Author Topic: 1974 Moto Morini 3 1/2 Sport restoration  (Read 15585 times)

Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #30 on: July 24, 2018, 09:20:47 PM »
Sliders cleaned, seals replaced, forks reassembled and filled with fresh oil. Fender bolted in place.




The brake shoes had already been assembled to the backing plate, but the anchor bolt was left out, so I had to remove them and insert the bolt.



Assembled the speedometer drive.



Missing the 58 x 70 x 6 grease seal that goes here. Ordered it today.


Test fitted the front wheel and brakes. It'll have to come back off once the seal arrives.


At some point the threads in the headlight bucket were drilled out.


Probably to mount these (obviously non-original) Japanese signals.


For now, I used nuts on the inside of the bucket. Eventually, I'll repair the threads with a Helicoil.


Test fitting the clutch cable. Starting to look like a motorcycle again!


Front brake cable is next.


Test fitting.


Need to find the barrel for the lever end. It's likely somewhere in all of the misc. hardware. 

« Last Edit: July 24, 2018, 09:22:15 PM by Antietam Classic Cycle »
Charlie
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'67 Sears Allstate/Puch SR250
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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #31 on: July 24, 2018, 09:44:18 PM »
The front brake on the early 3 1/2 Sport is sure pretty!

Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #32 on: July 25, 2018, 09:48:36 PM »
The barrel has gone missing, so I found another in my stash and modified it.



Had to enlarge the holes and cut a slot.


Fits perfectly and the brakes work, but it doesn't extend down to actuate the brake switch like the original.


Hooked the cable to the speedometer...


...but I'm missing the retainer clip that secures the cable inside the nut down at the speedometer drive.


Blurry photo of the cleaned and greased throttle


Less blurry photo of the same


I started working towards installing the rear wheel, but one bearing of the sprocket carrier felt a little rough. So, I removed the bearings and cleaned them. One needs to be replaced, the other is fine. Ordered the bearing and a grease seal.


Slipped the new reproduction rubbers onto the footrests and test fit them to the frame.


Installed the sidestand and test fitted the brake pedal as well.


Test mounted the brake light switch, hooked the cable to the pedal. 

Charlie
http://www.AntietamClassicCycle.com
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Offline Rod

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #33 on: July 26, 2018, 05:15:25 AM »
The barrel has gone missing, so I found another in my stash and modified it.
To paraphrase a line in one of my favorite movies, "Charlie, I think if you were named Admiral of the Turkish navy, you could dip into your "stash" and come up with the appropriate badges of rank."
Sure saved me a few times!
That bike is looking incredible.  :thumb:
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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #33 on: July 26, 2018, 05:15:25 AM »

Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #34 on: July 27, 2018, 03:23:05 PM »
Replaced both bearings and the seal in the sprocket carrier, mounted up the rear wheel.




Hooked up the rear brake cable







Down on it's wheels again!




Bird's-eye view.



The seal for the speedo drive side of the wheel arrived today, so I'll wrap that up next. That be a few days from now though - need to make some progress on other projects.


Charlie
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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #35 on: July 28, 2018, 09:50:57 AM »
You are setting the bar high on this one, looks fantastic!

Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #36 on: July 28, 2018, 06:53:50 PM »
You are setting the bar high on this one, looks fantastic!

There is still some "patina" on various parts, the owner wants it that way. So I must restrain myself and leave them as they were brought to me.  :grin:
Charlie
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Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #37 on: August 09, 2018, 03:38:55 PM »
Seal installed in the right front brake backing plate.



Still haven't found a clip for the speedometer cable...


...so I made one from an M6 flat washer.


Speedo cable done!


Drive chain is next.


Installed...


But it rubs on the clutch arm when the lever is pulled in and the wheel spun.


I had the countershaft sprocket on backwards  :embarrassed:, flipped it over and now there's plenty of clearance.



Charlie
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Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #38 on: August 09, 2018, 04:08:46 PM »
Cleaned the fuse block and voltage regulator and installed them along with the backing plate.



The tool tray is installed along with them.


Slipped the rubber boot onto the alternator harness.


Connected the stator leads to the fuseblock and voltage regulator.


Cut a piece of acid neutralizing battery mat...


...and set the battery into place.


Connected the rear brake light switch at both ends.


Mounted the transducers.



And the terminal block just ahead of them.


Connected the harness between the ignition switch...


...and fuseblock.


Hooked up the taillight at both ends.



The harness from the battery to the fuseblock was looking a bit melted.


So, I made a new one with heavier gauge wires and connected it.



Connected the harness from the ignition pickups to the transducers.

« Last Edit: August 09, 2018, 04:09:14 PM by Antietam Classic Cycle »
Charlie
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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #39 on: August 09, 2018, 04:22:38 PM »
Your getting real close, its looking great!

