sunny

This is the air filter from my M80. I was able to cut my own filter from bulk UNI filter mat which I got at my local motorcycle shop for like $20 can. I could easily make a lifetime supply of filters from the one chunk. I only had one sheet of perforated steel with the spring. The old filter had totally broken down.

Those bars were on my M80 when I got it and I moved the bars that were on the M159 over to the M80 and the mx bars to the M159 for the time being until I find some chrome vintage trials bars. I do have the head steady. I will install when I have it all lined up. I am having trouble with the exhaust hanger and motor mount and will likely have to remove the mount bolts and start over. Thanks for the reminder about the head steady. I think it is just the photo that makes the top tube look bent. Sunny

Sorry two of the same

I think I will be a weekend putt putt guy. I really enjoy the fixing refurbushing part the most. Here is another photo of the bike coming together. I just got an offer of a used Sammy Miller seat from a forum member. It pays to post and ask questions. I will post a photo when I get the seat.

I got the rings and the clutch thrust bearing in the mail from Speed and Sport and as expected they were a perfect fit. I have the engine back together and in the frame a few things have come to light I think it matters which way the mounting bolts go. I had them going head to the left and nut to right and I think it should be the reverse and I also had trouble fitting the exhaust and the hanger that goes to the top rear engine mount bolt. I think I will have to pull the mounting bolts and exhaust out and start over. I tried to start it up the way it was but the petcock leaks like crazy. Can it be rebuild? It take all of my 240+ lbs to turn the engine over which I think means it has good compression. Finally, the throttle does not have a stop and the cable pops off. The list of new parts and things to fix got a little longer. Does anyone have a seat pan for a M159.

I have ordered the rings and a radial thrust bearing for the clutch from Speed and Sport and I am putting the finishing touches on the engine. How do you guys polish the cases?

Thanks for the advise maybe I will get one of each and see if it make s a difference Mike

I am sure it has been mentioned somewhere here but a quick search did not turn up the answer. What NGK plug to I need for my almost complete M159? I have ordered the rings and clutch thrust bearing. I have turned a box of parts into what I hope will be a running engine.

Great News. It was too much of a project for me. Glad it made its way in to the hands of the right person. The guy I bought it from was going to junk it. I ordered a set of rings and the clutch thrust bearing so that will complete the engine on the 159. I also made up a brake rod out of 1/4 inch aluminum round stock and made a barrel bolt out of steel round stock. Tapped and threaded the works and it works well. Really just need fenders, a seat, and a set of trials bars. Mike

I sold the matador and engine to a member of this board. I will let him post about the purchuse if he wants to. I am curious if he has made any progress on the project? Mike

My M80 has 2 plugs and a compression release sunny

Dave do you know the size and can I get this at a bearing supply? I got all of the oil seals at Western Equipment in Victoria they were very helpful but I had the sizes from the parts book. Mike

Is there a brearing that goes in the clutch between the mushroom rod and the adjustable clutch plate? If so what size is it? It looks like the parts diagram shows this but difficult to make out. thanks Sunny

Yes I installed a paper gasket between the cases it was NOS bultaco. I also just picked up new oil seal from the industrial supply house today. Sunny

Thanks for all of the suggestions, help and personal messages offering assistance. I have got the cases back together. I heated the right side in the kitchen oven when the wife was out and it slipped right on without even using a rubber hammer. I have now started to assemble the ignition/flywheel, the gearshift etc.... I just need to get a few new things a seal, a lock nut for the kickstart spring holding nut ( is that avaliable?), the four long studs to hold the cylinder and head, a new set of rings (which i have to figure out what size they are), a holding washer for the sprocket, so really not all that bad considering it came to me as a basket of parts that changed hands a few times before I got it. I was looking at the manuls and saw that there is a speciality tool for clutch spring installation and I thought that I could make something simular.... but as I worked my way through the boxes of bits I found this modified power driver bit from the previous owner so I decided to make an improved one using an old nutdriver. Sunny

I was re-reading some of the posts that I have made sorry about some of the typos. I have made progress!! I cleaned everything and have blown it out with compressed air. I really am just trying to figure out what I have and what I do not have. I decided that I will reuse the "original" C3 bearings they seem to be in good condition --- they might have been replaced recently. My goal is to get it together and running and if in the future repairs need to be done then so be it. I love the experience of taking nothing and making it in to something. I am now ready to join the cases I have fit the crank and bearings. I just need to go over all of the gearbox stuff one more time to make it is all there. I am worried a little bit about the process it seems kind of like a one shot deal. If you do not get it all the way home you need to start all over. Pictures to follow Sunny

I have the parts manual but the only trouble is that it has no explanations and need to rely on the manuals for tips on the process. I was looking at the parts manual and does the crank on the 159 only takes two bearings? The haynes manual shows three bearings I think. I was looking at it this morning and trial "fitting" the cases and it looks like it only has one bearing on each side of the crank for a total of two. Thanks for the explanations on the bearings Sunny

Thanks for the advice. The bearings in the photo came with the basket of parts and I assumed they where for the crank due the same size. Where would these best used? I think the crank on the m159 needs 3 bearings. What should I ask for when I go the bearing supply house? C3 bearings but what size? I guess I need a quick tutorial on the language of bearing sizes. Thanks for the input and suggestions. I do have the haynes and clymers manuals, and the bultaco parts book but it is still nice to confirm with the 'experts" It did come with some new old stock stuff Thanks again Sunny

Can I use these bearings on the crankshaft? They are the same size but does it matter that they are sealed? I have to heat them to fit them back in to the case. I have started to re assembly the engine that came in the basket case of parts. It appears that almost all of the parts are there except for a few. The other question that I have is if the kickstart assembly looks like it is set up properly? I think I have but this if my first time doing a rebuild. Thanks for the help Sunny

The model 10 engine is locked up , has a few broken cooling fins on the head, ans is missing the side cover. What is the value of it roughly? Thanks for the help with I.D. Sunny

Any one know what the "old motor" in the photos is from?

You are right about the serial # m 7502185 I was going on my memory and I was wrong.

Here are a few shots of the recently aquired Bultaco's. Matador Mk 3 M70 Sherpa T M159 These are literally basket cases both bike have engines pulled and in multiple boxes. I just started to sort out the boxes and try to figure what goes with what. It also came with an old engine serial number M 400... D

Great Steve i am picking these up tomorrow in Nanaimo and bringing them home to Victoria. They are coming from Powell River they where purchused from an estate and where going to be restored by the purchuser but did not happen and he offered them to me as a bit of a project for a reasonable cost. I think the sherpa is a 159 but I did not get the serial #. I do not know anything about the Matador. I will post pictures when I get them home.

I got the last few important things worked out and "rode" the bike around the yard today. Still need new rear brake pads, switch the rear tire out... it is too big rubs on the muffler a bit, and to dial in the front brake for better performance. I have been bitten by the Bultaco bug. I posted an ad on the local internet classified ad site and was offered two Bultacos. I am to pick up friday The one not pictured is a Matador (not sure of the model #) I got all of the stuff in the photo and the matador (condition unkown.. motor is on the left in a box in the photo)