted them together and checked the movement and play of each piece and then added one component at a time, once satisifed I put the engine back together and hopefully once running it will shift crisply.
Title: Re: Any Morini Fans?
Post by: canuck750 on September 06, 2018, 10:16:15 PM
After sorting the gear change out I can close up the sides covers, I had the side cover of so many times fiddling with the clutch that I tore the gasket. To try and not damage another gasket (not like I can just drop into a parts store to find one) I cut the heads off a11 old long 6mm bolts and then loosely threaded them into the engine case

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3915_zps8ft0ikii.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3915_zps8ft0ikii.jpg.html)

Then I slipped the new gasket off the studs

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3914_zpsjy0u2y7l.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3914_zpsjy0u2y7l.jpg.html)

Then I could pop the side cover over the studs and press the side cover home and one by one remove a stud and thread in a permanent 6mm bolt

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3916_zps1mgwpuzv.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3916_zps1mgwpuzv.jpg.html)

Put the clutch basket back together

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3917_zpsr0a4ehh0.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3917_zpsr0a4ehh0.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3918_zps833dneya.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3918_zps833dneya.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3919_zpssfqx5sgm.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3919_zpssfqx5sgm.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3920_zpsoqs8ohvt.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3920_zpsoqs8ohvt.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3921_zpsfqoyx9yp.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3921_zpsfqoyx9yp.jpg.html)

my Morini 3 1/2 came with this great clutch holding tool from NLM

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3922_zpsdsiaze88.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3922_zpsdsiaze88.jpg.html)

Peended the lock washer over the centre nut

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3923_zpsb76jktdc.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3923_zpsb76jktdc.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3924_zpsmj4qvqps.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3924_zpsmj4qvqps.jpg.html)

New clutch discs, the thin one goes in first

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3925_zpsroxfkfql.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3925_zpsroxfkfql.jpg.html)

Then the cupper steel plate

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3926_zpsnwz0y9ik.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3926_zpsnwz0y9ik.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3927_zpses619nc5.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3927_zpses619nc5.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3928_zpsrbyd2rff.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3928_zpsrbyd2rff.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3929_zpsdpjukv8g.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3929_zpsdpjukv8g.jpg.html)

The pick up over the cam, the nut is an odd 7mm thread

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3930_zps1btm4ox5.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3930_zps1btm4ox5.jpg.html)

right side done

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3931_zpsr2zkolcy.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3931_zpsr2zkolcy.jpg.html)

right side I fitted the clutch arm and cable and fitted a new rubber boot over the stator wires leaving the engine case

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3932_zpse5zyt9zd.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3932_zpse5zyt9zd.jpg.html)
Title: Re: Any Morini Fans?
Post by: canuck750 on September 08, 2018, 10:35:08 PM
After a lot of fitting and some machining I finally got the left hand rear set bracket to fit without binding the brake pedal to the exhaust. A previous owner made the 8mm aluminum brackets from scratch, he put a lot of thought into them, the left bracket fits over the 25mm diameter stock foo peg stud, the second hole fits into the centre of the swing arm pivot. I drilled out the 6mm threaded hole that was in the end of the axle into a 8mm threaded hole. The bracket has to straddle the exhaust, support the brake pedal and allow the brake rod to master cylinder clear the header.

I made the alignment cap from stainless, it takes a 8mm bold in the foot peg stud.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3951_zpsrx59laxb.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3951_zpsrx59laxb.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3956_zpsrrzs77ib.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3956_zpsrrzs77ib.jpg.html)

A real tight fit!

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3957_zpsqkamljl3.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3957_zpsqkamljl3.jpg.html)

and the home made brake pedal just clears the 8mm bolt

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3958_zps3peehk2a.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3958_zps3peehk2a.jpg.html)

To use the kick starter the left rear set peg needs to be folded up, I hope the electric starter works!
Title: Re: Any Morini Fans?
Post by: canuck750 on September 13, 2018, 10:01:08 PM
I got the chain installed and then the left side cover with the starter motor inside it.

I don't love the home made shift pedal that came with it, might try and find something that looks like it was stock

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3998_zpszxzhuncc.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3998_zpszxzhuncc.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3999_zpsftvnlgsl.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3999_zpsftvnlgsl.jpg.html)

Clutch cable and adjuster fitted

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_4002_zps4vckuwfq.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_4002_zps4vckuwfq.jpg.html)

Carbs test fitted, still waiting on he new slides

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_4001_zpsv5hnzcjd.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_4001_zpsv5hnzcjd.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3995_zpscoyvgvon.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3995_zpscoyvgvon.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3993_zpstjf3wynu.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3993_zpstjf3wynu.jpg.html)

I bled the brakes and checked the nuts and bolts, almost done

Now to fit the throttle and choke cables and attach the last of the electrical wires
Title: Re: 1978 Moto Morini 500 almost done!
Post by: canuck750 on September 16, 2018, 05:27:43 PM
The Moto Morini 500 is almost done, I am waiting on a pair of handle bar grips and the new carb slides, today I set the valve gap, fitted new spark plugs and rocker cover gaskets, installed the choke and throttle cables and put the body work on. I need to order a pair of petcocks, the electronic petcock is not working and the other stock one that came with the bikes is in pretty rough shape as well, at least it looks done, I have not tested the electrical, that will be the next job.

Other than the rear sets and the Ikon shock absorbers she is pretty much stock, the bike would have come with chrome exhaust as well in 78'.

I think she is a pretty sexy red head.

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_4012_zpshlnjsvt6.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_4012_zpshlnjsvt6.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_4013_zpszjo37rnn.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_4013_zpszjo37rnn.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_4014_zpsa7zivrev.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_4014_zpsa7zivrev.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_4015_zpsltyy1knk.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_4015_zpsltyy1knk.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_4017_zpsek4wy2xl.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_4017_zpsek4wy2xl.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_4019_zpstgtc2aqf.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_4019_zpstgtc2aqf.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_4020_zpsrupjavzz.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_4020_zpsrupjavzz.jpg.html)
Title: Re: 1978 Moto Morini 500 almost done!
Post by: mjptexas on September 16, 2018, 05:43:06 PM
Simply amazing.  Now you need to add a Parillia and an MV Augusta to your Italian collection :)
Title: Re: 1978 Moto Morini 500 almost done!
Post by: Paul Brooking on September 16, 2018, 06:17:35 PM
Superb


Sent from my iPhone using Tapatalk
Title: Re: 1978 Moto Morini 500 almost done!
Post by: canuck750 on September 16, 2018, 07:39:49 PM
Simply amazing.  Now you need to add a Parillia and an MV Augusta to your Italian collection :)

Thanks!

A MV 350 would be real nice to have and any high cam Parillia would be an amazing find!
Title: Re: 1978 Moto Morini 500 almost done!
Post by: Rick4003 on September 17, 2018, 08:37:59 PM
Looking great Jim! Must be nicer than when it left the factory!
Title: Re: 1978 Moto Morini 500 almost done!
Post by: Turin on September 18, 2018, 12:01:48 AM
That's really purty ! :drool: