MT 500 Rebuild

[allanj255]

Well I rode my Armstrong this morning and on my return home I have started to strip it down for a rebuild / restoration job.
This you may remember what it looks like.
http://i243.photobucket.com/albums/ff268/allanj255/MT500016-1.jpg
4 hours later
http://i243.photobucket.com/albums/ff268/allanj255/mt5001.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2961.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2959.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2956.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2957.jpg
I will be re-spraying the bike to standard NATO green, sorting/upgrading the electrics out, pull the engine, changing cam belt, re-grinding valves and try to see why the bike is "wet sumping". Welding the exhaust up, it's rusted through where the mid section joines the lower rear section. rebuild breaaks, speedo hub gear plus anything else I find whilst it is in bits!
Will be doing it mainly at weekend and the odd evening.

[mattc]

A cam belt? WTF Well if it works...

Looks very interesting, I'll be looking for updates.

[Dirty_Sanchez]

That's a cool bike-

Would like to see some more closeup photos of that timing train and engine. That mill is a strange sight to behold.

Dirty

[allanj255]

That's a cool bike-

Would like to see some more closeup photos of that timing train and engine. That mill is a strange sight to behold.

Dirty
It's a 500cc single cylinder 4 valve single ohc(2 inlet - 2 exhaust) 4 stroke. The engine is a rotax from the 1980's. These engines were used by Armstrong, CCM, BMW, Aprillia, SWM, Cagiva amongest others. These engines are Bullet-proof, with magnisium cases. The cam belts save weight over a gear drive train and easy to maintain in the field by the military. A cam belt can be changed in next to no time. The bike is a dry sump - oil in frame, single carb.
Some close ups of the engine, I will post some more when the engine is out of the bike.
De-compression lever can be seen on top left of the engine - The bike is kick start only and the valve can be used to bump start the bike on soft ground down hill.
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2963.jpg

http://i243.photobucket.com/albums/ff268/allanj255/DSCF2964.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2965.jpg

[derf]

Yeah, I like the Rotax engines. I wanted an Aprilia Pegaso, which is about the same as the 650 BMW dual sport bikes.
Nice bike. The twin rear shocks make the bike look old-school but that motor makes it look like the best of both worlds.

[allanj255]

a few people I know have fitted Pegaso engines to MT frames to get electric start and more BHP.
I love the old school looks of the bike but frame is a bit heavy compared to modern kit.
Harley took over the contract from armstrong & built a 350 Rotax for the forces with electric start, front disc brakes but less power

[Redbird]

*subscribed* :D

[Juice]

++1


*subscribed* :d

[Rocky]

Thats something you don't see everyday. Subscribed!

[allanj255]

Bike almost stripped down, only front forks to go. You can now see the front part of frame that acts as engine oil tank. (oil in Frame) I removed rear wheel, swing arm and engine today.
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2986.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2988.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2989.jpg
Engine on the workbench. I will be pulling the head to check general condition and re-grinding valves when it's out, changing cam belt, check clutch and strip and repaint the engine cases
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2981.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2983.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2984.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2985.jpg

[Timo]

REME to the core!

[allanj255]

That's a cool bike-

Would like to see some more closeup photos of that timing train and engine. That mill is a strange sight to behold.
Dirty
Close up of valve gear.
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2994.jpg
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2990.jpg
The engine is a belt driven single over head cam. The cam belt drives the single cam shaft. The cam shaft has 2 lobes and each lobe has 2 rocker arms. 1 opens the 2 exhaust valves and the other the 2 inlet valves. Been a single cylinder the 2 exhaust valves open together as do the 2 inlet valves.
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2996.jpg

The exhaust valves are on the left and you can see the little lobe on the front valve. The decompression lever pushes down on this, opening the valve to aid starting this big 500cc kick start 4 stroke single.

Under side of exhaust valve cover showing decompression arm.
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2995.jpg
Top of cover showing decompression lever, which is cable operated from the handlebars.
http://i243.photobucket.com/albums/ff268/allanj255/DSCF2998.jpg

[allanj255]

Fully stripped down - ready for rebuild/respray.
http://i243.photobucket.com/albums/ff268/allanj255/dsrl004.jpg
http://i243.photobucket.com/albums/ff268/allanj255/dsrl002.jpg
http://i243.photobucket.com/albums/ff268/allanj255/dsrl001.jpg

[I_FLY_LOW]

Wow! You're really getting after it!
Patiently awaiting progress...

