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General Category => Bike Builds, Rebuilds And Restorations Only => Topic started by: Canuck750 on September 28, 2021, 07:25:08 PM

Title: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on September 28, 2021, 07:25:08 PM
I am slowly gathering up enough parts to build a 200 Sprite, I plan on using the Motobi decals and rubber bits rather than the Benelli markings, all of the Sprite frames are actually stamped MOTOBI and in Europe I think the egg motor bikes were sold as Motobi's whereas Cosmopolitan had the bikes they imported marked as Benelli.

This is a Benelli Sprite, a 200 I think, a 4 speed 4 stroke single (5 speeds were also available)

(https://i.postimg.cc/TPXFn71m/egg.jpg) (https://postimages.org/)

In a typical moment of weakness I fell for an Ebay add listing an 'almost complete' Benelli 250 Baraccuda, after a lot of back and forth a crate came in the summer

(https://i.postimg.cc/6610t4fv/9-D31-CBA4-1418-4-A3-C-96-D7-389-DFBDB204-A.jpg) (https://postimg.cc/7b07N6cH)

After sorting and cleaning I found that quite a bit is missing or not correct and the bike is not a 250 Barrcuda, it is a 4 speed 200 Sprite.
Missing from the engine was the transmission shift drum and related bits, the rocker cover was damaged, the cylinder appears to be for a 250 but is overbored beyond spec. The front fender is wrong, the left side cover and chain guard are from different models. Missing a piston, exhaust and tail light, headlamp and trim ring and much more.

(https://i.postimg.cc/yx5XP28P/C7-D6-A130-1860-48-D0-8818-17-C4-C3-F4353-B.jpg) (https://postimg.cc/xNvzjxHJ)

I sent the frame and metal parts off to get blasted and coated with powder primer. I found what I think is the correct front fender

(https://i.postimg.cc/6QMVQzDj/1-E0-DE8-E4-9-C01-481-F-ADB9-FAF519962-D85.jpg) (https://postimg.cc/4KhHLv4V)

I am starting to put it together as a dry build to determine what I have to find

(https://i.postimg.cc/G38pVH2Z/47-E2-EAFB-291-B-45-D6-810-C-5-F070-EBCB292.jpg) (https://postimg.cc/rzTcty5J)

I had a complete rear tail light bracket and made up a tail light form parts I had on hand

(https://i.postimg.cc/4xkyGZMB/82-D100-C8-BFD7-4767-92-D7-18-F22-B59119-C.jpg) (https://postimg.cc/2VGrFpCZ)

I found a seat cover in Italy (I think) and I have rounded up the MOTOBI stamped foot peg rubbers, my box of parts had a headlight and a

The head spark plug hole is stripped, used a steel rod to set up the compound angle on the milling machine, I drilled out the hole and fittd a new steel threaded insert

(https://i.postimg.cc/pLFTR36F/003-F77-B0-5592-44-D6-8-CFD-8366-CE5205-FC.jpg) (https://postimg.cc/68BwhbwW)

123 Bearings in the UK has provided all the ball bearings for the engine cases, great service, very fast shipping!

Mac Dennis in the USA has been a great help tracking down parts for me!

The rear hub is missmatched, I think some of it is for a 5 speed model and some for a 4 seed model, Mac is looking for the correct parts for me

(https://i.postimg.cc/pLtJcmfZ/F0615-B75-A6-ED-4-B95-B557-ACA8277-FC007.jpg) (https://postimg.cc/svwWvD0Q)

Ebay has been a great source of NOS Benelli / Motobi parts, Santo-Di Moto-Cicli has a lot of the smaller parts, all NOS

Tracking down parts, especialy from Italy is a long slow process so I have multiple 'projects' on the go, all waiting for parts, I hope to track down the rest of the pieces over the winter and plan on getting it running then strip it down and get the painting and plating done.


Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on September 28, 2021, 09:07:13 PM
I'll be anxious to hear your perspective comparing this bike to your Aermacchi Ala Verde bike.  I've never had a Benelli/Motobi single (missed a chance to get two of them long ago) and always wondered how diferent or similar they are to ride.  Back then, I basically equated the two engines so getting those two Benellis wasn't a huge priority.

And I really admire your focus, Jim.  If I had 2-3 bike builds happening at once, nothing would ever get done..
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on September 28, 2021, 09:19:39 PM
I'll be anxious to hear your perspective comparing this bike to your Aermacchi Ala Verde bike.  I've never had a Benelli/Motobi single (missed a chance to get two of them long ago) and always wondered how diferent or similar they are to ride.  Back then, I basically equated the two engines so getting those two Benellis wasn't a huge priority.

And I really admire your focus, Jim.  If I had 2-3 bike builds happening at once, nothing would ever get done..

What I can tell so far is the Benelli motor appears to be over engineered, I found the same to be true when I rebuilt the Benelli 650 Tornado. Example; the crank shaft is supported with two ball bearings on each end, one a single row ball bearing the other a close spaced double row ball bearing. All the other engine shafts run in ball bearings and the oil pump design appears to be very robust. The frame on the egg motor bikes is a welded up box section affair, very rigid as is the case with the 650 as well.
On the other hand the Aermacchi engine is known to have received constant improvements over the years, first introduced on the Ala d’Oro GoldWing race bikes then trickling down to the street models. I don’t think Benelli/ Motobi ever developed the egg motors to the race level of Aermacchi. I personally think the Benelli is a more attractive package but the Ala Verde bikes are almost an equal.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on October 05, 2021, 08:20:00 PM
I got a nice box of used Benelli 200 Sprite parts in the mail today, just in need of a good cleaning

(https://i.postimg.cc/h4kpzBWF/17-CBA4-C2-6554-420-A-9-F58-A5-B43-E23-C5-A8.jpg) (https://postimg.cc/F1xj8wHG)

Going back and forth between the ultrsonic cleaner with a heated mixture of Simple Green / water (to lift the grease and sludge) and the vapour blast cabinet, the parts all cleaned up real nice

(https://i.postimg.cc/SQ2gxKP7/26-B4-B5-CA-00-DC-4163-AB06-9-BD4218433-D2.jpg) (https://postimg.cc/t7b3r9pY)

I was lucky to find the correct left hand side cover on EBay yesterday for a very good price, slowly the parts needed list is getting smaller
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Michael Moore on October 05, 2021, 09:50:57 PM
I had an assortment of Motobi stuff with the intention of building a 200GP AHRMA racer.  That's all been cleared out and some of the bikes have been built up and are used for NorCal Giro events.

The street Motobi engines are a LOT different from the Sei Tiranti factory replica race engines that the Zanzanis are still making and selling.  Most every set of crankcases I had were cracked, and the 5 speeds are less strong than the 4 speed cases.  My Benelli-Motobi email list is still active at micapeak.com, and Mac has been on it a long time, it might help you source more parts from around the world.

Cool engines, and I got to meet the Zanzanis when I went to Italy to go to the Mostro Scambio at Imola, but for a race project I would have been better off starting with an Aermacchi -- the street engines were beefier and much closer to the race engines.  Just about everything in a Sei Tiranti engine is different from the street bikes.

Here's a photo of Primo Zanzani building up an engine


(https://i.ibb.co/R4cWzQy/NUOVO-17.jpg) (https://ibb.co/R4cWzQy)


and a crank case being machined in their shop


(https://i.ibb.co/Dr99tMn/NUOVO-16a.jpg) (https://ibb.co/Dr99tMn)

classic langston hughes poem 4 letters (https://the-crosswordsolver.com/langston-hughes-poem-4-letters)


cheers,
Michael
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on October 05, 2021, 10:05:38 PM

Here's a photo of Primo Zanzani building up an engine


(https://i.ibb.co/R4cWzQy/NUOVO-17.jpg) (https://ibb.co/R4cWzQy)


and a crank case being machined in their shop


(https://i.ibb.co/Dr99tMn/NUOVO-16a.jpg) (https://ibb.co/Dr99tMn)

classic langston hughes poem 4 letters (https://the-crosswordsolver.com/langston-hughes-poem-4-letters)


cheers,
Michael

Very cool!

Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on October 06, 2021, 07:33:39 PM
I stripped down the headlight bucket that came with the project, its a typical CEV all in one unit, 6 volts; headlight, ignition cut out key, headlight switch, headlight running light, speedometer, and inside the shell the electrical junction panel, regulator and rectifier. I had a NOS headlight trim ring and headlight in my parts stash to fit this shell.

(https://i.postimg.cc/HWtgpTNL/3-C2-C2-BE5-0-FDB-41-AF-ADCC-B41779-CF1-B0-C.jpg) (https://postimg.cc/QVVPmZhL)

Vapour blasted the shell, wiped it down with metal etch, then a wipe of acetone and powder coated it satin black.

(https://i.postimg.cc/wvPG0bfn/BF84-D7-C5-C7-C7-4619-977-E-BBADC776-F284.jpg) (https://postimg.cc/xJv5dgSP)

I stripped down all of the components, the cut out switch was seized, its a very simple design, inserting the key and twisting it depresses a plunger that meets a contact that completes the circuit. By soaking the bucket with the switch intact in muriatic acid the rust bubbled out of the components and I was able to unscrew the switch from the shell then get the plunger freed up.

(https://i.postimg.cc/xd85h3zQ/A28-FE1-DB-AB8-A-400-A-A3-FE-D039863-D1-C6-A.jpg) (https://postimg.cc/Fft0JcpC)

I had new plated screws in my stash that secures the regulator and rectifier, the light switch bakelight handle polished up a bit, same for the running light plastic lens

I bought a trio of small size speedometers a couple years back thinking one day they would come in handy, one of them is a perfect match

(https://i.postimg.cc/Z5ZD7NHY/F9320-E4-C-8-ED6-40-D0-818-E-3956-C564-AF62.jpg) (https://postimg.cc/5673j6DD)

all done, I had to trim down the inner flange of the headlight trim ring to fit properly over the shell lip

(https://i.postimg.cc/Nj7ZBDFr/92054398-6-C60-4-F97-A12-A-64-BC946419-DC.jpg) (https://postimg.cc/LJ5xVzzH)

back on the forks for now

(https://i.postimg.cc/BZkrgtRt/589-D42-FB-9-EFD-4-B47-A574-C7-C8-C29538-D2.jpg) (https://postimg.cc/dDRNQQsK)

I also stripped down the seat and vapour balsted the sprung seat frame

(https://i.postimg.cc/K8k4WK8V/C7-CEDF56-A216-488-C-B848-15-D0-C07-DD99-A.jpg) (https://postimg.cc/QFDX9d5k)

painted it with POR-15 satin black, this stuff is sprayed direct to metal and once cured is almost as tough as powder coat (my oven is too small to fit the seat frame in)

(https://i.postimg.cc/htz67n2T/89575-A75-3351-4954-9-C1-F-C9-FAEE441-DA1.jpg) (https://postimg.cc/K1bJd6S8)

I found a supplier in Italy for reproduction seat covers, they have none in stock for this particular seat but told me to ship him my seat frame and original cover and they will make a reproduction for me. I have bought seat covers for other small displacement Italian bikes in the past and the quality is excellent

(https://i.postimg.cc/j2B6ppyY/AAD89-C91-3284-46-C4-890-F-5692-D8-AE9374.jpg) (https://postimg.cc/8fBrWnyZ)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: berniebee on October 12, 2021, 09:44:23 PM
Very cool little Benelli. Amazingly long hanger for the muffler. Looking forward to see it come together!

Will you do the blue/silver-grey colour combo?
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on October 12, 2021, 10:47:35 PM
Very cool little Benelli. Amazingly long hanger for the muffler. Looking forward to see it come together!

Will you do the blue/silver-grey colour combo?

I am leaning to the blue / silver scheme, going to put the Motobi decals on it, all the Sprite frames are stamped Motobi, I think Cosmopolitan had all the Sprites they imported badged Benelli as that was the line they were marketing, by this time Motobi had been reabsorbed into the Benelli fold and the Motobi branded bikes were limited to Europe. I like the red and silver as well but I already have a few red bikes. I like the Motobi decal design better😉
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: riguzzi on October 25, 2021, 09:48:49 PM
I had a 250 when I was a young fellow in New Zealand. With a few minor tweaks it was a great bike that could lean over unbelievably far. I eventually put a different seat, clipons, megaphone, carb and raced it with some success, but the crankpin was very weak. I ended up rebuilding the crank every few races.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on December 17, 2021, 06:22:09 PM
my super cheap wheel building jig!

(https://i.postimg.cc/QttKbqd4/D39-C808-E-4431-46-C8-A8-D3-378-E03991-ECB.jpg) (https://postimg.cc/4KD34VtV)

A gallon paint can and a couple quart cans blocked up with wood scraps, works great for fitting spokes, I got a new set of stainless steel spokes and nipples from Buchanans, I am amazed the catalogue of specifications they have on file, I called them and asked for a rear set of spokes for a 1965 Benelli 200 Sprite, not a probelm they said, have the full specs for length and gauge, they fit perfect and cost about $110.00 and come with the assembly grease to keep the stainless nipple seizing on the stainless spoke.

Buchanans even had the specs for the 1961 Aermacchi with 17" rims (one year only).

True the rims up on a cheap balance stand and a dial gauge,

(https://i.postimg.cc/nhXHVqSt/99532-B86-B3-AE-4703-90-C0-0094-D81-F6-E5-B.jpg) (https://postimg.cc/xXSrtNSs)

A new pair of Duro tires and this 1965 will be back on two wheels after a very long slumber resting in peices.