On my 500 build I was flipping through the parts diagrams last night and realized I forgot to install the O ring onto the end of the kickstart shaft before fitting the outer case, darn!!

I need to remove the outer case again, the first two times was to get enough tension on the kickstart return spring to bring the pedal back up with a snap.

Nice work making the cable clip from a washer!

Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #40 on: August 09, 2018, 05:28:46 PM »
Your getting real close, its looking great!

On my 500 build I was flipping through the parts diagrams last night and realized I forgot to install the O ring onto the end of the kickstart shaft before fitting the outer case, darn!!

I need to remove the outer case again, the first two times was to get enough tension on the kickstart return spring to bring the pedal back up with a snap.

Nice work making the cable clip from a washer!

Right now I'm waiting on Moto Storiche Italiane to send me a total for a pair of new exhaust nuts. Guessing that'll be sometime in Sept!  :grin:

"Necessity is the mother of invention." I was just too tired to go searching for such a small, seemingly insignificant part.  :wink:
Charlie
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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #41 on: August 09, 2018, 05:44:48 PM »
Excited to see the finished product...loving the build thread!  :thumb:

Offline Diploman

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #42 on: August 10, 2018, 08:10:56 AM »
Outstanding work, Charlie! That is going to be a beautiful 3 1/2 when you are finished.  This thread is a fascinating document to your meticulous rebuild.  You and Jim are certainly on a tier above most of us mortals....

One bit that always impresses me is the painstaking efforts to restore old-fashioned cable drive speedos and tachs on vintage bikes from several decades ago.  That's the difference between a restoration - where the goal is to return a bike as closely as possible to OEM configuration and condition as delivered - and a modernization, where the goal is to adopt more recent solutions that can improve performance, simplify installation or lighten the bike (eg. lithium batteries, speedos and tachs free of cable drives, lightweight starters, etc.). I admit to being shamelessly in the latter camp, but I am full of admiration and awe for the true craftsmen like you and Jim who can pull off gorgeous, authentic restorations like this.  My sincere congratulations!!
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Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #43 on: August 14, 2018, 06:49:48 PM »
A few more harnesses to go.




Warning lights done. 


Started hooking up the tach, but discovered there's no light socket or tiny M3 nut that secures the ground wire. 


Connections all done to the transducers. 


Starting to look like an "explosion in a spaghetti factory"... in other words, just like original! 


Mounted the horn and connected the electrovalve temporarily. Ground the paint away from the ground point on both sides of the frame. 


Installing the harness for the signals.


Connecting the headlight.


Need to attach all of the blue wires to a clean ground on the frame. 


Even more spaghetti.


Time for the first electrical test. Connected the battery. 


Nothing came on when I turned the key.  :sad: Working on finding the problem.


Narrowed it down to the key switch. When I touched the red to the brown, the main circuit powered up.


Disassembled the switch and cleaned the contacts, still didn't work.


Someone has had the switch apart before and misplaced the tiny springs that push against the contacts.


I cut sections from an ink pen spring, inserted them, reassembled and everything finally came to life!

« Last Edit: August 14, 2018, 09:11:46 PM by Antietam Classic Cycle »
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Offline Rod

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #44 on: August 15, 2018, 06:34:53 AM »
Ink pen spring! Great workaround.
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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #45 on: August 15, 2018, 10:50:07 AM »
Nice progress. After making my Morini 500 harness pieces and refitting them to the CEV fuse box the method to Morini's madness makes sense, it may not look 'organized' but by having a separate harness for each component it does make trouble shooting and isolation much easier.

Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #46 on: August 18, 2018, 02:52:41 PM »
Thanks to Greg Bender, I was able to wrap up the tach wiring. He sent me a bulb holder, M3 nut and washer.




I also bought a nice "no-load" flasher and bracket from him. Started securing the harness to the frame.




More zip-ties to secure the harness.




Corrected the angle of the rear cylinder carburetor by rotating the manifold. Now to lock it in place.




In the meantime, lubed and installed the throttle cables to test fit. One is about 4 mm longer than the other. It could really use new cables.





Charlie
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Offline huub

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #47 on: August 20, 2018, 10:41:55 AM »
probably a good idea to fit a set of relays inside the headlight, the stock handlebar switches tend to overheat and melt if the bike ridden with lights.

Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #48 on: August 20, 2018, 12:40:10 PM »
probably a good idea to fit a set of relays inside the headlight, the stock handlebar switches tend to overheat and melt if the bike ridden with lights.