[Juice]

Looking good Allan.

[allanj255]

Thanks guys
The warm weather has turned up at last in Northumberland and the days are getting longer, so work should progress now. I recovered the seat tonight and hope to start to repaint the frame at the weekend.
Gasket set and cam belt ordered for the engine top end. Have bought a brand new old stock speedo with 00000 miles off eSlay for a bargin £29. they tend to cost £70 if you can find one

[Rocky]

Sweet!

[teethandnails]

I like the camo.

[Zutopong]

Progress, sweet!

[allanj255]

Main bike frame primed ready for NATO green paint, should get green paint on this weekend
http://i243.photobucket.com/albums/ff268/allanj255/MT500primer.jpg

[Juice]

PROGRESS, looking good buddy!

[allanj255]

It's green at last!
Now I've painted the MT the rebuild due to start Sunday - just hope i can remember where everything goes

http://i243.photobucket.com/albums/ff268/allanj255/MT500005.jpg

[Rocky]

That is going to be one sweet ride!

[Dusty]

Looking awesome Allan. That is going to be one sick ride!

[allanj255]

Slow but sure. Having to do rebuild around work and family. Swinging arm on today, and re-built & fitted a pair of Ohlins air assisted shocks
http://i243.photobucket.com/albums/ff268/allanj255/MT500005.jpg
http://i243.photobucket.com/albums/ff268/allanj255/MT500010a.jpg

[Zutopong]

What a cool project. I can't wait to see it upon completion.

[Ritten]

There is nothing red in that list of parts other than tape and hoods. What about rebuild stuff to retrofit Force with Red?


WTF?? :laughat:

Bitch, you had better start making sense before I ban your ass for excessive stupidity! A hood?? Are you kidding me? It's bots like you that give respectable spammers a bad name! GET A DAMN ROLE MODEL!!!!!

[allanj255]

WTF?? :laughat:

Bitch, you had better start making sense before I ban your ass for excessive stupidity! A hood?? Are you kidding me? It's bots like you that give respectable spammers a bad name! GET A DAMN ROLE MODEL!!!!!

+100 :grrrrr:

[Juice]

update????????

[allanj255]

To cold to work in my non heated garage over the winter, need to finish paint but hope to get back on track with rebuild and have goal to be finished by easter.(will bewell over 1 year late but been ill knocked me and project for 6) I have stripped and decoked the top end of the engine, re lapped valve seats and fitted new cam belt - once snow stops I will get some more pictures as I have a rolling frame again. Biggest job will be electrics as they were bodged up beyond belief but if I get a break in the weather it will be done before to long.

[Juice]

Please keep us posted when you get back to turning wrenches!!!

[allanj255]

Don't worry, I will but damn we have had snow and below freezing temperatures for 2 weeks straight here in Northumberland - we never get this in November - December. I think those Texas boys have turned off the Gulf Stream. We had two days of -4 F last week here in Northumberland .........brrrrrrrrrrr! I'm even cold indoors

[Juice]

Suppose to be in the low 70's here tomorrow!!! I'm considering taking the boat out,
Don't worry, I will but damn we have had snow and below freezing temperatures for 2 weeks straight here in Northumberland - we never get this in November - December. I think those Texas boys have turned off the Gulf Stream. We had two days of -4 F last week here in Northumberland .........brrrrrrrrrrr! I'm even cold indoors

[2Dogs]

Don't worry, I will but damn we have had snow and below freezing temperatures for 2 weeks straight here in Northumberland - we never get this in November - December. I think those Texas boys have turned off the Gulf Stream. We had two days of -4 F last week here in Northumberland .........brrrrrrrrrrr! I'm even cold indoors

Damn man, do try and uphold your Norse heritage. A little cool weather and you are falling apart.

It was the coonasses that turned off the valve. The flow runs east to west in the north of the gulf. We in Texas get it from them. They are at 70 degrees we are at 50 degrees so they hog all the heat.