Long time Benelli / Motobi Ebay parts seller "santo_di_motocicli" came up with a NOS rear wheel hub with brake plate and sprocket plate, amazing what still come up for sale
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on December 20, 2021, 08:25:23 PM
I had a 250 when I was a young fellow in New Zealand. With a few minor tweaks it was a great bike that could lean over unbelievably far. I eventually put a different seat, clipons, megaphone, carb and raced it with some success, but the crankpin was very weak. I ended up rebuilding the crank every few races.

Any pictures of your race bike?
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Scout63 on December 20, 2021, 10:03:51 PM
my super cheap wheel building jig!

(https://i.postimg.cc/QttKbqd4/D39-C808-E-4431-46-C8-A8-D3-378-E03991-ECB.jpg) (https://postimg.cc/4KD34VtV)

A gallon paint can and a couple quart cans blocked up with wood scraps, works great for fitting spokes, I got a new set of stainless steel spokes and nipples from Buchanans, I am amazed the catalogue of specifications they have on file, I called them and asked for a rear set of spokes for a 1965 Benelli 200 Sprite, not a probelm they said, have the full specs for length and gauge, they fit perfect and cost about $110.00 and come with the assembly grease to keep the stainless nipple seizing on the stainless spoke.

Buchanans even had the specs for the 1961 Aermacchi with 17" rims (one year only).

True the rims up on a cheap balance stand and a dial gauge,

(https://i.postimg.cc/nhXHVqSt/99532-B86-B3-AE-4703-90-C0-0094-D81-F6-E5-B.jpg) (https://postimg.cc/xXSrtNSs)

A new pair of Duro tires and this 1965 will be back on two wheels after a very long slumber resting in peices.

Long time Benelli / Motobi Ebay parts seller "santo_di_motocicli" came up with a NOS rear wheel hub with brake plate and sprocket plate, amazing what still come up for sale

Just found this thread on the bump.  Great pictures and wonderful work.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on December 20, 2021, 10:09:13 PM
Just found this thread on the bump.  Great pictures and wonderful work.

Thanks! It’s just a cheap little 4 stroke single but I have a soft spot for the Benelli / Motobi brand, they had a wide range of bikes that get little coverage these days.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on January 07, 2022, 08:12:01 PM
I got my Benelli / Motobi seat back from Italy today, less then three months turn around, even though I had cheaped out and shipped the frame and old cover by surface to the upholstery shop.

They did a fantastic job copying the old seat pattern, mounting to the frame and adding the grab strap.

(https://i.postimg.cc/FFBmkg2F/7472-B79-A-9857-44-C7-B96-C-852-A4-E028-F55.jpg) (https://postimg.cc/kDKLk8JL)

(https://i.postimg.cc/cHJyrrh8/868-C0-F13-42-BA-4821-959-F-E95-EC1422349.jpg) (https://postimg.cc/XZtDPNTV)

they remounted the original name plate, I had asked if they could find a Motobi emblem but no luck, cocst me just over 100 Euro plus shipping there and back

(https://i.postimg.cc/rwSLb6zz/E8-F785-CC-9-F3-C-4-F0-A-923-A-5-DC5-FCCBA598.jpg) (https://postimg.cc/MnK4MF78)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on April 06, 2022, 02:56:26 PM
I have been making some progress of late on the Benelli 200 Sprite, I think I may have sourced all the missing engine / transmission parts,

(https://i.postimg.cc/661WVyWx/D4398-E6-C-4-BDC-44-F3-8-BBD-9-CC850613960.jpg) (https://postimg.cc/NLmvBG2d)

All new case bearings from 123 Bearings  https://www.123bearing.com/
 
missing transmission and engine parts from Mac Dennis  - (New York State) Moto Spares LLC  - Motospares@fastmail.net / Detlef Burian (Germany) Benelliparts.de / William Kuehn - Santo Di Motocicli - (Ebay USA) liamkuehn@gmail.com

(https://i.postimg.cc/ZKBTw4nB/C00-AA015-D537-4002-AAC3-C36-AA74-C9-D44.jpg) (https://postimg.cc/2VYR6p4r)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Antietam Classic Cycle on April 06, 2022, 08:26:11 PM
 :thumb:
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on April 25, 2022, 09:14:10 PM
I have come to a stand still with the Benelli Sprite motor build, the crank shaft that came in the boxes of parts appears to be for a 5 speed 250 and not a 4 speed 200. I was able to find what was advertised on Ebay as a 150 / 175 / 200 Sprite 4 Speed crank shaft, good and bad, the con rod is good but the crank web pieces are worn out, the pin just about falls out. I need to find at a minimum a pair of crank webs but the sources I have been using don't have any.

worst case my machinist says he might be able to use the pin out of the 250 crank and bore out the 200 crank webs to take the bigger pin (the 200 pin is stepped with 20mm for the webs and 24mm for the big end, the 250 pin is a straight 24mm).

These are the basic dimmensions of the crank shaft I am after should anyone have one available :rolleyes:

(https://i.postimg.cc/Bb9w6j0H/80-F824-BF-6-F48-4-BCB-AE50-69-DE64-A1-F9-A8.jpg) (https://postimg.cc/9RbBgFzQ)

(https://i.postimg.cc/YSPs5XDX/E6-B32-E85-738-E-4548-9-A79-87746-C363664.jpg) (https://postimg.cc/v1Wh9vs9)

(https://i.postimg.cc/xd8ZFr5J/A65-D6-B77-94-F9-4439-A1-FC-849-EBB1-C8775.jpg) (https://postimg.cc/Lqdvnbr2)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on June 17, 2022, 07:47:42 PM
A bit of progress on the Benelli Sprite, I found a decent crank shaft (it came with a motor  :grin:) and the good news is the engine is a 4 speed 250 (74mm bore), good head, cylinder, crank and transmission but one of the cases is cracked, might be able to get it welded up.

(https://i.postimg.cc/mZFmNS7T/030-B57-DD-1-EE8-40-DD-B342-33-B7-B7-CD1108.jpg) (https://postimg.cc/hhc8KTCY)

Ebay seller - santo_di_motocicli (William Kuhen) has a NOS oversize piston / rings so I think I can build a 250cc motor for the bike and put the 200 4 speed engine on the shelf for when I find a decent crank for that motor.

The Ebay seller ( yz12910rv ) gave me a very generous refund for the cracked case, there are good people out there!

(https://i.postimg.cc/0yKF6qZ0/9-FD9209-F-08-DB-453-F-B091-4401-C8-F6560-D.jpg) (https://postimg.cc/xXYt7hwX)

Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Muzz on June 20, 2022, 05:03:17 AM
I don't see a picture of the inside of the head Jim, although the valve angles say it is a hemi. piston is a flat top.  Any idea of the compression ratio?
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on June 20, 2022, 04:55:39 PM
I don't see a picture of the inside of the head Jim, although the valve angles say it is a hemi. piston is a flat top.  Any idea of the compression ratio?

It's a Hemi head Muzz,

250 cc Barracuda, claimed compression of 8.5:1 - 24 hp at 8500 rpm,  232 pounds and a maximum speed claimed 95 mph with the 4 speed and 80 mpg.

200 cc Sprite, claimed compression ratio 8.8:1 - 19.5 hp at 8600 rpm, 231 pounds, claimed top speed 90 mph, fuel consumption 85 mpg, 4 speed.

The retail on the 250 SS in 1971 was $769.00 from Cosmopolitan (dealers cost $577.00)

(https://i.postimg.cc/pTh9nXX5/8-A82-B4-DF-F8-F0-4769-8064-C6330875745-B.jpg) (https://postimg.cc/5YJ9hJzf)

(https://i.postimg.cc/PJ1P23Dt/7-F76-D98-D-78-BD-442-F-893-C-DD1-E62-D0-C0-AB.jpg) (https://postimg.cc/2L8k5xTJ)

(https://i.postimg.cc/FRMYb57W/2-E3498-A6-C482-476-D-92-DF-F4-D39695-A1-E2.jpg) (https://postimg.cc/G8j3rfPG)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on August 28, 2022, 06:21:45 PM
I have been making slow progress on my Benelli 200 Sprite, its been a long search to find a good sued crank shaft and a bunch of the small pieces of hardware, bearings, seals and gaskets, I had to make up some spacers and shims on the lathe but I am close to having a running motor, I hope.

The cases have been rebuilt with new bearings and seals, replacement crank, new oversize piston and the head is off to get new guides and a valve grind.

(https://i.postimg.cc/cC6JfKXk/7009088-F-A275-4433-93-F8-DE073-D417273.jpg) (https://postimg.cc/K3SF2YXt)

Found a crack in the case from where the bike probably went down on the right hand side and the kick start shaft pressed against the retaining bush, my welder friend touched it up and it will be solid

(https://i.postimg.cc/FsPB9xmy/72-B0-E696-C6-C1-4-E6-E-A93-D-0228-FA1222-C1.jpg) (https://postimg.cc/CzqN7kR5)

Benelli does not call for a center case gasket but I fond the shafts bine without one so I made up a gasket and now the gears and shafts spin free

(https://i.postimg.cc/KjG0b1Hp/9-D057-D07-6-E4-E-4-D83-9390-4727-E65-A73-CF.jpg) (https://postimg.cc/34qXCx72)

(https://i.postimg.cc/bNY5c5XY/84-A29250-E0-A0-49-B9-A0-A4-8239009-C5-EBD.jpg) (https://postimg.cc/HjKzbBsF)

unique clutch pressure plate attachment and the basket springs actually tread into the basket, the spring pitch is M12 x 2

(https://i.postimg.cc/fbjksQVC/EDBA9-ABE-75-FA-4-A8-B-B272-32995-D27-A3-EC.jpg) (https://postimg.cc/sBx3P89G)

The stator plate and coils are a mess, will probably need to have thrm rewound

(https://i.postimg.cc/W1Zh9kjQ/C59-E0-B4-B-04-DA-4-A7-A-8-D08-762-ABF925-A2-B.jpg) (https://postimg.cc/689WqT80)

Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on August 29, 2022, 06:18:50 PM
I cleaned up the stator plate and fitted a NOS lighting coil

(https://i.postimg.cc/nzBzKFfm/8-C88-D97-D-C4-BE-4-D40-8-F65-8811-F36-D1309.jpg) (https://postimg.cc/bDYppjJY)

fitted the stator

(https://i.postimg.cc/02dSRC3S/9-B55-CB6-B-D5-F2-4250-BE8-F-A0257-ABAA90-A.jpg) (https://postimg.cc/Xpqq99nN)

The parts manuals for the  125, 200 and 250 list different rotors for each bike but I think the stators are the same, all use the same lighting and ignition coil part numbers

Al of the rotors are the same dimensions but each as a unique weight. Regardless I don't think the rotors are sitting deep enough on the crank shaft taper, not a lot of threads sticking out. The manuals have unique part numbers but the numbers stamped on the rotors donlt seem to have any correlation to the parts numbers.

(https://i.postimg.cc/XvhGc1ZR/67-BC1-A29-E305-4039-AD2-A-94-E02-D49-EC37.jpg) (https://postimg.cc/JyNzRq5x)
(https://i.postimg.cc/ZnPWmTfm/FF596707-5900-42-AE-9794-C9000-D0-B273-A.jpg) (https://postimg.cc/vxBYLdF2)
(https://i.postimg.cc/c4ZKmnHL/0-E0-DF001-7-FAB-4885-A8-CB-67-F953-D5-CB64.jpg) (https://postimg.cc/rznFyzxB)

If anyone knows these motors I would sure like to hear from you  :undecided:

(https://i.postimg.cc/jdrfF18K/B87-C579-A-D68-F-4-B50-96-F0-0-E16-EBC28-F78.jpg) (https://postimg.cc/DmBmWxkY)

This is the problem with buying a bike in parts, not having any history of working on them and not a lot of knowledge out there on the variations of thee three Egg motors.

This Benelli has been a deep dive down a rabbit hole and I haven't seen daylight yet.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on September 01, 2022, 07:14:16 AM
I really like what you’re doing with this project in particular, Jim.  The obscurity of the specific details of many of these bikes often seems to define them as do run or will never run.  fixing them with any manner of originality can be really tough and definitely not financially realistic.    Thanks for sticking with this project and for posting so many details.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on September 01, 2022, 10:17:01 AM
I really like what you’re doing with this project in particular, Jim.  The obscurity of the specific details of many of these bikes often seems to define them as do run or will never run.  fixing them with any manner of originality can be really tough and definitely not financially realistic.    Thanks for sticking with this project and for posting so many details.

Thanks Clint!
I think I may have solved the Rotor, I took the worst one as a test and chucked it in the lathe then with a small boring bar cut back the outer surface around where the retaining nut seats, took of about 6mm so now the nut has plenty of threads. The position of rotor to Stator appears to be ok.
I got into Rome today and plan on getting to the big Imola swap meet on the weekend of September 10, hopefully I can spot some Benelli/ Motobi things amongst the 3000+ vendors that are expected. I would like to find a NOS ignition coil for the Stator and a bunch of bits for my 61 Aermacchi Ala Verde tribute. Friends have sent me a list of obscure parts needed for restorations.