Yes, I am well aware of that issue - the same one that "plagues" Loopframe Guzzis. However, since the original 45/40 watt sealed beam blew out as soon as I put power to it, I will be fitting an Autopal H4 headlight with RTD LED bulb. The LED bulb only uses 20 watts on low and 40 on high, so not enough load to melt the switch.
Charlie
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Offline Tom in VA

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #49 on: September 01, 2018, 08:03:03 AM »
Nice work Charlie, super clean work.
Tom in SE VA

Offline hidn45

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #50 on: September 01, 2018, 10:05:19 AM »
Hey Charlie - is there a particular RTD bulb you prefer, or a place you normally get yours?

Thanx!

ps - BTW - great work!
« Last Edit: September 01, 2018, 10:07:05 AM by hidn45 »
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Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #51 on: September 01, 2018, 03:35:23 PM »
Hey Charlie - is there a particular RTD bulb you prefer, or a place you normally get yours?

Thanx!

ps - BTW - great work!

This is the bulb I use:
https://www.amazon.com/gp/product/B06XHMJQCB/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1
Charlie
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Offline F-22

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #52 on: September 03, 2018, 05:49:26 AM »
I've noticed you (also) use two gaskets on the complicated early cast carburetor intakes. If I remember right, they originally came with O-ring seals in that place. They were known to leak, but I've also simply tried using a gasket there (also left the O-ring in there), and never had a problem.

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #53 on: September 03, 2018, 09:17:49 AM »
I've noticed you (also) use two gaskets on the complicated early cast carburetor intakes. If I remember right, they originally came with O-ring seals in that place. They were known to leak, but I've also simply tried using a gasket there (also left the O-ring in there), and never had a problem.

They have both gaskets and o-rings, that's the way the parts diagrams show it. Right now they are only "test fitted", when I final assemble them, I'll apply a little sealer to make sure there are no leaks. 
Charlie
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Offline F-22

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #54 on: September 03, 2018, 11:18:10 AM »
Well, I've also straightened them on a flat surface with 800 grit sandpaper, perhaps worth a try if you have any problems... My 77' was mostly stock, I really doubt anyone ever pulled the intakes off, but it certaintly only had o-rings there. But who knows, it's even possible they forgot the gasket at the factory, or decided to include it later (although mine is a fairly late model for the alloy intakes).

Offline Antietam Classic Cycle

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #55 on: September 03, 2018, 11:32:43 AM »
Well, I've also straightened them on a flat surface with 800 grit sandpaper, perhaps worth a try if you have any problems... My 77' was mostly stock, I really doubt anyone ever pulled the intakes off, but it certaintly only had o-rings there. But who knows, it's even possible they forgot the gasket at the factory, or decided to include it later (although mine is a fairly late model for the alloy intakes).

If you look through all of the photos, you'll notice that I already flattened all of the surfaces.

Original parts diagram. 17 are o-rings, 18 are gaskets.


Charlie
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Offline F-22

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #56 on: September 03, 2018, 01:34:14 PM »
Well, it's odd that mine did not have it.

By the way, I remembered I have this A4 copy of the english Morini manual on my PC:
https://drive.google.com/file/d/0B90E_BFXZAM5LXdQVmtkS0pnTEE/view?usp=sharing

It's really hard to find one, there's only the small version which is also in Italian and with smaller photos. This one is a bit more clear with larger photos... If it is any help to you. :thumb:

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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #57 on: September 03, 2018, 05:00:04 PM »
Well, it's odd that mine did not have it.

By the way, I remembered I have this A4 copy of the english Morini manual on my PC:
https://drive.google.com/file/d/0B90E_BFXZAM5LXdQVmtkS0pnTEE/view?usp=sharing

It's really hard to find one, there's only the small version which is also in Italian and with smaller photos. This one is a bit more clear with larger photos... If it is any help to you. :thumb:

Thanks! My "blue book" is a copy of a copy, so any photos aren't very good. Thankfully, the Morini Owners Facebook page has better ones in the Files section, including very nice wiring diagrams.
Charlie
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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #58 on: September 14, 2018, 06:56:14 PM »
Installed the front signals and finished up headlight installation.




Installed the new front brake light switch along with the original brake cable barrel that activates it. The switch is made by Magura and came with new terminals and the rubber boot.




Roughed out a mounting bracket for the rear signals. Early 3 1/2s had no tabs on the frame to mount signals, so this is my solution.


Charlie
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Re: 1974 Moto Morini 3 1/2 Sport restoration
« Reply #59 on: September 24, 2018, 09:46:51 PM »
Installed the breaher hose...



while the paint on the bracket cured.


Signals done.


Bracket mounts in under the taillight bracket like so.


On to the exhaust finally. Rear/left head pipe in place, muffler fitted to position it correctly.


Test fitting the heat shield to see if it clears the kickstart lever. It does.



Preparing to install the front/right headpipe. Stuck the gasket to the head with a little RTV, applied copper anti-seize to the threads. 


The half-rings are stuck in place with RTV and exhaust nuts threads coated with copper anti-seize as well. 



Charlie
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