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Posts posted by lorenzo
  1. Ninja -

    + 1 on woody's comments.

     If the leak persists, check that the gearbox breather is clear. It's a small hole high up on the left crankcase, just forward of the fixed end of the kickstart  spring. If this hole is blocked, some have found that this can cause an oil leak from the gearbox or worsen an existing one, especially when the motor gets hot.  (The air inside the gearbox will expand with heat, and it has to go somewhere, I suppose..........)

    On this 199 engine I've pushed a piece of wire into the breather to make clear its position :-



    • Like 2
  2. 3 hours ago, Gearboy said:

    My parts does say my frame number (9077) uses the bushing.

    The spacer in reality is narrower than it appears on the drawing. The frame bracket provides an ideal "chute" for the spacer to roll down and out (to get lost) when the bolt is withdrawn.......

    Without the spacer, tightening the bolt will possibly deform the frame bracket and makes the bolt likely to come loose.

    On 3/16/2022 at 7:32 AM, carl ekblom said:

    199A head steady is not a good design.

    .......and can give trouble even when all fixings are tight.

  3. When you fit the head steady, make sure that the spacer #138.10 - 119  (no. 39 in the illustration) is in place on the frame fixing bolt , otherwise it will not tighten correctly. This spacer is easily lost.........


    Bultaco 199 engine.jpg

  4. Slowrider -

    Holes in the pistons are one part of the booster ports, the other part being the slots in the cylinder liner. You need these if your engine is to perform as Bultaco intended. First o/size Mahle piston :-


    The hat shaped sheet metal caps you refer to are oil baffles/deflectors (Bultaco called them "oil breakers")  ; AIUI their purpose was to influence the amount of oil coming out the top of the damper tube. You appear to have non-standard dampers, and I can't see how the caps would fit, but who knows ?.

    • Thanks 1
  5. Mark -

    Based on my experience with these engines, your main area of concern is likely to be the crankshaft assembly and its bearings and seals, and piston and bore, rather than problems with the gearbox. These tend to be reasonably robust, although possible weaknesses are covered in feetupfun's post.

    Did you use heat when dismantling ?  Difficult to see, but from your tenth picture it looks like main bearings are possibly loose on shafts........

    Are you in the UK ?

    Don't worry about being quite young and lacking experience - we all were once !

    • Like 1
  6. 14 hours ago, Bloomfield said:

      Is that one of those Indian repro tank units, or did you strip and polish the original? All we see are fibreglass ones over here.

    Homerlite alloy tank/seat unit, standard on models 124/5 and 150/1, etc. supplied in UK. (see front cover of Heinous manual).

  7. 9 hours ago, slowrider said:

    After looking at the outer cases, they are pretty hammered,

    Pics. ?

    Unless they are damaged beyond saving, you may be best off cleaning up the originals. Cracks can be welded. The primary case is usually thick enough to get away with a fair amount of filing/grinding. Failing this, as Bloomfield states it is the same as fitted to various other models.

    Not so the mag. cover, which is quite thin and fragile in comparison - and probably also the reason that it's in very short supply. (you may be very lucky to find one that's any better than the one you have). It was also used on a smaller range of models - (for Sherpa range, 198/199 A & B models only)


    • Like 1
  8. Slowrider -

    This is a TRIALS bike, and most trials riders would expect well-tucked-away controls, to reduce the possibility of accidental operation or snagging on obstacles. The brake pedal you have appears to be a version of the standard l/h fitting ; the original version of r/h pedal offered by Bultaco was equally tucked away, but unfortunately also provided a less usable brake.(see responses above). For comparison :-


    The Spanish pedals mentioned are very nice, but you may also want to consider something a bit less eye-watering, price-wise :-


    It's your bike and you do what you like with it,  but my personal feeling is that your views may change once you have ridden it a bit. Good luck with whatever you decide.

    • Like 1
  9. Alpina M85 was available 1971-74. Which of these years / what model is your Sherpa engine ?

    Factory parts book (later issue) for Sherpa 250 M80 lists M85 frame and also upper/lower yokes (triple clamps) as replacement parts ; I take this to mean they are mutually interchangeable, even if not actually identical.

    • Like 1
  10. 8 hours ago, Fogcity said:

    Number on frame: B-10000131     

    Number on engine: M-68018557  

    Frame :    Model 100  125 Pursang  Mk. 6

    Engine     Model  68   250 Pursang  Mk 4

    Many components are shared throughout the 100/101/102/103/104 Pursang range. If it still has original Amal carb. this might provide a clue : 27mm. on the 125, 36mm. on 250.


  11. Hmmmm.......

    On 5-spd. Sherpas,  the early type sleeve gear bushes were replaced  from mod. 124 onwards with needle roller bearings and the 20mm. o.d. seal #160-031 and this arrangement continued to the end of production as far as I know..

    I've dug out a mod. 124 sleeve gear so you can see what yours should look like: (ignoring the worn sprocket splines)


    As far as counterboring your existing sprocket,goes,  it looks to have suffered some significant scoring to its bore. If your new needle roller bearings are to enjoy a worthwhile  service life, the bore needs to be very smooth. (see above).

    To save yourself lots of further grief, you may do well to check off all the other gearbox parts against the parts book; some earlier (or later) parts will interchange and work, many will not. Who knows what mechanical mischief it may have suffered in the last 40-odd years ?


    • Like 1
  12. Colin -

    As purchased, was this a complete (running) engine, or was it already dismantled ?

    Does the mainshaft have needle roller bearings ?

    The sleeve gear you have appears to be an earlier variant, which would have had 2 bronze plain bushes..........and NO oil seal..... It doesn't belong on a 191.

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