Jim
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: blackcat on September 03, 2022, 04:34:25 PM
First time looking at this thread, nice job!
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on September 06, 2022, 12:45:18 PM
First time looking at this thread, nice job!

Thanks! I am in Italy, near Milan, Mandello tomorrow. I am going to the Imola swap meet on Saturday to look for some parts for the Benelli and my Aermacchi project.

Cheers

Jim
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on September 29, 2022, 09:42:48 PM
I was fortunate to visit the Benelli / MotoBi museum in Pesaro Italy, in September, located in what remains of the once large Benelli / MotoBi factory in the center of town. On the display floor amongst many other fantastic machines is this MotoBi Sprite 200, I took many pictures of the machine for reference purposes. I think I will go ahead and paint it this colour and label it as a MotoBi.

Unfortunately I don't have the European style triple clamps / fork ears and clip-ons that are on this bike, Cosmopolitan imported these labeled as "Benelli" and they came with typical American style hi-rise type handle bars clamped to the top triple, I will fit some flat or clubman style bars.

(https://i.postimg.cc/Pfz6PDt6/48-E90243-43-E8-4039-8-CED-29478-F66-C21-C.jpg) (https://postimg.cc/Lh5kWngf)

(https://i.postimg.cc/tCJhpn7n/F4-A5-D904-3504-40-AA-9-C29-B833-BABD4-F92.jpg) (https://postimg.cc/KRXK5zPm)

(https://i.postimg.cc/YCXZjWxc/43-E8771-D-13-E7-4-FC0-B39-E-D27693-AB9736.jpg) (https://postimg.cc/fV9BrkF5)

(https://i.postimg.cc/4ybFG73S/C54-FCFCA-232-A-4969-8-F74-E6-FD12-E9615-D.jpg) (https://postimg.cc/JH0QchZN)

(https://i.postimg.cc/nLB4N8rd/103231-D9-13-BA-41-D5-AB71-88312-BA732-B9.jpg) (https://postimg.cc/3yr0Dcgp)

(https://i.postimg.cc/NfnRMGrJ/8-B1-DD78-E-BFA7-46-A9-8-D8-E-C452913-CDC80.jpg) (https://postimg.cc/0bpzXsnD)

(https://i.postimg.cc/BvXyFnhj/0-E7-A6786-1-FC8-468-E-BE02-BC9098-BBD223.jpg) (https://postimg.cc/Z9zVt4zm)

(https://i.postimg.cc/5NgkkCTH/10676-FC2-FCCB-4140-98-B7-D4-BFF503-F2-AA.jpg) (https://postimg.cc/JGyqsG1m)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: huub on September 30, 2022, 06:24:39 AM
for the dansi ignition ,
my MV 350 was fitted with a dansi ignition , of course the stator coil had failed.
i fittedd a new guzzi TS 250 coil  ( they also had dansi ignition. )
apparently lambretta scooters has the same coils,  aftermarket lambretta parts are easy to find.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on September 30, 2022, 10:31:01 AM
for the dansi ignition ,
my MV 350 was fitted with a dansi ignition , of course the stator coil had failed.
i fittedd a new guzzi TS 250 coil  ( they also had dansi ignition. )
apparently lambretta scooters has the same coils,  aftermarket lambretta parts are easy to find.

That is great information!!
Thank you so much

Jim
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on October 10, 2022, 02:06:48 PM
One thing I learned from my visit to the Benelli / MotoBi Museum this summer is that for the most part the fasteners on the bikes appear to be chrome with no face stamping

(https://i.postimg.cc/C18Qv6pY/A2508883-8-AD6-467-E-8-DF9-9-EDC8-E7-F2412.jpg) (https://postimg.cc/wy62M2Bb)

The fasteners on my project were badly corroded and I did clean them up and have them cad platted but the finish is nowhere as nice as the chrome bolts I would like to have, but chrome is very expensive and I have had bad results in the past trying to get bolts re-chromed. So for this bike I bought a bunch of new stainless steel bolts and nuts but the faces are stamped and the stainless is not bright polished

(https://i.postimg.cc/zDMD168m/9-D537442-AC68-4715-AED9-A6-DAD6-FAC570.jpg) (https://postimg.cc/V5qPq7J4)

I filed off the face stamping, then I ran a foam pad random orbital sander with 240 grit over the face and slightly domes the top surface followed by a buffing on a coarse wheel with white polish

(https://i.postimg.cc/wTmqx2j1/9-FAD5014-FD12-4-B11-9-F07-657-DE8-FA9681.jpg) (https://postimg.cc/rKqXQSWT)stores open 24 hrs near me (https://gasstation-nearme.com/open-24-hours)

I replaced all the 6, 8 and 10 mm bolts and nuts, the results are hard to tell that the fasteners are not chrome

(https://i.postimg.cc/ht8KTGxg/A3423292-57-C4-4-D46-A835-596280858-B8-F.jpg) (https://postimg.cc/sMXFRsw0)

(https://i.postimg.cc/Rh3MHQ1b/22-F50-E87-230-A-4-AFC-BBC9-73-EC78-AC6-C9-E.jpg) (https://postimg.cc/2LDRpWK4)

(https://i.postimg.cc/KYZxNyrT/F917-D8-A7-6-A55-4-C70-9257-E16-AF19-E8-CED.jpg) (https://postimg.cc/NKP3sSnG)



Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Antietam Classic Cycle on October 11, 2022, 08:55:19 AM
I've seen more than a few "fresh from the crate" Benellis and none had chrome plated bolts. My guess is whoever restored the bikes for the museum added that touch.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on October 11, 2022, 10:38:17 AM
I've seen more than a few "fresh from the crate" Benellis and none had chrome plated bolts. My guess is whoever restored the bikes for the museum added that touch.

Good point Charlie. Going through my museum pictures I can see that all of the mini bikes have standard bolts with face markings. Most of the egg motor bikes have polished heads on the bolts but not all. The 1967 125 Sprite has a bit of both. Maybe early Motobi models had chrome or polished stainless or perhaps, like me, the person who restored the bikes on display prefers a little more bling.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on October 18, 2022, 04:26:27 PM
I bought a pair of cheap chrome shocks, 12" eye to eye for the Benelli, I will eventually strip the shocks down and paint the bodies black to look like the originals, the outside diameter of the springs are a bit larger but its ok for what I am after.

(https://i.postimg.cc/fyTKkGQg/IMG-4757.jpg) (https://postimg.cc/XGmFzDJw)

https://www.ebay.com/itm/292976459948
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on October 31, 2022, 06:31:42 PM
Waiting on some engine parts to move forward so in the meantime I made up a fresh set of axle nuts; an odd size, M15 x 1.25, 22mm wrench size. I used 304 Stainless a steel rod, 25 mm (1”) diameter, cut the flats on the milling machine and bored the center to cut the threads with a tap, parted to length on the lathe. A lot of work for three nuts but this is a very hard size to find, could only find them in the UK as Ducati single axle nuts, would cost me about $12 a piece, not that I saved anything with the cost of stainless and cobalt drill bits to bore out the centre’s.

(https://i.postimg.cc/vB982kB4/9-B7-CF8-F8-B18-D-4-CBE-9-CFE-B6-C0-A2853-A6-A.jpg) (https://postimg.cc/Vrfcd7Xw)

(https://i.postimg.cc/NFcs3D9p/D60965-C6-F3-C1-4936-B5-B3-2-A4-D56-CBFBFF.jpg) (https://postimg.cc/cgFGYQcn)

I took a shot at making stainless dome nuts for the shocks, a lot of work, I found the correct thread pitch of M10 x 1.0 stainless on eBay for a reasonable price.

(https://i.postimg.cc/xdBTRn0r/FD8137-CB-21-E7-44-C2-B1-D0-0-A751-DCBDE06.jpg) (https://postimg.cc/v1Ls8RgX)

Made up stainless washers as well for the 15 mm diameter axles. Something very satisfying about making something so simple.

Three nuts, three washers, three hours later, good thing I am not doing this for a living!



Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on October 31, 2022, 07:17:36 PM
Very cool- I like them, Jim.  That’s the whole point of having the machines in the first place. 

On Sat, I did similar work making a couple of spacers for the slightly long throttle cables on my CX.  Eventually, I’ll shorten the cables but didn’t feel like that much fiddling work at the time. 
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on October 31, 2022, 10:07:00 PM
  the whole point of having the machines in the first place. 


Very true Clint. I wonder though if the need to make something precedes the purchase of a tool or does owning the tool create a need to make something? The more I explore machining the more I think I can make, fix or create and this keeps leading to purchasing more tooling.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Huzo on October 31, 2022, 11:29:12 PM
So this a Benelli ?
(https://i.ibb.co/MRdNFHz/B9-A5-B423-82-BC-4-A47-83-E8-A3-AA3-AC91-DDD.png) (https://ibb.co/MRdNFHz)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: 2WheelsUp on November 01, 2022, 08:57:23 AM
Just stumbled across this thread... amazing work on a beautiful bike! In the past I had little to no interest in bikes of this era but since viewing builds like this on the forum over the last year I now appreciate the quality and technology that goes into them. Wish I had the skills and knowledge to offer technical advice, all I can say is to keep doing what you do.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on November 01, 2022, 10:21:36 AM
Very true Clint. I wonder though if the need to make something precedes the purchase of a tool or does owning the tool create a need to make something? The more I explore machining the more I think I can make, fix or create and this keeps leading to purchasing more tooling.

Not sure how it works at your place, Jim, but the line between “need to buy” and “excuse to buy” often gets blurry around here.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 01, 2022, 10:27:52 AM
So this a Benelli ?
(https://i.ibb.co/MRdNFHz/B9-A5-B423-82-BC-4-A47-83-E8-A3-AA3-AC91-DDD.png) (https://ibb.co/MRdNFHz)


Yep, Benelli retained the MotoBi label after the MotoBi wing of the family where brought back into the fold. The two stoke twin was developed during the DeTomasso reign and was also badged as as a Moto GUZZI.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 01, 2022, 10:31:51 AM
Just stumbled across this thread... amazing work on a beautiful bike! In the past I had little to no interest in bikes of this era but since viewing builds like this on the forum over the last year I now appreciate the quality and technology that goes into them. Wish I had the skills and knowledge to offer technical advice, all I can say is to keep doing what you do.

Thanks Two Wheel, I never used to pay attention to the smaller bikes but now I find I am fascinated by all the small displacement Italian bikes that were so popular in the 50’s and 60’s. The quality of the engineering in the small machines is pretty high. I particularly like the aesthetic of the MotoBi / Benelli ‘egg’ motor bikes.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Huzo on November 01, 2022, 10:33:03 AM
Yep, Benelli retained the MotoBi label after the MotoBi wing of the family where brought back into the fold. The two stoke twin was developed during the DeTomasso reign and was also badged as as a Moto GUZZI.
I thought of no one but you when I saw it.
A roadside two bit vendor had it for sale at €500….
He did not start it, but had no qualms about doing so if I’d wished. Was on the way from Venice to Cortina in the Dolomites.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 01, 2022, 11:30:09 AM
I thought of no one but you when I saw it.
A roadside two bit vendor had it for sale at €500….
He did not start it, but had no qualms about doing so if I’d wished. Was on the way from Venice to Cortina in the Dolomites.

That’s looks pretty nice for 500 Euro! I read they were decent bikes but I don’t think they had oil injection. If it were on this side of the Atlantic it would be on its way to my garage for that price.
Thanks for posting!
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Huzo on November 01, 2022, 11:47:36 AM
That’s looks pretty nice for 500 Euro! I read they were decent bikes but I don’t think they had oil injection. If it were on this side of the Atlantic it would be on its way to my garage for that price.
Thanks for posting!
No worries.
Reply #176 on my trip thread reveals a lot more.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Antietam Classic Cycle on November 01, 2022, 03:53:02 PM
That’s looks pretty nice for 500 Euro! I read they were decent bikes but I don’t think they had oil injection. If it were on this side of the Atlantic it would be on its way to my garage for that price.
Thanks for posting!

Sold in the US as the Benelli Phantom. Down on horsepower from their Japanese contemporaries, largely due to smaller ports. Cast in provisions for an oil injection pump and delivery lines, but one was never fitted. Conjecture was that they meant to use a Mikuni oil pump, but since it was imported it would have had a tariff attached. Would have driven the cost of the Phantom even higher.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 05, 2022, 04:08:54 PM
The 'before' picture, a big box of joy arrived via UPS this week, a box only a gear head could love

(https://i.postimg.cc/RVhpp9sh/BFD2-F002-3-C2-A-4-ACB-8-D22-4486-FC2957-AE.jpg) (https://postimg.cc/BXWCXWGf)

The engine sat in the ultrasonic cleaner overnight in Evaporust, it was pretty clean this morning but neither the crank pinion gear or the magneto were in the mood to leave the engine behind despite my best coaching with pullers and a big impact.

The magneto did eventually come free with a lot of small taps with a brass hammer on the end of the puller bolt torqued down as much as the impact would deliver, it came free with a thud, shot up a couple inches and gave up.

(https://i.postimg.cc/5tWSqMQX/648289-E0-C4-AA-4353-B7-D6-CEFE0126272-B.jpg) (https://postimg.cc/9D19CKp2)

The crank pinion was another beast, one of the puller leg threaded studs snapped clean off from the pressure but the pinion did not budge.

