bondy Posted December 19, 2015 Report Share Posted December 19, 2015 Make sure thrust washers face in with the dimples. 1 Quote Link to comment Share on other sites More sharing options...
guys Posted December 19, 2015 Author Report Share Posted December 19, 2015 Thanks Bondy, good tip. Quote Link to comment Share on other sites More sharing options...
bondy Posted December 19, 2015 Report Share Posted December 19, 2015 The dimples hold the oil so the big end bearing gets lubricant. 1 Quote Link to comment Share on other sites More sharing options...
pschrauber Posted December 19, 2015 Report Share Posted December 19, 2015 ... Some damage by the kick start mechanism ... The middle gear on the left axle seems to have to much play. ... The vid is nice I thing the third bearing had some debris inside. Anyway I would try to replace damaged engine parts, especially to the kickstarter and to the gearbox, a broken gear can cause some damage. (I would replace whenever possible the pair of gears). I had some really in depth going issues with gears and kickstarter mechanism which ended a big rebuild. 1 Quote Link to comment Share on other sites More sharing options...
stevem75 Posted December 20, 2015 Report Share Posted December 20, 2015 As noted in a previous post stating "only 500 159's were built making it relatively rare" is incorrect. I know this as I owned at one time serial 4703 and a good friend has 4698. They made thousands of 159's. Steve 1 Quote Link to comment Share on other sites More sharing options...
guys Posted December 22, 2015 Author Report Share Posted December 22, 2015 Now isn't that lovely, they stamped a little hart in the case. Cylinder and head ready for painting, which in the meantime has been done. The cylinder is at the shop for a re bore and the crank shaft for a new con rod. 6 Quote Link to comment Share on other sites More sharing options...
bondy Posted December 23, 2015 Report Share Posted December 23, 2015 Lovly job 1 Quote Link to comment Share on other sites More sharing options...
guys Posted January 7, 2016 Author Report Share Posted January 7, 2016 (edited) Although I thought that the free spinning gear on the layshaft had too much play, it wasn't as bad as I thought. Thanks to InMotion I got a brand new, about 40 year old shaft and gear. Thanks to a manual, and the simple lay out of the Bultaco engine, the rebuild is coming along nicely. Crank and cylinder are expected back from the shop any day now... Home made engine support: Edited January 7, 2016 by guys 5 Quote Link to comment Share on other sites More sharing options...
guys Posted January 15, 2016 Author Report Share Posted January 15, 2016 Just bought me an original 1975 style aluminium petrol tank for my Sherpa. In the south of England of all places. It's to replace the slimmer 199 type plastic petrol tank that was on my bike when I bought it. Great! 5 Quote Link to comment Share on other sites More sharing options...
Popular Post guys Posted February 17, 2016 Author Popular Post Report Share Posted February 17, 2016 All's well that ends well. Heating up the engine case to insert the crankshaft: Putting Loctite 510 on the gasket, just to be sure. The work on the engine is done and it's back in the frame: Before: After: Very pleased with the result. Money well spend if you ask me 12 Quote Link to comment Share on other sites More sharing options...
greeves Posted February 17, 2016 Report Share Posted February 17, 2016 (edited) Sounds "perfecto" !!! Good work. Edited February 17, 2016 by greeves 1 Quote Link to comment Share on other sites More sharing options...
lbhbul Posted February 19, 2016 Report Share Posted February 19, 2016 (edited) Good work Guy , it doesn't get much nicer sounding than that!! Best regards Larry Edited February 19, 2016 by lbhbul 1 Quote Link to comment Share on other sites More sharing options...
jonjeans Posted January 14, 2018 Report Share Posted January 14, 2018 Fascinating read and education thank you all. My 191 has perhaps a Mahle piston, assistance in identity will be welcomed, at 84.75mm size. Some scuffing and broken lower ring. 20mm diameter gudgeon pin retained by circlips, and 2 alloy spacers. InMotion stock 84.70 ring sets, and I have asked them if they will fit. Hope so, as do not wish to buy complete new piston at this stage in the rebuild. So, what piston do I have, it looks like "guys" in earlier post this thread, and if new required, what do you suggest with 84.75mm bore? And should bottom of barrelled be chamfered to aid piston with rings insertion? Many thanks, jj Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.