Rickman Zundapp Metisse Build

[Tossa]

Well lets see what I've started with belong to a family friend and has sat under a tarp outside for about 30yrs or more.  I want to rebuild it as a MX

Was given this




Today pulled and ground it apart.  Have ended up with this











Problems already, as usual, can't get the swing arm pivot out totally solid.
The rear sprocket is also solid in the end of the swing arm
The triple clamp needs a 34mm socket, which i don't have
and i think you can see the corrosion and rust around the crank.  The decision i have to make is whether to use this motor or find another as this is all i have of this one.  The exhaust I have are the enduro model so was going to send it over to Brad and darryl Lewis and let them work their magic.  I've just run over the frame with a wire wheel the welds are bloody brilliant and the rust not too bad.  But i'll find an expert to give me abetter opinion.  I have already ordered the plastics and tak from the UK.  They aare being made courtesy of the Flkowerpot man ben Penny.  Been a great help

[firko]

That Zundapp motor seems a tad 'used' . I'd be fitting something a bit more powerful in there or maybe picking up another Zundapp off eBay. I reckon these little beauties are made for a centre port 250....A DT1 slots in nicely. It's hard to believe but the little Rickman Zundapp 125 frame has much more room in the cradle than the Rickman Montesa frame.

I wish I didn't keep buying other projects, I want to finish my own project Micro Rickman. I highly recommend Bens fibreglass....it's faultless.

[oldfart]

Mix up a bowl of 40% sugar and 60% hot water , or get some molasis and soak that crank, prior to pulling cases apart.

[VMX60]

Hey Tossa
That will keep you busy over summer the Zundapp motor when complete is still a rare bird

Keep it as a 125cc or to chop it up to fit a 250cc ??

Funny thing is i am just about to start on my CZ Rickman again only part needed is a fuel tank let us know how yours turn up and the cost

Cheers

[ola_martin]

Keep it Zundapp, and fit one of these engines...

[Tossa]

Now that is nice where can I get one of those, I gather that is the 250

[ola_martin]

Have no idea, I found the pic, you do the rest...

If you're serious, try trough this German web-site, my best tip. http://www.crossoldy.de/

[JC]

I go w a change of engine too. Perhaps 125 Yam engine??

[Tossa]

I would really like to stay with the Zundapp as there is some sentimental value to the bike, as wife of family friend who passed away gave me the bike.  But will see how hard it is either to restore this motor or to find a good replacement. Otherwise will look for another 125 to slot into it

Any clues on getting the sprocket out of the swing arm, or the swing arm bolt out.  my thoughts are to find someone with a hydraulic press.

[VMX60]

Tossa

Just having a look back at VMX no11 the write up on Rickman Montesa and Wayne  had a 125cc Zundapp back then worth a phone call for parts

Go with a Ossa motor if going to another motor twin rail frame plus centreport ex should fit easy as Firko said a one off as the Bultaco was a std listed item


Cheers

[Tossa]

You got one murray

[flower pot racing]

Oh dear.  That motor is shagged (technical term)

But of course anything can be rebuilt.  Every spare part you will ever need is available (at a price).  The gear box has 89 false neutrals and setting it up correctly requires skill and expertise (and regular specialist attention ~ they werent called Zuncraps for nothing)

It has a rod and a ball bearing that selects gears inside a drum.  The rod wears and your problems start.....

The good news is that when they are done correctly they will scare you if you liek revving the nuts of a bike to keep it going in the right direction. 

I think you will be upset if you start doing the research into what is needed to sort that motor.

[flower pot racing]

Not forgetting the ignition packs which were also rubbish in their day.  Rickmans used to do a service exchange on Monday morninsg to replace the failures from the weekend!   Good news is that electronic modern versions are available.  Modern price of course, but at least you reall can fit and forget (once to have rebuilt that crank, gearbox (good luck) replated the barrel, new Mahle pistons etc etc etc)

I dont think this is a budget racer.  (guess that depend on the budget of course!)

Swinging arm will have to be cut out.  The stell with rubber bonded bushes that hold it all in place will have welded them selves together.  No heat of pressure will shift them ~ you could break the frame before you press them out.  Save time and cut cut them out, then set fire to the rubber then knock what you have left out.  Albsolute butchery, but the only way of they are really stuck in there.  Refit with new sealed taper rollers, new spindle etc etc and lots of grease when rebuilding.  Everythin is metric on he bike so replacements should be easy to find or make.

I have a rear spindle for you and will stick it in the box.

[Tossa]

Thanks Ben for all the happy news!!lol.  Yeah your right about the swing arm, having it cut off and will burn out the bushes.
I've located another zundapp motor, that's in one piece and turns over (in australia).  Have filled the crank of the one I have with molasses and leaving it to soak, will be a case of what i can salvage
Nice to know all the problems with the gearbox, but if i can find the right expertise, because i have absolutely none!! (a lot of people will agree with that), hopefully it will be good.  I believe there is an updated selector system around, saw them on ebay in states but they have disappeared, hopefully they will come up again.
I have acquired a new Bosch electronic ignition for it, though i believe they aren't that good either, but will try it first, before pvl, etc
I can honestly say have not pulled a complete motor down before, and will have to throw a few cartons of alcohol around to get assistance (hopefully).  Mean time will get the frame in peices and have it sand blasted, paint it and await your contribution.

It may cost a lot more than an arm and leg, but there are some bikes you can't put a price on, especially if you get it right
May end up expensive,

[firko]

Nice to know all the problems with the gearbox, but if i can find the right expertise, because i have absolutely none!! (a lot of people will agree with that), hopefully it will be good.  I believe there is an updated selector system around, saw them on ebay in states but they have disappeared, hopefully they will come up again.

If you're determined to stick with the Zundapp motor THE bloke for Zundapp info is Terry Davis from Pennsylvania who used to be a member of this forum under the Name Zundapp Guy. He's a really entertaining and funny bloke who knows everything there is to know about the little buggers. I believe he's the guy who has something to do with the improved gear selectors you mentioned. Unfortunately he bailed out of the forum (he ain't Robinson Crusoe) and I seem to have lost his contact details. He often sells parts on Marks Swapmeet, including his 'Falta CZ' and 'Zundapp' t-shirts so my advice is  to keep an eye out for his listings. If you google Terry Davis Zundapp you'll come up with a few of his posts on other forums.