(https://i.postimg.cc/tJs6GrV0/2-F89-B049-2-AA5-4402-93-CD-C4-EA7-F1-E14-C0.jpg) (https://postimg.cc/8fVchmHw)

After replacing the puller leg I took the block to the welding table, crossed my fingers and struck up the oxy/acet, a slightly carbon flame and with the puller cranked to the nines I touched some heat on the gear, bang, almost immediately the puller and gear literally flew off the crank shaft end and fell to the floor. Success!

The crank feels real good, it was the crank I needed most for another engine, stator and magneto and some gears and hopefully I will finally have a complete 200cc motor for my Beneli / Motobi build.

Everything stripped and vapour blasted, lots of parts to now sort through and pick the best between two motors

(https://i.postimg.cc/nVSKSmQb/0-DB82-B99-97-A8-4-EAD-97-E3-C5-F4-AB8-D3696.jpg) (https://postimg.cc/bdb2ssT3)

(https://i.postimg.cc/k4fNm61S/75-D8-BAF2-BF0-F-4100-BA3-C-08-A679-AA47-CA.jpg) (https://postimg.cc/9RwwPMjX)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on November 06, 2022, 06:36:57 PM
Very cool.  Glad to hear about good progress.

But what about having most/all of a spare egg motor lingering around the shop…? Do you think it may serve as the grease on that slippery slope to a second Benelli?
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 06, 2022, 07:49:24 PM
Very cool.  Glad to hear about good progress.

But what about having most/all of a spare egg motor lingering around the shop…? Do you think it may serve as the grease on that slippery slope to a second Benelli?

A confession:

I bought a complete (well mostly complete) 200 Sprint along with the motor, the second box is still on transit, fingers crossed it arrives! UPS has been a nightmare for shipping to Canada, had to fight to get duties and taxes reduced from $492 to $92, on top of shipping.

In any event my plan is to build a 250 racer type for a regional hill climb in British Columbia called the Rocky Mountain Giro. I have accumulated a complete 250 egg motor (early 4 speed) and after seeing the faired Motobi racers in Pesaro I have a new itch to scratch. The long fibreglass race tank, short hump back seat, rear sets, clip ons and 2LS front brake on Borrani rims is calling to me.

I have been secretly thinking of an Aermacchi Ala d’Oro race replica using a Harley Aermacchi race frame (ERS type) I have got a hold of and fitting a dry clutch 350 five speed motor to it, will still pursue collecting parts for that long term build but a Motobi racer is going to be a cool project as well.

It’s a disease, hopefully incurable, and I have ideas for custom rear sets, triple clamps etc I could take a try at fabrication.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on November 06, 2022, 08:06:22 PM
A confession:

I bought a complete (well mostly complete 200 Sprint along with the motor, the second box is still on transit, fingers crossed it arrives! UPS has been a nightmare for shipping to Canada, had to fight to get duties and taxes reduced from $492 to $92, on top of shipping.

In any event my plan is to build a 250 racer type for a regional hill climb in British Columbia called the Rocky Mountain Giro. I have accumulated a complete 250 egg motor (early 4 speed) and after seeing the faired Motobi racers in Pesaro I have a new itch to scratch. The long fibreglass race tank, short hump back seat, rear sets, clip ons and 2LS front brake on Borrani rims is calling to me.

I have been secretly thinking of an Aermacchi Ala d’Oro race replica using a Harley Aermacchi race frame (ERS type) I have got a hold of and fitting a dry clutch 350 five speed motor to it, will still pursue collecting parts for that long term build but a Motobi racer is going to be a cool project as well.

It’s a disease, hopefully incurable, and I have ideas for custom rear sets, triple clamps etc I could take a try at fabrication.

Misery (ecstasy?) enjoys company,  Jim.  Numerous projects are waiting here, too- Guzzi, Ducati, HD, Aermacchi and more.  Then, when I went next door a couple of hours ago, my mother had set out a few pics she had found of me in the TR3B from when I was 16 & 17.  It’s also waiting in the garage for some r&r love and attention.  Man, I love that old car… 

Maybe we can convince each other along the way that there’s really nothing wrong with doing what we love to do…
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 07, 2022, 10:47:59 AM
Maybe we can convince each other along the way that there’s really nothing wrong with doing what we love to do…

Well said Clint!
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 08, 2022, 05:44:34 PM
Another stuck part, the rocker pins are secured into the cast body with set screws, these small ( M 5) set screws have a pointed end which mate to a groove in the dowels. The dowels are not moving smoothly, probably rusted and full of gritty oil.

The set screws are stuck, really stuck, I drilled out the staked edges of the screws, tried tapping, tapping ... and more trapping, penetrating fluids and finally heat, no way they would budge. I clamped the casting in my mill vice and drilled out the set screws, I used an 8 mm diameter end mill, it will work with the 6 mm steel inserts I have.

(https://i.postimg.cc/6qSKTQZx/AC00-D2-C9-1-A33-459-F-BC05-5280-AB250488.jpg) (https://postimg.cc/p5D46Rks)

tapped the cast body to take the new steel inserts

(https://i.postimg.cc/j2CKsfLh/A3838-FBF-5-A33-4094-A34-B-E5-F9-EDA3237-D.jpg) (https://postimg.cc/T58B0pjy)

screwed the inserts in, then using a 10 mm end mill cut out the section of the insert that fell below the 11 mm dowel pin opening, then used a 11 mm reamer to get the correct finished opening

(https://i.postimg.cc/pX4VLsQ5/4-E14-DB9-F-3-D50-4-BA9-A429-6-E4-C0-CF7-E258.jpg) (https://postimg.cc/ZCPzfFMJ)

(https://i.postimg.cc/yNF850Zg/6-F910-ED9-3-B09-44-C0-B3-A4-D17-EAE0-B4-FF0.jpg[/img[/url]

[url=https://postimg.cc/ZCPzfFMJ][img]https://i.postimg.cc/pX4VLsQ5/4-E14-DB9-F-3-D50-4-BA9-A429-6-E4-C0-CF7-E258.jpg) (https://postimg.cc/p9Lv5hkR)

I made new 6 mm set pins from a 6 mm x 1.0 stainless steel bolt with the end turned down to a point

(https://i.postimg.cc/VNyNDKdP/A02-C82-A6-10-B3-4817-8437-5-CAAA269-DD76.jpg) (https://postimg.cc/CRNYKHGc)

(https://i.postimg.cc/cH0LN6RD/1-DFDEE7-F-BAD4-4516-9-F6-A-1504782-F68-C4.jpg) (https://postimg.cc/Mc3S76rR)

marked the depth with blue marker, then cut off the bolt and saw cut a flat slot into the stub

red locktight to secure the new set pins, pre-oiled the pins and reassembled the rockers and sprung washers

(https://i.postimg.cc/dVCskGnH/06-F24-D8-A-D18-F-4-F5-F-8459-7-C6314-A59-C02.jpg) (https://postimg.cc/jDs0BwpP)

One more part ready to reassemble.

I am going to try and make up new bronze valve guides, the guides are so badly worn, the motor must have smoked like crazy when it last ran.



Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 12, 2022, 09:48:24 PM
One last bit of work on the replacement crankcases, Benelli used a couple roller bearings in steel cases for the cam support, earlier versions of the motor I have used caged rollers open on the inner and outer faces. These steel cases seize to the steel bearing supports, not an ideal design but I am sure Benelli never thought these old nails would be brought back to live some 55 years on.

The steel cases would not budge so I poked the rollers out and used my MIG to weld a healthy bead along the circumference of the roller case and across a face to knock it out.

(https://i.postimg.cc/sDFTZv1x/057D706C-4D0E-4800-BF6E-C2E5DCB1DD48.jpg) (https://postimg.cc/14HGkRG1)

Let it cool and it pokes free with little effort

(https://i.postimg.cc/7hzXWytq/93099541-1EC9-4C8E-BBA6-875B4228E17D.jpg) (https://postimg.cc/H8pQrFCN)

I found a listing on eBay for a company in the UK that will make any valve guide, I ordered four, they will run me about $40 a pop all in. I can barely buy the stock guide material for that price. I sent them this sketch to make up new guides. I found a 7.5 and 7.48 mm reamer on eBay from China for cheap to finish the guides to my used valves. Based upon factory tolerance I should finish to 7.48 based upon the slight stem wear of the valves.

(https://i.postimg.cc/90CdgYV8/E405B6C2-D485-46C1-A4FE-FFDE7BC5AAE0.jpg) (https://postimg.cc/62b4yR8n)






Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 14, 2022, 06:13:03 PM
I pressed the con rod small end bush out of the replacement crankshaft I picked up. Glad I did, not only is the fit to the piston pin sloppy but the bush is cracked.

(https://i.postimg.cc/TPLgkmVh/41-B00-EB6-9287-482-C-AAAF-2-BF29083-E1-FF.jpg) (https://postimg.cc/yJKDxDrz)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 16, 2022, 03:05:28 PM
I found a big surface plate, new at Busy Bee Tools in Canada for under $90! 3" thick X 12" x 18", a bargain. I had been waiting for over a year for one to come in, all the others were apparently scoped up by a company that makes headstones for pets, I guess a nice big piece of granite is not cheap, no idea how they can sell these for so cheap.

(https://i.postimg.cc/LXh0ZD4t/B7-B77-BB9-E27-B-4784-B308-82-D25-A017-FF8.jpg) (https://postimg.cc/7G8NFg2h)

I coated the surface with valve lapping paste and a couple of minutes of vigorous figure eights and back and forth and the surface is smooth, I did all the gasket surfaces and lapped the head top cylinder as well.

(https://i.postimg.cc/ZRDxthS3/F944402-E-3-E5-B-47-F2-9-E7-E-950-B8-DA08704.jpg) (https://postimg.cc/JDZkZvt4)

I surfaced smaller parts with a sheet of 400 wet and dry paper

(https://i.postimg.cc/3w8q37Pb/D4-DF6-C7-E-C19-C-4-D02-B5-F7-FF90-C1-E9-F670.jpg) (https://postimg.cc/rDHjJ6yS)

(https://i.postimg.cc/T2FBgzDp/1-D233803-23-E1-48-BD-9986-98590-B6-A5309.jpg) (https://postimg.cc/LhkyM0vp)
I started wiut
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on November 19, 2022, 08:11:01 PM
Not surprised it’s hard to get stone.  My orders for custom granite (raw stock) from the manufacturers are currently requiring min 8-12 months lead time.  Even more pedestrian dimensional stone components are comparable lead times if you aren’t ordering a semi trailer load at a time.   So I would expect properly lapped surface plate stone to be a long schedule as well and not surprised that cheaper priced stones were bought up to be repurposed.  You just can’t get stone right now.  It’s an industry-wide issue.

So, while I impatiently wait, it’s to see more of your bike progress, Jim.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 20, 2022, 02:48:17 PM
Not surprised it’s hard to get stone.  My orders for custom granite (raw stock) from the manufacturers are currently requiring min 8-12 months lead time.  Even more pedestrian dimensional stone components are comparable lead times if you aren’t ordering a semi trailer load at a time.   So I would expect properly lapped surface plate stone to be a long schedule as well and not surprised that cheaper priced stones were bought up to be repurposed.  You just can’t get stone right now.  It’s an industry-wide issue.

So, while I impatiently wait, it’s to see more of your bike progress, Jim.

I shouldn't be surprised that finished stone, like everything else is in short supply these days.

I have been busy getting a bunch of parts ready for bright zinc plating but this time I am taking the extra step to finish the bare steel parts of the visible components to a decent bright finish in the hope that once plated the bright zinc will have that like new bolt look. In the past the plating I get done is very good but it has not been like new in shine. I have three sets of kick start and brake pedal levers and a bunch of axles and shafts with exposed heads. Some pits remain on the pedal components, the depth of the rust was very deep and I have already spent three days getting this small batch of parts prepared.
The kick starter parts should be chrome plated but I am not too happy with the chrome shop I have used for years and until I can find a good shop the bright zinc will have to do,

(https://i.postimg.cc/rsbZtDKy/7-DA18-A2-B-9989-4773-963-B-2-BFB4572-E88-D.jpg) (https://postimg.cc/JHN5f4NS)

All of these pieces were rusted and several had very deep pits, I almost considered throwing a brake pedal away but went after these parts with a series of random orbital foam backed sander papers, 100 / 150 / 240 / 400 and then on the polishing wheel with white polish stick

(https://i.postimg.cc/RZhdPxbt/A3-F0-C656-8-E54-491-D-8476-E2-ADE20-BF90-F.jpg) (https://postimg.cc/VJyX6pws)

The 'other' parts are mostly inside the motor and not visible, the rest of the exterior fasteners are stainless steel

Most to the engine studs and shaft threaded ends needed attention, everything chased and ready for plating. I pulled the axles and swing arm shaft out of the Aermacchi 250 as well, the bolt hex ends had to be cleaned up on the lathe and mill, just knackered after decades of ham fisted abuse, likely from pipe wrenches and vice grips grabbing the heads.



Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 21, 2022, 03:26:05 PM
I can finally say with confidence I understand the differences between the Benelli 4 Speed 'egg' motors; 125, 200 and 250 cc.

