Another Benelli Egg bike

[Canuck750]

This summer I met the fellow who started the Rocky Mountain Giro in Nakusp BC and we got talking about Motobi/Benelli egg motor bikes. I had rebuilt a spare 250 4-speed motor and was interested in finding a rolling chassis to form the start of another Giro bike, in this case it needs to be 250 cc or smaller and 1969 or older.

The fellow had some spares I could take a look at, when I went out to his place he offered me a nearly complete 1969 125 Sport Special, identical to the 250 Sport Special except for the motor. I bought this project and am in deep restoring it, the paint is original and will be saved. The stainless fenders cleaned up real nice and the frame parts have been powder coated. These port Specials have 18" wheels front and back, clip-on bars and a gas tank and seat unique to this model, 1969 ~ 70 only I believe and very few imported to North America.





the 5 speed bikes have a wider swing arm and rear hub as the engine drive sprocket sits further from the motor on the 5 speed bikes. I was able to modify the rear hub, sprocket carrier and brake plate to bring the sprockets into alignment with the wheel about 6 mm off center. I will try and offset the hub in the wheel to accommodate that.







Plenty of work to do over the winter, wheel building, seat re-upholstery, source exhaust, re-wire, etc....

[kballowe]

That's going to turn out nice !

Oh and as usual, we'll need more pictures !

 

[cliffrod]

Man, Jim, you live on a slippery slope.  That’s another great looking bike.  I’ll be watching.

Curious about the smooth top triple tree.  Is it alloy or stamped steel painted argent?

[Canuck750]

Man, Jim, you live on a slippery slope.  That’s another great looking bike.  I’ll be watching.

Curious about the smooth top triple tree.  Is it alloy or stamped steel painted argent?

Hello Clint,

The triple trees are alloy, painted silver, I couldn’t find a powder colour I liked locally so I used POR-15 stainless steel in a spray bomb, this POR-15 paint is the toughest stuff I have found that is almost as durable as powder.

I just ordered the exhaust from Detlef Burian at Benelliparts.de. Plus a few other small things that were missing. I found new polished alloy flanged rims; 1.85 x 18” from the Jawa Shop in the Czech Republic, for the air including delivery, under $150 US.

[Dave Swanson]

This bike is so cool!  Finding one in restorable shape is very rare indeed.  Fabulous

[Canuck750]

This bike is so cool!  Finding one in restorable shape is very rare indeed.  Fabulous

Thanks Dave!
You know I am a sucker for anything Italian, I keep being attracted to these small displacement bikes. When I saw the quality of the original paint I knew it was coming home with me.

[Canuck750]

A couple parts came in the mail, new fork seals (4) and a pair of reproduction dust caps, these Marzocchi forks are the same as on my 1972 Benelli 170 Enduro, they take 160 ml of fork oil.





Cleaned the headstock loose balls, fresh grease and fitted the triple clamps, the headlight brackets were polished along with the clip-ons



polished up the scratched fenders with a wool wheel in my 4" hand grinder, man do these FaceBook advertised polishing wheels do the job with a green wax stick, so much easier to hold the fender between my knees and move the polisher back and forth rather than holding the fender while I move it across a bench top polisher.



some pretty deep scrapes in the rear fender but its much better than it was, I think just a finishing polish will smarten them up for good



The chromed spring bands that wrap over the fork dust caps are in pretty bad shape, I need to find some reproductions.

I did order some new '250 Sport Special' side panel decals and a new gel battery that matched the size and look of the original and new 6v headlight and tail light bulbs from B&B Mechanica in Italy - they use the Ebay name 'Bebricambi' plenty of vintage Italian motorcycle parts, new and used on their Ebay store.

Time to move the 'project' to the lift bench before it gets any heavier to lift of the table.

[Canuck750]

I got most of the electrical redone over the past couple days, made a new wire harness with new wire from British Wiring and new open barrel crimps. I was lucky to source a new CEV ignition cut out switch. Waiting on lots of parts to arrive; rims, piston pin,  gaskets, head to come back from the machine shop, exhaust coming from Europe, seat from the local
Upholstery shop, new shock springs, speedometer … etc.

[Canuck750]

I am always pleasantly surprised what NOS parts continue to turn up, William Kuhen - Ebay seller 'Santo Di Motocieli' has listed some hard to find NOS Benelli, Motobi, Aermacchi etc parts over the years, I got this new in the box speedometer from him this week, fair price and suoer fast shipping.



