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harrymuffin - what do you regard as the correct torque figure for this nut? I found it quite tricky even to get this nut up to 5mkg, maybe it's the tools I have (spoken like a true bad workman!). The holding tool and "socket" are: http://jgweb.org/500_morini/primary_tools.jpg and the busin...

Hi Steve,
It sounds a lot like mine! So I shall be interested to hear how you get on with it, and in the interest of encouragement, despite a number of setbacks, I’ve found it a lot of fun to work on and great to ride. Good luck with it and how about a couple of photos?

Joe.

Continuing the torque figure saga for the oil pump drive worm gear, I contacted NLM this morning and they recommend the blue book figure of 5mkg. Their feeling is that 13 mkg is "silly" - their word, not mine. They strongly recommend a new nyloc nut, which is of course good practice anyway...

Hi Tom, and thanks for the torque settings list. 13 mkg (~130 Nm) is not the answer I wanted, particularly as I have now reassembled the primary, clutch, etc. Neither of my torque wrenches go up that high and the tool I got from NLM for the oil pump nut is not suitable for such a high torque, so I’l...

Thanks for the info guys! Curiously that torque figure has now appeared on Page 59of my copy of the Blue Book, it definitely wasn’t there last time I looked! For most purposes, mkg x 10 is near enough equal to Nm as marked on modern torque wrenches. My old Norbar torque wrench has mkg marked on it. ...

Steve, Thank you for your comments and encouragement! After cleaning and examining all the gears, etc without finding any very clear problem, I just fitted the new cluster with its selector mechanism. I didn't check the stop plate setting with the original gears. I only moved the plate a whisker and...

Hi George, Thanks for the Loctite info. I eventually went for the "new" gearbox complete. After cleaning up, there was slightly more play in the bushes on my old one - I think the oil was misleading us the other day. Having said that, it isn't awful and I would have thought both sets of bu...

Time for another update! I'm conscious that this mght be a bit boring for the experienced Morini engineers, but I also hope some of this will be helpful to other newcomers like myself - it's certainly a voyage of discovery for me! Back in the 1970s oil filters were uncommon on motorcycle engines and...

Well the engine is out and almost fully stripped now. I am a bit disappointed to see that the pistons are already at +0.4mm, so in less than 30,000 km it had been re-bored at least once and maybe twice. The good news is that it doesn't need doing again yet. I haven't taken the valves out of the head...

Yesterday I had a bit of time and started stripping the engine. It's always a slow start I find with these jobs as there are a lot of bits and pieces to strip off the bike before you really begin. Anyway, the first proper job was to take the heads off and bear in mind that this is the first time I'v...

simonnorthroad wrote:Hi,
I have a copy of a 6-speed 501 parts book, if you need the exploded diagram.

I also have a 5-speed gearbox sold me by the Man From Luton as a good spare, if anyone needs it

Thanks, but this is a 5-speed and I do have the parts book - essential reading I think!

Another update. My eBay gearbox arrived this morning and I'm pleased with it. I can't see any wear to the gears, in fact the teeth are barely even polished. There is a small polish mark to the "leading edge" of some of the dogs and that's about it for wear and tear. I slipped the second ge...

I'm glad you like the K2, I think it's a pretty sorted bike and I was lucky to get mine with less than 2000 miles on the clock. For a 350 it's pretty amazing, though I must say, the extra bit of grunt you get with the 500 makes a big difference. I will await your next bearing bulletin with interest....

Harrymuffin- good work! Ijust had a quick look on Simply Bearings and the 6204 from whichever manufacturer and in whichever variant is under a fiver ex-vat. The QJ306MA is another story, they only quote the SKF bearing and it’s £81.11 + VAT. All the same, this looks like a good option if needed. I r...

Another small update. I spoke to NLM this morning and they do stock all those bearings, though the last one of item 59 was just sold a week or so ago(!) Rob tells me he gets them from Italy and although the supply has been reliable, they are expensive - £46 +VAT. He is intending to try an alternativ...