The rumor I have been told a couple times is that all three share very similar bottom ends, this is only partially true to the extent of the transmission parts, even the cases are slightly different across the range. For example a 125 and 200 4 speed motor share the same frame mounting bolts, the 250 has a different lower frame location point.
125 and 200 cases are very close but there are differences in the type of small diameter needle bearings used between the two, including the depth and bearing covers.
My point, which I have now learned the hard way, is that not much actually interchanges with the bottom ends other than a 125 and 200 share the same con rod but the crank webs are not interchangeable.

When Its all said and done I have accumulated a 125, 200 and 250 motor for a 200 bike! One day the 'other' engines may find a home in a chassis.

Nerding out here but for the recorded here are the measurements and diagrams I did to catalog the bottom end differences in my quest to find ONE good crank.

(https://i.postimg.cc/Qxtts0FB/02-C13-F22-00-D8-469-E-BF3-A-1-B5-B57-D8-AB75.jpg) (https://postimg.cc/hhkg18bg)

(https://i.postimg.cc/FzhYjvFG/57-E8-DD5-C-FEAC-4369-B373-BA9-DCB1-B4560.jpg) (https://postimg.cc/TLH26ZDW)

(https://i.postimg.cc/NFb5Dn5t/9336-B90-A-6-CDC-4-D0-F-9885-7-BBB726-FC9-F7.jpg) (https://postimg.cc/CnBhLmGr)

(https://i.postimg.cc/htXf8pgF/A50-B0-E4-F-4938-48-A4-862-B-50288-C53-EFE6.jpg) (https://postimg.cc/ZWhb4PCj)

(https://i.postimg.cc/mrMkJkt8/AC176-BA0-6-EEB-477-B-9-C92-75-F12-C31-ABB2.jpg) (https://postimg.cc/R3SvnM1H)

(https://i.postimg.cc/6557qBmp/B9852488-E77-C-408-E-8407-DF71-AB3-B7255.jpg) (https://postimg.cc/V5psHPwx)

(https://i.postimg.cc/Y9H0H7Fk/CEC8295-E-6-D10-4-BDC-8-E1-E-234-DDD18-B22-C.jpg) (https://postimg.cc/FfTNy2Gn)

(https://i.postimg.cc/rmNmyHG4/D1521282-4780-45-C5-97-B5-BDE092-D09219.jpg) (https://postimg.cc/ygWBvvb6)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 23, 2022, 06:28:02 PM
My friend George, retired professional welder TIG welded replacement aluminum fins on my Benelli 200 engine case and rocker cover. This outer long fin was almost completely broken off, I have just a little bit of cleanup to do and the repair will be almost invisible

(https://i.postimg.cc/FRvvb9Lp/B138061A-386F-40C4-BC5C-347ECA89DA86.jpg) (https://postimg.cc/gwg1mb4L)

Four fins were broken off the rocker, again just finishing to do

(https://i.postimg.cc/DfBhs3yQ/E93AAA68-534A-48B3-97E8-BF5D2F73A23B.jpg) (https://postimg.cc/c6gPyj36)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 25, 2022, 04:16:23 PM
I picked up the reconditioned head today from the machine shop, new guides pressed in and reamed to size and the valves reground.

(https://i.postimg.cc/Tw5LzY24/5-B6-B2-DAE-39-D6-4-C71-8-CE9-C1154-E383-ABE.jpg) (https://postimg.cc/xJY1HQzv)

(https://i.postimg.cc/8C0fXrGv/780384-F5-F387-43-A6-B13-A-178-A2-ABA69-D1.jpg) (https://postimg.cc/PL1qPJPf)

(https://i.postimg.cc/yxqgs4kY/E3815603-AFA9-4705-9-AB5-646-A59-C0-F3-E4.jpg) (https://postimg.cc/wyVTQrXS)

I dropped the crankshaft off with a NOS crank pin and a new caged needle roller bearing I purchased from 123 Bearing in the UK - 30 mm O.D. x 24 mm I.D, x 15 mm width. I asked the machinist about the suitability of the bearing and he told me he uses similar bearings all the time rebuilding dirt bike cranks so I think I am good to go. Dry fitting the bearing ion the con rod with the pin felt great, almost no play whatsoever.

The 'new to me' pair of crankcases have been cleaned and all new bearings fitted, double row close fit ball bearings, standard ball bearings and cup needle bearings all purchased from 123 Bearing in the U.K.

(https://i.postimg.cc/Xvd6mRSg/4111-A4-F4-3-F91-48-C1-B4-A6-FFF5534370-DE.jpg) (https://postimg.cc/NysnrP0y)

(https://i.postimg.cc/RZjzPM8F/67-AE2207-7586-4-EAC-979-E-81-CDC4-CC8935.jpg) (https://postimg.cc/CRHt5VwT)

I have sent the cylinder studs and misc bearing covers out to be bright zinc plated, I will hopefully have the bottom end back together in a couple weeks at the latest.


Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Antietam Classic Cycle on November 25, 2022, 08:26:28 PM
Looks great! BTW, 123 Bearing is in France.  :wink:

123Bearing
CRT 4 de Lesquin Rue Léo Ferré
59273 FRETIN - FRANCE
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 26, 2022, 12:17:07 AM
Looks great! BTW, 123 Bearing is in France.  :wink:

123Bearing
CRT 4 de Lesquin Rue Léo Ferré
59273 FRETIN - FRANCE

I guess I wasn’t paying attention to their website, I just assumed they were UK, great service though, I ordered the crank big end needle bearings and cup rollers late last week and less than a week later they arrived. Can’t beat the prices either, I used to have a helpful local supplier but no longer.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on December 04, 2022, 08:30:10 PM
I got another 200 Sprite parts motor bottom end in trade for some Cardellino parts. The cases are excellent and will be used in my 200 motor. A bunch of other bits will find a home in the 250 and 125 motors.

(https://i.postimg.cc/JndqW46J/D4BF8016-855C-411B-A592-C76F7FB9CD89.jpg) (https://postimg.cc/N9mT6Ywf)

(https://i.postimg.cc/W488X705/8EBC6804-1E45-4166-A1EB-F7634E170149.jpg) (https://postimg.cc/yJJ0NcQR)

A night in the ultrasonic tank then an afternoon of vapour blasting.

(https://i.postimg.cc/D067zHGq/0C9F7D09-C314-4DDD-8FE6-6D05E3DD821D.jpg) (https://postimg.cc/T5Kz7kCw)

The bike suffered a broken transmission gear, probably sat for decades after the transmission went bang.

(https://i.postimg.cc/8zsLNHSJ/F2C61F9D-1C58-4884-9BC0-BEF6135068FA.jpg) (https://postimg.cc/zyZykT38)

I am hoping I can repair the damaged crankshaft tip with
My MIG and turn it back in the lathe.

(https://i.postimg.cc/fTD623hg/8E998918-F89D-4549-A2E9-93279D55F168.jpg) (https://postimg.cc/Dmpjmw0q)

The rotor was fused to the crank, someone had tried to get it off before and whatever puller they tried damaged the crank and tore the threads out of the rotor spindle. I cut the rotor brass body off the steel Center (I have a spare) and used serious heat and a big bearing puller to get it off, amazing how stuck it was.

(https://i.postimg.cc/658QQ18X/57162DE1-1A1B-4EAF-9202-051BCE359A25.jpg) (https://postimg.cc/hfqnys8y)


Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on January 09, 2023, 08:23:15 PM
It’s taken many months of searching for parts, buying a couple donor engines, and research but I have finally got a rebuilt 200 crankshaft with new rod, pin and main bearing and while I was at it I had a 250 crank rebuilt with new pin and bearing and a 125 with NOS webs and bearing.

(https://i.postimg.cc/j5WcbCMF/01241DA7-47A5-4DA0-BBAE-7C5CACFDBE19.jpg) (https://postimg.cc/hzBT84WL)

So now it’s time to go through all the boxes of parts and build a 200 for the project bike.  I will have a rebuilt 125 and 250 for future projects

(https://i.postimg.cc/przBm4bQ/4F98AB0A-CD32-4EF1-945E-E7CA91131AA4.jpg) (https://postimg.cc/ct13jDJ6)

Back to work on the Benelli

Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on January 11, 2023, 07:59:12 PM
sorting through parts today, I have three sets of transmission pieces and used the best of the gears and dog, getting the snap ring off the output shaft to separate the rotating gear was a heck of a job, there must be a trick or a special tool, this snap ring has no holes in to open with a standard set of snap ring pliers. three small flat blade screwdrivers opened the ring to free the gear, I sure could have used three hands.

A very helpful tool is the Tusk crankshaft puller, not too expensive and it cleanly pulls the crank into the ball bearing without resulting to a soft mallet on the opposite end of the crank and disturbing the freshly trued crank

(https://i.postimg.cc/MH7TbVp3/54-E3-A233-BBB2-4582-910-E-96-CAAD153-E9-D.jpg) (https://postimg.cc/RJ04v3fw)

I pressed in a new small end bush I had made up by a machinist and reamed it to 18mm, drilled the oil passage holes. I also ran a 10mm reamer through the case cam follower bushings, one of the bushing was very tight.

crank set in one case and it spins so smoothly

(https://i.postimg.cc/yNGkV7Gj/842-CFD5-E-A461-4179-B8-C4-96-E21-BE6-AED1.jpg) (https://postimg.cc/06p8n1PK)

Once the transmission and gear shift drum were installed I found there was a very stiff / tight fit across one set of meshing gears. I went back through the stash I had and found another gear that fits much better. I tested the shift mechanism with a small vice grip on the shift drum output shaft, it moves easily through the gears and neutral seems to be easy to find without the detent in place,

(https://i.postimg.cc/nrbrD0pQ/C193-F40-D-0-F6-A-4-C5-B-91-DF-0373-D82-CCEA0.jpg) (https://postimg.cc/r0jq6Gd8)

I should get the cases joined tomorrow and get on with the top end.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on January 12, 2023, 05:08:13 PM
Looking great, Jim.  How much difference is there between transmissions vs displacement?  Have you accumulated that many spares for each combination or are many of the parts interchangeable regardless of displacement?
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on January 12, 2023, 06:07:41 PM
Looking great, Jim.  How much difference is there between transmissions vs displacement?  Have you accumulated that many spares for each combination or are many of the parts interchangeable regardless of displacement?

Thanks Clint,

As far as I can tell the 4 speed transmission is the same across the 125 - 200 and 250, The 125 and 250 were also available in 5 speed and I think the crank cases are unique for the 5 speeds. There are many small differences between the engines, the 125 and 200 share side covers, the 250 is unique, the heads and cylinders are individual but some head parts are interchangeable. I am learning every day about the differences and I think I now hopefully have all the parts for the 125, 200 and 250.

Today I must have assembled and split the cases a dozen times to shim the transmission shafts, shift drum and kick start shaft. Benelli does not show a case center gasket but on each of the three engines I have put together the cases are just far too tight without a thin center case gasket. I have made my own gasket in each case and I have collected a good stock of thin shims to fit the various shafts.

(https://i.postimg.cc/xCSv5w5Q/68-E32767-1-C17-4-DCE-B119-7-C560-CB090-E2.jpg) (https://postimg.cc/QB0KxnvY)

I previously had a 200 cylinder bored 2nd over and matching NOS piston and rings, fitted a set of new cylinder base gaskets - paper / aluminum / paper, and fitted re-plated studs.

(https://i.postimg.cc/g0hyvzv4/1-FA8-DB21-0-C29-4-F35-B039-A5-D3-D373078-A.jpg) (https://postimg.cc/679GKNbG)

I will pull the 125 motor out of the frame tomorrow and install the 200 motor then fit all the rest of the parts with the engine in place.

I want to get the engine running and sorted before I pull the bike apart for painting. I need to tackle all the electrical next.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on January 13, 2023, 07:59:39 PM
swapped out the 125 motor for the 200, just three bolts and the motor drops straight down, so simple and its pretty light without the clutch and primary gears.

the head gasket is just a thick rubber seal for the push rod tubes and studs, the head is sealed by the cylinder liner fitting tight into the aluminum head recess, I think this is the design in many engines, Ducati does similar on the bevel twins.