I have our valve wide open Allan. Just try'in to help.

[allanj255]

Typical UK we just fall apart with 1/8 inch of snow. Caught every one out - it's normally January before we get our first significant snow but I can never remember it getting down to -4F here.
It's warmed up today and the 2 weeks of snow is now melting - causing flooding lol. Thanks for turning the tap wide open Dawgs - it obviously worked - just wish I asked you earlier in the week to help out.
http://i243.photobucket.com/albums/ff268/allanj255/Pictures/DSCF4286.jpg

[allanj255]

Suppose to be in the low 70's here tomorrow!!! I'm considering taking the boat out,

I would do the same but I remember what happened to The Titanic

[Save-the-Manatee]

Looking good man!

[Busboy]

You got to get yourself a little diesel blow heater for the garage Allan. Loosing impetus on a project can lead to garden art.

[allanj255]

Got a week off work at the end of this month, so expecting major progres - I have been working on the engine/gearbox over the winter but not much to see in a photo.
My goal is to have bike MOT'd and back on the road for Easter

[scooterhose]

A poke with a stick.:wall:

http://i220.photobucket.com/albums/dd109/falsalot/Dragon%202011/IMG_4439.jpg

http://i220.photobucket.com/albums/dd109/falsalot/Dragon%202011/IMG_4442.jpg

[allanj255]

I've got a week off in 2 weeks time and hope to be well on the way to getting the Armstrong back on the road - watch this space for update then

[Busboy]

The one for sale, is owned by the same fella I nicked the tigger and Tenere from. When it comes to spanner work he's master of the half job

http://i220.photobucket.com/albums/dd109/falsalot/Dragon%202011/IMG_4439.jpg

[allanj255]

Is that picture from a MT Riders Club outing in Wales - some good guys in that club, but a lot of arse wipes too. I gave one guy some parts for free - damn I even paid the postage for him to "get his bike back on the road" - only to see that he had sold them on ebay for £60 two weeks later

[Juice]

Should be nice and warm in Northumberland by now. Just Say'n.

[allanj255]

Ha ha , it's still cool - we missed out on the heatwave the rest of the UK got (no change there), warmest day today for 2 weeks and it was 58 F at noon but I am making progress -rolling chassis - engine rebuilt - just need to paint the the engine cases and cylinder, busy with the electrics - they were a real bodge job by previous owners. I will post some pics up at the weekend I want it finished for July as I plan to take it to the Jeeps and Jets rally.

[allanj255]

The sun came out after work today - lets hope it stays out - electrics next
http://i243.photobucket.com/albums/ff268/allanj255/bikes/060611.jpg
http://i243.photobucket.com/albums/ff268/allanj255/bikes/060611a.jpg

[Juice]

Damn, that looks nice Allan!!!!!

[allanj255]

A bit more done today - a lot of which can't be seen - rebuilt front brakes, made spacer for front wheel hub, fitted new gear to speedo hub drive - air box & air box mud guard fitted, painted rear mud guard and fitted. Head light cowl painted and fitted. As luck would have it or not! I found a fair few small parts that I forgot to paint - then it rained just as I was getting ready to paint them

This is where I was up to
http://i243.photobucket.com/albums/ff268/allanj255/bikes/060611a.jpg

and at 5pm

http://i243.photobucket.com/albums/ff268/allanj255/bikes/CIMG0214-Copy.jpg
http://i243.photobucket.com/albums/ff268/allanj255/bikes/CIMG0215.jpg
http://i243.photobucket.com/albums/ff268/allanj255/bikes/CIMG0218.jpg
http://i243.photobucket.com/albums/ff268/allanj255/bikes/CIMG0217.jpg

[Juice]

That thing is going to be sick!!!!!!!

[Juice]

Where you at? Progress? Update?

[allanj255]

Well Juice, best laid plans - I changed the timing belt without looking - only to find out that the last owner had changed the timing gear without marking the new pulley. I need a tool to find tdc on the bike n mark up the pulley - as you will remember its a belt drive ohc. I will have it sorted next month - work, family, cold weather etc eat my time but there is only about a days work in it and my friend has the tool I need so fingers crossed