I replaced the 125 Sport Special side cover decals with '250 Sport Special' reproductions to go along with the 250 motor I have fitted. the original chrome plating has polished up nicely, the condition of the original copper paint continues to impress me



B&B Mechanica in Italy provided a new headlight trim and reproduction battery along with the decals.



almost out of things to do while I wait on parts to come in, Buchanans's for new spoke nipples, Bennlei Parts.de for exhaust and a piston pin, springs for the rear shocks, the seat to be recovered .....

I had new stainless steel shock springs made, after polishing they turned out great.

[Canuck750]

I received my new stainless steel spoke kits from Buchanan’s on Friday, built a pair of wheels today.



The original chrome plated steel Radeli rims are rusty and I don’t want to pay to have them rechromed. The aluminum rims I bought from the Jawa Shop in Czech Republic were cheap at $200 for the pair with shipping but the punched holes in the rims were too big for the original spokes nipples and too small for the new nipples Buchanan supplied. After speaking with Buchanan’s I was told to increase the rim holes to 7.5mm, they were about 7.35mm so it took a second to run the drill through each hole.

I covered the aluminum rims with masking tape as I hate scrapping rims assembly the spokes.





The spokes were made about 6mm too long so after I tried the wheels a due grinder was used to flush the spoke to the nipple.



The rims were probably punched for a bike with a larger hub as the spokes don’t fit all that great, they kink slightly at the nipple, it will work but I wish it were better. I could try and angle drill the hole in the rim but that could just weaken the whole wheel. You get what you pay for….





The RaceTech front suspension upgrade kits arrived this afternoon, cartridge emulators and new springs, should make a difference.

[Dave Swanson]

The wheel looks great!  A major milestone complete.  You are the only person that will ever notice the drilling is not perfect.   

[Canuck750]

The wheel looks great!  A major milestone complete.  You are the only person that will ever notice the drilling is not perfect.   

Thanks Dave!
It bugs me to no end though, OCD issues.

[Dave Swanson]

Thanks Dave!
It bugs me to no end though, OCD issues.

OCD works to the benefit of our bikes, but can certainly be annoying at times.      I have a very slight lacing issue on one of my wheels that even I have a hard time seeing up close, but I know it's there.  Ha

[Canuck750]

I spoke with Matthew at RaceTech suspension a couple weeks ago, after discussing the potential to upgrade the Marzocchi 32mm forks he asked for pictures and dimensions of all the internal pieces. Matthew called me back and confirmed that he could supply new springs and cartridge emulators to bring the forks into this century.
$415 including shipping to Canada with excellent instructions and everything dialled in according to the bikes weight, intended use and my (over) weight.



Pretty simple to install, the lower damper rods need the four original bleed holes enlarged to 5.5mm and two more bleed holes drilled. The top of the damper rod needed the welded cap machines to fit the emulator and spacer supplied. Also supplied are plastic preload spacers that need to be cut flush with the top of the fork tube. Then just add 110mm of 15wt fork oil and it’s all done.

[SIR REAL ED]

Fantastic thread!

That is one of the coolest looking bikes I have ever seen, even prior to being restored.

In my next life, I want to do something similar.

[Canuck750]

Fantastic thread!

That is one of the coolest looking bikes I have ever seen, even prior to being restored.

In my next life, I want to do something similar.

Thank you!

It’s a fun little bike, once I get the seat back from the upholstery shop it’s really going to start to come together.
I am shifting more to older small bike to restore, cheaper to buy and cheaper to restore than a big twin or multi. For actual riding around town I think a 250 - 350 is just right.

[Canuck750]

It feels good to get it back on two wheels,  without the brake shoes, I dropped them off yesterday for relining and arcing.

I got the new piston pin I was waiting on to install the cylinder, the original pin is playing hide and seek in my shop



hose clamp ring compressor







The machine job installed the exhaust guide off center so the valve grind can not be done accurately, damn!! plenty of daylight shining through as a large crescent, it is so obviously not installed right

I put a 200 head on it to see if it would fit but the recess for the cylinder is much smaller on the 200.

Now I am hoping the machine shop can get the guide out and installed true, the guide was oversize and I don't think the machinist put a micrometer on it before he drove it though the head. I supplied the guides and just assumed the shop would measure them before installing them

[Huzo]

Thanks Dave!
It bugs me to no end though, OCD issues.

Yes Jim, it just isn’t….”you…”
This is what I did to bore my Norge spoke holes from blank.




It guarantees the spoke will be STRAIGHT..!
Just the lightest lick will take the high point off the hole.