(https://i.postimg.cc/6pt9XtPH/E4-D0-F0-AD-1-D05-43-B1-87-EC-DFF71-A1-A5-BFC.jpg) (https://postimg.cc/ykpqh4s9)

(https://i.postimg.cc/y6RB3D4Q/40-F816-DC-7-F9-A-4240-A6-F6-491-F9-ECFEE74.jpg) (https://postimg.cc/kD7LkX5K)

installed the drive sprocket and the sheet metal cover that keeps dirt out of the stator area, fitted a new condenser and replaced the lighting coil with a spare I had, new wires

(https://i.postimg.cc/rmBkYkWN/7-BDB6-B1-E-7-F89-4844-A53-C-33200-AC0-B67-A.jpg) (https://postimg.cc/Q9JwHvfF)

I should have installed the shift drum cap and woodruff key with the motor on the bench, twice the key fell to the floor and I spent a long time finding it each time

(https://i.postimg.cc/5ttbXpbL/93-DE5-D52-A677-4-E9-E-8137-ED01-BE19-B0-E2.jpg) (https://postimg.cc/fV16Fc3R)

Clutch is pretty simple, the five springs are put into tension by hooking the top of the springs over a loose steel ring

(https://i.postimg.cc/HnMppxHN/996A9ED7-9F10-4BA6-A222-8486453C68AA.jpg) (https://postimg.cc/tnX0k9sd)

stripped and cleaned the oil pump, its slides in from below and the gear engages the center of the cam shaft, a new soft rubber seal was installed

(https://i.postimg.cc/fLWzQ8G1/796-F3-F05-7-E22-4-D95-9325-3-B31-BC64275-A.jpg[/img[/url]

[url=https://postimg.cc/svgdZDds][img]https://i.postimg.cc/fTxwpJ8t/8-DA5-AE76-0196-4-D27-BE26-1-C21768-F0-FA9.jpg) (https://postimg.cc/mcqfQy2S)

this motor was missing the M9 x 1.25 head nuts, I found flanges examples on Ebay from China but the wrench size is 14mm not the stock 12mm, I machined the flanges off and I can just get an open end wrench over the nuts but torque is by feel, I cant get a socket on

(https://i.postimg.cc/y8j76247/C875373-B-87-F7-469-C-929-D-4-B22287-EDB4-D.jpg) (https://postimg.cc/rDDBQnwH)

The bike deserves a period correct Magneti Marelli plug, love the pink

(https://i.postimg.cc/xChfDHrH/68-C261-DC-DFC7-4-D09-8604-29-C11-FB10-FF1.jpg) (https://postimg.cc/ZBPt6W5K)

(https://i.postimg.cc/jSNLfNSb/EDECB9F5-CA13-47EE-8525-CF2C3F71985B.jpg) (https://postimg.cc/68WWJ8Zj)

made up some 6mm studs for the carb flange, I need to rebuild a carb from my stock of used Dellortos,

(https://i.postimg.cc/T252jkmc/E2-DDA4-CC-BCEE-439-F-AD7-B-5-B4-FC764-A864.jpg) (https://postimg.cc/kD9dqvTV)

Next to go through the wire schematic and make some new wire harness sections, fit a 6V coil and connect the electrical up inside the headlight shell. Hopefully I will get a good spark.

I gave up on building a 125 motor, the NIS crank I bought won’t work, it is for a 5 speed. I decided to build up another 200 cc 4 speed with all the spare parts and a gods pair of 200 crank cases. I guess if I do build a race replica it will have the 200 motor.

(https://i.postimg.cc/5NDXjp1g/FDEA5E29-482F-4C3B-874F-C52645B46FDB.jpg) (https://postimg.cc/1fcmjG8V)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on February 13, 2023, 07:59:59 PM
I got some time in on the Sprite this past week, installed a reproduction wire harness I found on Italian EBay, it’s an accurate copy.

(https://i.postimg.cc/Btf34CWS/1725-B58-C-5-ADE-43-A0-9314-D1596-A0-F2635.jpg) (https://postimg.cc/64cghn5g)

I installed a brake, clutch and throttle cable. For the throttle I had to make a solder ball end to fit the throttle, I made a little ‘pot’ from 1/2” diameter pipe, about 1/2 “ tall, melted solder into the pot and then dipped the bare end of the cable, I balled up the strands, and then once cooled I sanded the blob into a ball.

(https://i.postimg.cc/BZrPj946/1EFA0CB4-93A6-484C-8CB4-214AA907940C.jpg) (https://postimg.cc/Cd4x22ZT)

I ordered a NOS light dip switch/horn button and a rear brake pedal switch to finish off the electrical. The CEV speedometer I have had a very small diameter threaded mount for the cable and doesn’t work with he speedo cable I bought, need to come up with something for that.

I used the original type wire terminal connectors used on Italian bikes of this vintage.

(https://i.postimg.cc/PJwHgRRV/F51A7D0C-DB69-4C39-BEB2-980FF90DA281.jpg) (https://postimg.cc/MfqgRdx1)

(https://i.postimg.cc/15Dn6C3K/DCF21958-AB74-44F9-8920-26F551076D87.jpg) (https://postimg.cc/rKFw29Wd)

I ordered from Detlef Burian what I hope is the last of the parts I need, a new exhaust header pipe, a few little clips and rubber parts. I think I am getting close to completion of the dry build and starting up the motor. Then to strip it down and get on with paint.

(https://i.postimg.cc/bw8GRxGf/0C010240-3185-41CA-9BC7-1FC034117F27.jpg) (https://postimg.cc/F7WsrJgT)



Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Antietam Classic Cycle on February 13, 2023, 08:36:23 PM
Sweet!
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on February 15, 2023, 07:22:28 PM
I got a nice pair of Orlandi fuel taps that came with a donor motor, good shape and even the rubber seals remain pliable.

(https://i.postimg.cc/2yGNnPfc/8F7148EE-8459-470B-864B-8DC002600947.jpg) (https://postimg.cc/ZvWQSsnp)

I punched two little indents into the fuel tap faces and dabbed a spot of red paint at the ‘off’ position and an unpainted indent for full ‘on’   I always forget which position is off and on on the various petcocks on my bikes, this little marking makes it easy.

These are the correct taps for this bike and fit the Siamese fuel line to the carb

(https://i.postimg.cc/g2JmHkjv/7A568B43-9CBC-4768-BBB0-503BA3F6F3D5.jpg) (https://postimg.cc/dLzbqF81)

I sorted out the clutch today, de-burred some plates and reassembled the unit, nice smooth clutch pull now. Many of the Italian manufacturers used bared end cables with the clamp on terminals, the stub end of the cable is then folded back 180 degrees and a plastic tube was fitted over the end. I used a short piece of green fuel line as the plastic retainer.

(https://i.postimg.cc/fbd483N0/4FF2B490-1CCF-463E-A765-DD3FB3AB0E88.jpg) (https://postimg.cc/cKd5HL6s)

(https://i.postimg.cc/GhzbDsLL/427B627E-3ECF-4B65-8FA8-35A043968CCD.jpg) (https://postimg.cc/MvMk2HfN)

Next job is to assemble the steering damper, I found a NOS plastic knob and have replayed the compression plates. I had not noticed the steering stop plate appears to be snapped off short of the lower triple clamp stops. I will strip down the front end and weld up a stop tang.

(https://i.postimg.cc/gjmPXG1L/42DD88D8-9624-4637-ABE3-B4AD7924E71E.jpg) (https://postimg.cc/gXS71bzG)

Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on February 16, 2023, 08:18:47 PM
I removed the front end to get access to the steering stop, cut a piece of plate to add to the broken stub,

(https://i.postimg.cc/Wbnh8XzD/IMG-5326.jpg) (https://postimg.cc/xcXfTGKY)

A quick splash of primer to keep it clean until painting

(https://i.postimg.cc/nh39F0t8/IMG-5327.jpg) (https://postimg.cc/sMZgKPXK)

fitted the damper parts, needs another piece of strap to engage the damper stationary piece

(https://i.postimg.cc/63nQvhFp/IMG-5340.jpg) (https://postimg.cc/dkQvMGqb)

Tha'ts done for now

(https://i.postimg.cc/6qKpLvNL/IMG-5342.jpg) (https://postimg.cc/XG2WnXqp)

I fitted the steering stem ball bearings and set the triples, I had to machine down the top of the triple at the stem to get enough good thread out of the stem for the top nut, only had to shave off about 3mm, good bite now picked up a few parts I had sent out for powder coat primer, chain guard, side covers, now everything has been media blasted and coated with a thick base of sand-able primer ready for final prime and paint.

(https://i.postimg.cc/cJ8xpmxB/IMG-5343.jpg) (https://postimg.cc/d7wcdGTh)

The to do list is getting smaller:

- install light dimmer / horn switch
- install rear brake pedal switch
- install rotor, set points and timing, install engine side cover
- Install drive chain
- strip shock absorber, paint bodies semi gloss black
- install speedometer and cable
- install exhaust manifold and muffler
- install 6V battery

Then start up the bike and tune it, followed by stripping it all down for painting, this little Benelli / Motobi has taken more time and effort to source parts, repair, rebuild etc than anything else I have restored in the past.

I did a summary of what I started off with from the initial parts bike in a crate I bought off Ebay:

Frame / swing arm with axle / rear fender loop / triple clamps, forks and shrouds / head light / seat base / right side cover / center stand / gas tank / front hub / brake pedal / kick starter / rear axle

What was not correct for the bike that came in the crate:

engine (was a 125 bottom end with a 250 top end and a miss matched crank) rear hub / right side cover / front fender / front axle /

Things I found:

200 cc complete engine / oversize piston and rings / valve guides / gaskets, seals and O rings/ engine case bearings / big end rod bearing, small end bush / repro seat cover / NOS handlebars / repro exhaust pipe and header / NOS speedo and cable / rear hub / spokes / rims / tires and tubes / shift pedal / headstock steering races / carburetor / chain guard / front and rear fender / licence plate bracket / tail light / wire harness / brake and clutch cables / air pump / horn / braided fuel line / grips / foot peg rubbers / tank rubbers / front and rear sprockets / Dansi 6v coil / stator lighting coil / condenser / levers and cable adjusters / front brake cam and brake cable lever / rear shocks / battery strap / steering damper knob / passenger foot rests / front brake shoes ....

There is truth to that old saying to never buy a disassembled motorcycle in boxes, I should have just steered away from this bike when it came up for sale as a 'Project that was 95% there'.... but here we are nearing the end of the dry build, I got in too deep but when its all done I think I will be happy with it.









Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on February 17, 2023, 09:37:40 PM
Man, Jim- I’m loving it.  That bike is going to be great!  Thanks for all the pics and details.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Pescatore on February 18, 2023, 07:17:19 AM
Hey Canuck, I knew I had seen that motor on this forum.
I found this Motobi at a museum in Beverly, MA.

(https://i.ibb.co/Qb3JH27/20230211-104523.jpg) (https://ibb.co/Qb3JH27)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on February 18, 2023, 11:17:00 AM
Hey Canuck, I knew I had seen that motor on this forum.
I found this Motobi at a museum in Beverly, MA.

(https://i.ibb.co/Qb3JH27/20230211-104523.jpg) (https://ibb.co/Qb3JH27)


Thanks for posting that picture. I think it’s a 5 speed with a gear driven tach and it’s a sport model with the clip ons and shorter fork shrouds, very cool.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Scout63 on February 18, 2023, 03:44:14 PM
Great work and wonderful photography/ descriptions Jim. I agree re buying disassembled bikes.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on February 18, 2023, 08:01:25 PM
Hey Canuck, I knew I had seen that motor on this forum.
I found this Motobi at a museum in Beverly, MA.

(https://i.ibb.co/Qb3JH27/20230211-104523.jpg) (https://ibb.co/Qb3JH27)


Jim, do you know what approx diameter front hub/brake or wheel rim (17” or 18”)  that bike would have?  Looks like a  grimeca sls twin panel 4 shoe brake, but if 17” brake looks smaller than typical 180mm version.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on February 18, 2023, 08:44:25 PM
Jim, do you know what approx diameter front hub/brake or wheel rim (17” or 18”)  that bike would have?  Looks like a  grimeca sls twin panel 4 shoe brake, but if 17” brake looks smaller than typical 180mm version.

Hi Clint, the stock Sprite rims are 18” front and rear. The race bike in the picture has a non stock front hub, looks a lot bigger than the stock hub

(https://i.postimg.cc/3RtRyjCD/22C7BD5A-EC10-4B28-9571-4166FF17C4DB.jpg) (https://postimg.cc/qhC0S3Fk)

A couple of the Motobi race bikes at the Pessaro museum.

(https://i.postimg.cc/7hP7PJm8/2B156619-25B2-4275-B916-B838042E4516.jpg) (https://postimg.cc/62STY3kY)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on February 18, 2023, 09:33:01 PM
Good info.  Thanks, Jim. 
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on February 24, 2023, 05:05:44 PM
A few things off the to do list today, I picked up some clear braided vent hose; 5/8" I.D., for the crank case breather,

(https://i.postimg.cc/sg1nXjPt/B846AAFF-06B5-4646-99ED-F5301995C323.jpg) (https://postimg.cc/mPf3pG5w)

(https://i.postimg.cc/htw2Qkph/8156D721-1630-4C66-BB68-EB33225BADA6.jpg) (https://postimg.cc/Mn77hFk8)

The CEV horn and high/low light switch came in the mail yesterday,

(https://i.postimg.cc/mk8wLJPL/87433F36-D50D-4538-AC90-96C1D56F500F.jpg) (https://postimg.cc/tnnPDrdw)

(https://i.postimg.cc/gJb4Nv9W/E602C57D-9937-4419-9073-5AFA47EDF769.jpg) (https://postimg.cc/mcVQr12X)

Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on February 25, 2023, 04:49:56 PM
A reproduction exhaust pipe arrived from Italy on Friday, looks to be correct

(https://i.postimg.cc/7YPb8x4C/97-B3-F832-FFB0-4078-9-CA1-AD5-B4-A387654.jpg) (https://postimg.cc/8s3TLgjD)

The fit to the cylinder head exhaust studs is very tight on one side, I can get the special long nuts just in

(https://i.postimg.cc/GhRGBwCr/32640404-13CA-4252-8C46-96A88A85DDC1.jpg) (https://postimg.cc/Z0fCgQnD)

The hanger bracket is a long ways from the frame

(https://i.postimg.cc/XNKg4M1M/CA767BC0-F28B-46F8-84DE-6028D21A037D.jpg) (https://postimg.cc/qgRKxFdQ)

I made up a stainless steel spacer

(https://i.postimg.cc/y6pK8Gbd/6446B10C-D432-4DE6-9748-297A9EC512DC.jpg) (https://postimg.cc/RqtyPg95)

The exhaust pipe seems far too long and the reproduction muffler has only one hanger bracket

(https://i.postimg.cc/VsqbPGbh/FD7EC727-756C-4ECD-8409-06DE916D0B3F.jpg) (https://postimg.cc/5jttwmg5)

The muffler is supposed to slide over the exhaust pipe but the outside diameter of the muffler matches the inside diameter of the header

(https://i.postimg.cc/XJFBJx1p/D99AF0AC-9EEA-49AC-BA37-1AA719800086.jpg) (https://postimg.cc/hzDtZ8BB)

I decided to trim the header length and slide the muffler into the header

(https://i.postimg.cc/BbB85b03/4CDD8253-1685-4DB6-98BA-2550E2561E0B.jpg) (https://postimg.cc/QKVxhXCY)

With the muffler clamped tight to the header and the rear hanger in place it’s all quite rigid. I may make a 3mm thick stainless steel bracket and weld it to the back of the muffler with a TIG

(https://i.postimg.cc/RCgSnhNv/D5CF3823-6DCC-48EB-A4E8-D8EFCBCAE9EC.jpg) (https://postimg.cc/t7VQKX3c)

I installed some more reproduction rubber parts

(https://i.postimg.cc/ZRTmWzm9/6A87A3A9-0660-4ACF-8314-0B1D27C26681.jpg) (https://postimg.cc/JydvFgGm)

(https://i.postimg.cc/25xRR9WC/ACF52873-4FB0-42F6-A8F0-F40BAF1CEE63.jpg) (https://postimg.cc/gwrB3D47)




Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Pescatore on February 26, 2023, 11:32:20 AM
Great job, looks like you're almost ready to crank it.
Is that how the crank breather hose used to run?
Seems like it could hide under the seat.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on February 26, 2023, 01:09:04 PM
Great job, looks like you're almost ready to crank it.
Is that how the crank breather hose used to run?
Seems like it could hide under the seat.

I need to tuck the breather hose under the tail light bracket, that's how it is routed on the bike in the Beneli / Motobi museum in Pessaro.

(https://i.postimg.cc/YCXZjWxc/43-E8771-D-13-E7-4-FC0-B39-E-D27693-AB9736.jpg) (https://postimg.cc/fV9BrkF5)

I am just waiting on a few small things before I cross my fingers and crank it over.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Pescatore on February 26, 2023, 05:39:33 PM
I need to tuck the breather hose under the tail light bracket, that's how it is routed on the bike in the Beneli / Motobi museum in Pessaro.
:thumb: I would not have guessed that's where it vents.

Quote
I am just waiting on a few small things before I cross my fingers and crank it over.
Best of luck   :popcorn:
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on February 28, 2023, 04:11:59 PM
I picked up a woodruff key to mount the rotor but before doing so I took an old rotor I had for this bike that was damaged from being seized to a donor engine crankshaft, the taper bore is not the best but the advance sleeve moves freely and the advance springs mechanism is good. I hate trying to set points and timing through the small access slots in the rotor so I milled off most of the brass on this donor rotor, just keeping the timing marks and the attachment points for the advance springs.
This is going to be used for quickly setting the point gap (0.16), ( 0 on the rotor) and the points opening point (A on the rotor)

(https://i.postimg.cc/RF2KFSdH/7592-B011-B5-D5-44-EB-87-C9-9-C0232885-DB9.jpg) (https://postimg.cc/r0CKZLvV)

so much easier to access the points adjusting screw and the three points plate screws that thread into the crankcase. And I can torque down the points plate and still check the points opening in the event the stator plate flexes as the screws are tightened.

(https://i.postimg.cc/FRY0Ndyv/6-FDA7-C01-F79-C-4-BDD-9-B28-67-F119-CA92-D2.jpg) (https://postimg.cc/zb1ykf22)

pulled off the 'timing tool' and fastened the rotor, popped the side cover on.

(https://i.postimg.cc/G3Bj1NKD/E0-D41208-C553-4-D66-86-A2-72-E178-BCA1-EF.jpg) (https://postimg.cc/LhpPtxr4)

Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Lotus54 on March 03, 2023, 09:39:03 AM
I just read through the thread- great work!  I appreciate the specs on the cranks.  I’m splitting a 250 5 speed due to shifting issues, even though it only have some 1500 miles since new. 
I may have to cut off the flywheel also- but I’m going to give it a few more heat/cold cycles and try some of the ‘freeze and loosen’ penetrating stuff.  I guess get it hot, freeze it and hope it gets in there and maybe I can get it loose.

 
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on March 03, 2023, 02:59:27 PM
I just read through the thread- great work!  I appreciate the specs on the cranks.  I’m splitting a 250 5 speed due to shifting issues, even though it only have some 1500 miles since new. 
I may have to cut off the flywheel also- but I’m going to give it a few more heat/cold cycles and try some of the ‘freeze and loosen’ penetrating stuff.  I guess get it hot, freeze it and hope it gets in there and maybe I can get it loose.

I have rebuilt a couple 200 - 4 speed engines. In both cases I assemble the selector drum, input and output shafts only, then bolt up the cases. Check the end float of each shaft. You can wiggle a screwdriver under a gear and feel how much the input and output moves. I have had to add shims to the shafts to get the gear surfaces to align and the shaft to have very little movement. Too much slip and the shift digs will bind.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Muzz on March 05, 2023, 12:35:11 AM
Again, appreciate the work you do Jim. Excellent with the photos and the descriptions.

Fingers crossed that it fires up perfectly.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on March 05, 2023, 10:35:29 AM
Again, appreciate the work you do Jim. Excellent with the photos and the descriptions.

Fingers crossed that it fires up perfectly.

Thanks Muz!
As soon as my doctor gives me the ok to swing a leg and try kick starting I am on it.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: kballowe on March 06, 2023, 07:54:10 AM
Excellent thread !  Thanks for sharing !

 :thumb:

Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on March 08, 2023, 08:26:37 PM
Some parcels showed up this week, being at home for a week after surgery is starting to get old. I packed up my parcels and drove to my shop to have a present opening!

I got a very nice 22 mm Dellorto carb ( the 24 will go on my Aermacchi 250)

(https://i.postimg.cc/SRGkPPXm/3-C431-F72-D2-BF-47-E1-B21-A-FBF4981-F5-C3-C.jpg) (https://postimg.cc/30Ws4nCq)

A new chain, a rear brake light switch, a NOS speedo and some rubber grommets for the ignition wiring passing through the crank case

(https://i.postimg.cc/Y2NrjvdT/5-EE41-B02-9-A27-4-B0-B-825-C-78-D7-F6-D596-C0.jpg) (https://postimg.cc/Yj9KsCKx)

(https://i.postimg.cc/qMkkKpYq/E8-C15-DD7-4-EA8-418-B-9-D82-B85-A6-E32-DB0-E.jpg) (https://postimg.cc/BtV99fJf)

I also received a whole bunch of NOS parts for a 1968 Aermacchi 250 short stroke motor I am rebuilding, con rod and pin kit, oversized piston and rings, valve guides, gaskets and so on. The parts availability for the 60’s Aermacchi Harley Davidson’s is pretty good! 

By the time I dropped the Aermacchi parts off to the machine shop for a crank rebuild, cylinder hone and guides I was pretty much worn out.



Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: kballowe on March 09, 2023, 03:58:57 AM
It's amazing to me that any of these parts are still available !

I'm guessing that you need to be a good detective.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on March 13, 2023, 05:38:21 PM
It's amazing to me that any of these parts are still available !

I'm guessing that you need to be a good detective.

I like the searching for parts and researching the history of these old bikes

Installed the speedo today.

(https://i.postimg.cc/bJB5b66J/85867-D07-9305-4-D4-D-A76-B-13940195-EE44.jpg) (https://postimg.cc/ZB6jzLzt)

Fitted a new chain

(https://i.postimg.cc/0QQ3zg0F/64-EBA3-DC-1547-4-AB9-82-AA-9747-C84-E2-B37.jpg)[/url

Santo Di Motociclio sent me this real nice NOS wire grommet, it’s real deep to fit through the case casting

[url=https://postimg.cc/FYnTyRVq](https://i.postimg.cc/0N9hqKM8/04-A66-D05-A558-495-D-A587-14-C18-E203838.jpg) (https://postimg.cc/kV0wHpZv)

I welded up a bracket to hold the rear brake light switch

(https://i.postimg.cc/xdghjjML/BC97-B1-F4-4-DD7-40-D6-8310-155-A4-C27-F7-A2.jpg) (https://postimg.cc/gwXNNWM0)

Works like a charm

(https://i.postimg.cc/6qFDsHRS/6-E5-A59-FF-9-DBD-4-D3-D-BA43-03-EDE1-FE48-FD.jpg) (https://postimg.cc/5QqPLSsq)

Moved some wires around to get the chime lever to be clear of the high tension led

(https://i.postimg.cc/qqN95fty/F14-F4-E56-0-E06-42-E1-9047-FBDA3-CEAF4-B3.jpg) (https://postimg.cc/GT1745xm)


Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: kballowe on March 14, 2023, 07:54:17 AM
Great pictures. 

Thanks


 :bike-037:
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on April 25, 2023, 07:41:33 PM
The day finally arrived to try and fire up the Benelli Sprite 200, installed a new spark plug, set the points and timing, I filled the crankcase with 2 litres of Castrol 20/40, attached the fuel bottle to the carb. After a couple kicks it started and briefly ran. After that it would not catch, it was close but it was kicking back a bit and only trying to start on full throttle. Spark is bright, kicking it without a battery as it does have magneto ignition. I have the air screw set to the recommended 1 full turn out from bottom. Turning the screw out richens the mixture.

(https://i.postimg.cc/RCgSnhNv/D5CF3823-6DCC-48EB-A4E8-D8EFCBCAE9EC.jpg) (https://postimg.cc/t7VQKX3c)

I checked the timing again and its still spot on so I cant figure out why the kicking back feel. It seems to be flooding, perhaps I don't have the carb set up right. None the less it did start so that is positive, I will give it another go tomorrow.

Any ideas?
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: kballowe on April 25, 2023, 07:58:41 PM
Nice.  Very nice.

Can we get more more pictures ???
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on April 25, 2023, 08:22:43 PM
Glad to hear it did start.  As far as starting manners…. My singles have generally been good to start at approx the correct settings.  But some benefitted from minor tweaks.  If it’s kicking back hard, the timing could be slightly advanced.  Before you change timing, some minor kickback is probably normal.  Even if the process is generally similar, It seems like each single has its own individual starting procedure and will not tolerate anything else.

But you may have a carb or condition (like only starting on full throttle, then stalling) that’s rich , which promptly fouled the plug so that now it will not spark hot enough or at all to function.  Even if they were the same heat range, gap, etc, Some plug brands always seem to work more reliably in my old single bikes than others. I’ve got a coffee can with several brands, including some pink Lodge plugs that always seem to save the day.   If you haven’t swapped a plug (new plug, burned dry with torch or bead blasted) yet, I would give that a try first before I started changing anything else.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on April 25, 2023, 08:49:13 PM
Glad to hear it did start.  As far as starting manners…. My singles have generally been good to start at approx the correct settings.  But some benefitted from minor tweaks.  If it’s kicking back hard, the timing could be slightly advanced.  Before you change timing, some minor kickback is probably normal.  Even if the process is generally similar, It seems like each single has its own individual starting procedure and will not tolerate anything else.

But you may have a carb or condition (like only starting on full throttle, then stalling) that’s rich , which promptly fouled the plug so that now it will not spark hot enough or at all to function.  Even if they were the same heat range, gap, etc, Some plug brands always seem to work more reliably in my old single bikes than others. I’ve got a coffee can with several brands, including some pink Lodge plugs that always seem to save the day.   If you haven’t swapped a plug (new plug, burned dry with torch or bead blasted) yet, I would give that a try first before I started changing anything else.

Good points Clint. I have a pink Magneti Matelli plug in but will try some others tomorrow, I have some NOS Champions to try and the typical NGK as well.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Antietam Classic Cycle on April 26, 2023, 08:40:48 AM
I steer clear of Champions since they seem to damage the threads in alloy heads too easily. I've had issues with NGKs - my V50 III would barely start and would only run on one cylinder with new, properly gapped BP7ES. Installed a pair of Denso W22EP-U and it started right up and ran perfectly. Runs even better with Denso IW22 (Iridium).

This poor little Benelli is for sale near me. If I didn't already have five projects waiting. I'd think about buying it.

(https://i.ibb.co/M8bKkhc/Benelli-Sprite-crusty.jpg) (https://ibb.co/M8bKkhc)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on April 26, 2023, 09:06:11 AM
I steer clear of Champions since they seem to damage the threads in alloy heads too easily. I've had issues with NGKs - my V50 III would barely start and would only run on one cylinder with new, properly gapped BP7ES. Installed a pair of Denso W22EP-U and it started right up and ran perfectly. Runs even better with Denso IW22 (Iridium).

This poor little Benelli is for sale near me. If I didn't already have five projects waiting. I'd think about buying it.