[SIR REAL ED]

Thanks Dave!
It bugs me to no end though, OCD issues.

Never buy a Ural.  Sometimes the number of spokes in the hub is different from the number of holes in the rim...

[Canuck750]

Yes Jim, it just isn’t….”you…”
This is what I did to bore my Norge spoke holes from blank.




It guarantees the spoke will be STRAIGHT..!
Just the lightest lick will take the high point off the hole.

What a cool tool!!
Did you make that or purchase it?

[Huzo]

What a cool tool!!
Did you make that or purchase it?

Just thought it up and built it.
 If you sight down the hole where the drill goes, you’re looking straight at the point of the locating dowell at the other end, putting the drill through that hole means the nipple is sitting square in the chamfer.
You’ve to make sure that the locating dowell is placed where the bend in the spoke will be the the hub.
The semi circular end on the barrel ensures a centralised placement in the indentation. Absolutely imperative when boring a blank from scratch.
The first 1/8” hole required a sleeve in the barrel that stepped the size down to pilot diameter, then out with the sleeve and in with the final size to take the blind nipple.
Bingo…!
I’ll post it to you if you need it.

[SIR REAL ED]

Yes Jim, it just isn’t….”you…”
This is what I did to bore my Norge spoke holes from blank.




It guarantees the spoke will be STRAIGHT..!
Just the lightest lick will take the high point off the hole.

Very slick!

Good on ya Mate!

[Canuck750]

Just thought it up and built it.
 If you sight down the hole where the drill goes, you’re looking straight at the point of the locating dowell at the other end, putting the drill through that hole means the nipple is sitting square in the chamfer.
You’ve to make sure that the locating dowell is placed where the bend in the spoke will be the the hub.
The semi circular end on the barrel ensures a centralised placement in the indentation. Absolutely imperative when boring a blank from scratch.
The first 1/8” hole required a sleeve in the barrel that stepped the size down to pilot diameter, then out with the sleeve and in with the final size to take the blind nipple.
Bingo…!
I’ll post it to you if you need it.

Excellent work!
I am going to live with the way the spokes fit for now but if I ever decide to strip the wheels down I may ask for some measurements of your custom alignment tool to make one of my own

[Huzo]

Excellent work!
I am going to live with the way the spokes fit for now but if I ever decide to strip the wheels down I may ask for some measurements of your custom alignment tool to make one of my own

No worries.

[Muzz]

That is a really pretty wee bike there Jim. Nice to see it being brought back to pristine condition, and with a larger motor.

[Canuck750]

That is a really pretty wee bike there Jim. Nice to see it being brought back to pristine condition, and with a larger motor.

Thanks Muzz!

I arced the relined brake shoes on my lathe after shimming the cam arm so the shoes are perpendicular to the brake plate. I welded up a simple tool from scrap metal I had to keep the shoes from rocking while spinning in the lathe. Two 6mm set screws snug up to the shoes and hold them from moving while the tool is trimming the lining. Should be decent stoppers.
A very experienced tech (50 years in the business) at a local brake shop that relined my shoes told me how to properly set the back plate in the lathe, shim the cam arm and secure the shoes to get the best performance out of the brakes.

But

[Cam3512]

You guys are unbelievable.  Imagine you, Dave and Charlie under one roof!

I lost interest in my “- purchased” Benelli 250SS, and sold it last fall.  Went to a good guy, so I’m happy.

Cam

[Canuck750]

You guys are unbelievable.  Imagine you, Dave and Charlie under one roof!

I lost interest in my “- purchased” Benelli 250SS, and sold it last fall.  Went to a good guy, so I’m happy.

Cam

Thanks Cam!

I finished the front end and then found a pretty cool upgrade for the front brake



Benell / Moto Guzzi used this double sided single leading shoe Grimeca brake on the early 250 cc two stroke twins, I think Ducati used one very similar on the 350 Desmo. Its got functioning vents on both brake plates, the stock Benelli brake 'vents' are fake.



I bought a reproduction exhaust from Detlef Burian in Germany  www.benelliparts.de

Took a little trimming of the header pipe, about 4" too long to fit into the muffler





A new 428 chain fitted

[Canuck750]

I got this in the mail from the UK yesterday, a Grimeca double sided single leading shoe front brake, I spent an afternoon stripping off a horrible silver paint job smothered in soft clear urethane. Then sanding, still plenty of wet sanding and finishing plus getting the shoes relined.



I think this will be a great upgrade

[kballowe]

This just keeps getting better and better !