(https://i.ibb.co/M8bKkhc/Benelli-Sprite-crusty.jpg) (https://ibb.co/M8bKkhc)


That Benelli would make a decent parts bike, it would cost me far too much to ship it.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on June 07, 2023, 09:16:17 PM
I got some of the Benelli / Motobi parts back from my painter, enough to get started on the reassembly. Hopefully the tank, fenders and side covers get finished next week

(https://i.postimg.cc/s264HkfJ/IMG-6209.jpg) (https://postimg.cc/67ZZy1v7)

I tore this ‘second’ 200cc motor down and checked all the bearings once again following the crank case bearing failure I had on the other motor, reshimmed it all and put it back together. I now have two complete rebuilt 200cc egg motors for this bike

I made up new swing arm bronze thrust bushings , tapped all the bolt holes in the chassis parts and started reassembling. I went a little crazy wrapping the fresh paint with clean white rags.

(https://i.postimg.cc/x1PRMkWh/IMG-6211.jpg) (https://postimg.cc/WdhgP4pw)

I will get the rear wheel on, also waiting for the headlight ears to get painted before I can put the forks together.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Dave Swanson on June 08, 2023, 12:16:05 PM
This bike will be amazing. 
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on June 09, 2023, 09:27:03 PM
I got the rear wheel, header and muffler on today

(https://i.postimg.cc/j58QQnph/IMG_6219.jpg) (https://postimg.cc/8J66TcPF)

(https://i.postimg.cc/cC2RPy4g/IMG_6216.jpg) (https://postimg.cc/p5Q5nSjR)

The front forks went together, I made new felt fork tube seals from leftover felt seals I had from my Airone restoration. Polished up the aluminum shrouds chucked over a steel tube and chucked in the lathe. Progress finer grits of sandpaper and polishing compound to get all the scratches out.

(https://i.postimg.cc/SsQfMfvs/IMG_6217.jpg) (https://postimg.cc/zLMhmK5Z)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on June 10, 2023, 09:24:46 AM
It’s looking fantastic, Jim.  They’re going to make a very impressive pair of motorcycles.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: SIR REAL ED on June 10, 2023, 06:29:15 PM

Very cool to see these bikes where almost every component is eye candy.

the good ole days....
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on June 15, 2023, 09:27:55 PM
A bit more progress, I picked up all the parts from the painter on Tuesday except for the gas tank.

(https://i.postimg.cc/wTF9WKCD/IMG-6238.jpg) (https://postimg.cc/kB6r4HX5)

All is good except the side covers will need redoing, for some reason the painter applied the side cover decals off level (he had pictures of the museum bike in Pessaro)

(https://i.postimg.cc/gjHGF1nF/IMG-6243.jpg) (https://postimg.cc/Lg5cjCtN)

 this ignores me to no end!!!!

(https://i.postimg.cc/Vk6mpGwp/IMG-6240.jpg) (https://postimg.cc/svtkZJv4)

Paint is pretty good, I wish I had insisted on the pin stripes being hand painted, they were going to be masked and sprayed but they ended up being tape stripes with clear over, not the end of the world but I am picky. I can live with it, 99% of the world would think nothing of it, it will probably bother me to no end.

(https://i.postimg.cc/sD3V9fNV/IMG-6242.jpg) (https://postimg.cc/bdFcqPPM)





Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on June 16, 2023, 07:02:03 PM
Just waiting on the gas tank now, will attempt to fire it up this weekend

(https://i.postimg.cc/kGJbkszh/IMG-6252.jpg) (https://postimg.cc/Q9zC7QXp)

(https://i.postimg.cc/zBSht6tg/IMG-6253.jpg) (https://postimg.cc/Q9CVV4r8)

(https://i.postimg.cc/2Sp45jfY/IMG_6246.jpg) (https://postimg.cc/nCksRJzS)

(https://i.postimg.cc/T1D93CC2/IMG_6266.jpg) (https://postimg.cc/BPJDh5rR)

(https://i.postimg.cc/j20fZK4K/IMG_6275.jpg) (https://postimg.cc/gXsr2C7B)

(https://i.postimg.cc/3xKgs85x/IMG_6274.jpg) (https://postimg.cc/kBp68dg0)

(https://i.postimg.cc/s2CGQLhq/IMG-6256.jpg) (https://postimg.cc/XrxYtQxk)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on June 26, 2023, 06:42:03 PM
I fired up the Egg today after stripping down the engine to replace a big double row ball bearing that jambed up last time I started the bike. It fired up on the first kick! Hurrah. Settled into a nice ideal, ran it for ten minutes then drained and replaced the break in oil.

I am waiting on the final paint and decals, won’t get the parts back until when I return from a vacation mid August.

Still working on figuring out the head light and tail light switch, Benelli indicated two types of lighting coil electrical, a single and double wire lighting coil and two types of headlight switch, a simple on/off type and a more complex headlight and taillight position and a taillight only position. The horn and battery are always live when the battery is connected and the Stator ignition coil deals with the spark. While the engine is running power is fed from the lighting coil to a rectifier and a separate regulator inside the headlight shell. So in effect there are three distinct circuits to the electrical system. Just to make it interesting my project bike came with the two wire lighting coil and the off/on switch, a miss match I believe, but I think I figured out the system today, just need to swap some wires around and try it again.

Fortunately I have the electrical diagram for both Stator options

(https://i.postimg.cc/vTnJYwyD/IMG_6332.jpg) (https://postimg.cc/p52GC7pt)

(https://i.postimg.cc/V62yPL33/IMG_6331.jpg) (https://postimg.cc/xJGpKYjR)

The challenges of old Italian motorcycles keep coming.
 
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on August 26, 2023, 07:14:05 PM
I have been away for the past two months but its back to the work bench to finish the Motobi in time for the Rocky Mountain Giro in Naksup B.C. this coming September 8 - 9 - 10.

My painter has finally finished with the gas tank and side panels and I have got the bike to start on one or two kicks and idle nicely.

(https://i.postimg.cc/1zWbCKCs/IMG_7117.jpg) (https://postimg.cc/sBhn15CN)

The oil pump is still leaking from the underside despite drilling and tapping the engine cases for M5 inserts and installing stainless steel M5 studs, all with locktite. I need to seal the four bolts that secure the two halves of the pump body together, I am amazed how much oil can run through the M4 machine screws.

(https://i.postimg.cc/QtHwRWw5/IMG_7113.jpg) (https://postimg.cc/1n1vF495)

(https://i.postimg.cc/Gp3ZxfjX/IMG_7114.jpg) (https://postimg.cc/rDbn8Q34)

(https://i.postimg.cc/K8D6LbtK/IMG_7115.jpg) (https://postimg.cc/9Dzg5v8V)

(https://i.postimg.cc/Bn3WXbP9/IMG_7116.jpg) (https://postimg.cc/N5dCngxp)

I made up some upper triple clamp to fork ear spacers, the rubber bits keep stretching and deforming so I turned up an polished stepped aluminum pieces.

(https://i.postimg.cc/PqqRwwtc/IMG_7105.jpg) (https://postimg.cc/Snwd0jY7)

(https://i.postimg.cc/pTwG4cDb/IMG_7103.jpg) (https://postimg.cc/8JbmrHKt)

(https://i.postimg.cc/sXQHnCG4/IMG_7106.jpg) (https://postimg.cc/S24Gs5rn)

(https://i.postimg.cc/0yn4jfqD/IMG_7107.jpg) (https://postimg.cc/WdD8f0z1)

The steering damper got sorted by using an Aermacchi Sprint damper rod and hand wheel, stock is a plastic hand wheel but I like the aluminum look.

(https://i.postimg.cc/MKT4fGYb/IMG_7111.jpg) (https://postimg.cc/fkG56DpJ)

I rewired the headlight bucket spaghetti junction, tore out the old selenium rectifier and coil regulator and rewired the light on - off switch.
Honda 6V reg/units would not work but a friend of mine who used to teach University electrical engineering circuit design found me a silicone rectifier that takes two alternator wires and delivers 6V DC, hurrah!! For the regulator he gave me a bundle of three resistors to run in line with the power to the battery, its great to have a guy look at this who knows what he is doing.

I bench shifted the running bike through the gears so I have my fingers crossed its going to be a smooth runner.

One fork leg is leaking out the bottom, I need to strip it and see what is up with the O ring base seal.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on August 27, 2023, 08:47:25 AM
Great to see new pics and hear good news about your bike, Jim.  It looks really great.  Good luck with these last gremlins.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on August 29, 2023, 07:29:49 PM
Thanks Clint!

I have been working through snags for a couple days, solved an oil pump leak, reworked the fork base seals, rewired for a silicone rectifier, solved an intake manifold leak, lots more small stuff, ready to get it on the road.

(https://i.postimg.cc/Pf9x5JYc/IMG-7147.jpg) (https://postimg.cc/DmQFC2Cd)

(https://i.postimg.cc/1Xn3K1hJ/IMG-7150.jpg) (https://postimg.cc/jnTTs9j7)

(https://i.postimg.cc/GpKtLjxJ/IMG-7153.jpg) (https://postimg.cc/677tznSy)

(https://i.postimg.cc/Cxjdt0Z2/IMG-7154.jpg) (https://postimg.cc/1839nLr0)

(https://i.postimg.cc/JhMtCFZz/IMG-7155.jpg) (https://postimg.cc/Bj7JxMmr)

(https://i.postimg.cc/rw6KQspW/IMG-7156.jpg) (https://postimg.cc/KRNGYZBv)

(https://i.postimg.cc/BQPjTHJ4/IMG-7157.jpg) (https://postimg.cc/0bx5x66B)

(https://i.postimg.cc/J72yHPVp/IMG-7158.jpg) (https://postimg.cc/5j89Z5tz)

(https://i.postimg.cc/Y924YPCs/IMG-7159.jpg) (https://postimg.cc/2qJ8f2vQ)

(https://i.postimg.cc/dtgTpn5h/IMG-7160.jpg) (https://postimg.cc/fJjL07ns)

(https://i.postimg.cc/6QX45qJw/IMG-7161.jpg) (https://postimg.cc/RWgZgMZb)

(https://i.postimg.cc/dVdTYdf4/IMG-7162.jpg) (https://postimg.cc/VJfN9SmC)

(https://i.postimg.cc/d1WhB97t/IMG-7165.jpg) (https://postimg.cc/FdLFF3g2)

(https://i.postimg.cc/pr4pNXYw/IMG-7164.jpg) (https://postimg.cc/CnCFk027)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: kballowe on August 30, 2023, 09:41:10 AM
Wow.  That turned out extra nice!!!

We're gonna need video.   LOL

 :thumb:
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on August 30, 2023, 05:16:52 PM
Wow.  That turned out extra nice!!!

We're gonna need video.   LOL

 :thumb:

Thanks!
I will be getting my registration this week, running video to follow.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 06, 2023, 09:17:29 PM
An update on my Motobi Sprite 200, I posted some pictures on the Benelli / Motobi site and Mac Dennis contacted me to tell me the tail light and license plate frame were incorrect plus a metal shield that covers the open end of the carburetor was missing. Now Mac is a great guy, he has helped me out a lot on this build, and to just top it all off, Mac gave me a NOS tail light, license bracket and the near impossible to find carb intake shield!!
I am so grateful to Mac, there are some really excellent folks out there, thanks Mac for your generosity.

The NOS tail light and bracket, never been on a bike before

(https://i.postimg.cc/02sJZpmB/IMG_7333.jpg) (https://postimg.cc/0rVQyKVY)

(https://i.postimg.cc/CxMnpScC/IMG_7334.jpg) (https://postimg.cc/dLXV8PPD)

And this sheet metal cup shaped shield that bolts to a nut welded on the underside of the gas tank, almost never seen on these bikes, I think only a couple in the Benelli museum had this piece on their bikes

(https://i.postimg.cc/66RvdH7Z/IMG_7332.jpg) (https://postimg.cc/Jtr08557)

(https://i.postimg.cc/mrtchVft/IMG_7329.jpg) (https://postimg.cc/QBZNyQM3)

I entered this Motobi in this past Septembers Rocky Mountain Giro in Nakusp BC Canada, on the Friday night before the weekend rides I took the bike up the 10 km mountain run and at the top I found the intake manifold split so I was out of action on the Sprite, very disappointing but I had brought my 1972 Benelli Enduro as a back up. On the Saturday it ran flat out for 300 km on a big loop through the spectacular Kootneys mountains of British Columbia and on the Sunday it got in two hill climb timed trials, the Enduro is unbreakable. Next year the Motobi will be back in the Giro for another try.

(https://i.postimg.cc/Kj75gMT3/IMG-7255.jpg) (https://postimg.cc/H8xMqjBT)
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: kballowe on November 07, 2023, 06:25:38 AM
This thread just gets better all the time !

Thanks for sharing !!!

 :thumb:
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: cliffrod on November 07, 2023, 11:44:31 AM
It really does get better.  Love the new pieces. 

Glad to hear you’re riding them and doing well, too.  As much as I like seeing your bikes, I like that even more.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Canuck750 on November 07, 2023, 06:00:13 PM
It really does get better.  Love the new pieces. 

Glad to hear you’re riding them and doing well, too.  As much as I like seeing your bikes, I like that even more.

Thanks Clint! I was down for the count for 5 weeks with my inner ear infection / loss of balance but I think I am mostly over it. Back to projects, my Aermacchi 250 is going to get worked on this winter.
Title: Re: 1965 Benelli / Motobi 200 Sprite
Post by: Turin on November 14, 2023, 11:04:42 PM
Love those egg shaped motors.