Thanks everyone.  I ordered a clutch puller kit. Would this project be a good
blog for others to see my steps you guys have outlined?

Gerry.


--- In MAICOMOTORCYCLES@yahoogroups.com, "booth_racing" <booth_racing@...>
wrote:
>
> Hi guys - my first 490 and the clutch is very stiff.  Fresh motor and clutch,
no oil in since rebuild.  What can be done to improve the pull?
>
> Thanks,
> Gerry.
>

--- In MAICOMOTORCYCLES@yahoogroups.com, "gtx426hemi" <lauran@...> wrote:
>
> Hello Rick, you might want to look at a photo file, under "Maico 501 sales
brochure" . Look at the last picture.
> Joe



    Thanks for the help Joe. I would believe that is exactly what I was enquiring
about.
     Got one for the 400?? heh heh.
    I am really looking forward to completeing this square barell
project. And porting options are of interest.
    Cheers Rick
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
> MAICOMOTORCYCLES@yahoogroups.com, "rick hudson" <rhudson2@> wrote:
> >
> >   Hi guys, new to your forum, but not new to Maico's.
> > By the way, this is an excellent site. Tons of info here.
> > I've read the 1st 10,000 posts and picked up some good tips.
> >    Back in the early 70's, when I was trying to keep my MC125 tranny
working, I hung out at the Canadian Maico importers shop,
> > and recall the talk of Stage 1/2/3 porting on the Sq. bbl 250's and 400s.
Stage 1 was a simple cleanup and match ports, however stage 2 and 3 got into
much more serious modifications.
> >    I am currently building a 71 MC400, after racing a 400 and 450 Radial for
many years in Ahrma.
> >    I had 3 jugs to chose from when building the engine, and the one that was
in the best condition has had some work done on the liner.
> >    What was done was the liner was ground out at the bottom, both sides, to
radically open up the transfer ports, pretty much to match up with the cutout on
the bottom sides of the piston.
> > Doubled the opening size of the transfer ports.
> > Dont see much else done however.
> >   This sound familiar to anyone?
> >    The 3 stages of porting apparently were mods suggested from the German
factory as I recall. Anybody know about this?
> >   Cheers to everyone,
> >                                    Rick Hudson #43r
> >
>

does anyboby have a used 87.00mm piston for sell?

Hello and Happy Thanksgiving to all of my Maico Brothers.
I want to thank yall for your help with my questions on my bikes, Even my Honda
Odyssey that you forced yourselfs to dish out - he he.
You're a good bunch of Dude's !
Rick

Hello Rick, you might want to look at a photo file, under "Maico 501 sales
brochure" . Look at the last picture.
Joe




















MAICOMOTORCYCLES@yahoogroups.com, "rick hudson" <rhudson2@...> wrote:
>
>   Hi guys, new to your forum, but not new to Maico's.
> By the way, this is an excellent site. Tons of info here.
> I've read the 1st 10,000 posts and picked up some good tips.
>    Back in the early 70's, when I was trying to keep my MC125 tranny working,
I hung out at the Canadian Maico importers shop,
> and recall the talk of Stage 1/2/3 porting on the Sq. bbl 250's and 400s.
Stage 1 was a simple cleanup and match ports, however stage 2 and 3 got into
much more serious modifications.
>    I am currently building a 71 MC400, after racing a 400 and 450 Radial for
many years in Ahrma.
>    I had 3 jugs to chose from when building the engine, and the one that was
in the best condition has had some work done on the liner.
>    What was done was the liner was ground out at the bottom, both sides, to
radically open up the transfer ports, pretty much to match up with the cutout on
the bottom sides of the piston.
> Doubled the opening size of the transfer ports.
> Dont see much else done however.
>   This sound familiar to anyone?
>    The 3 stages of porting apparently were mods suggested from the German
factory as I recall. Anybody know about this?
>   Cheers to everyone,
>                                    Rick Hudson #43r
>

Sounds almost eaxactly the same as my 2004 500MX. Probably becouse they use the
same pipe and silencer. Not sure why they would use a pipe designed for a 500cc
bike on a 685cc bike though. It is not a 700cc bike, usual marketing games,
rounded up like KTM or ATK does. Our bikes are pretty much the same, other than
the cylinders, and his has a Bing on it, and mine came from Koestlers with a
38mm Mikuni TM. I put a few pictures in the photo section under new 2004 Maico.

--- In MAICOMOTORCYCLES@yahoogroups.com, "travisagle" <travisagle@...> wrote:
>
> Check out this helmet cam video of a Maico 700 in the desert.  Make sure you
have the sound on, it sounds like a Maico:
>
> http://www.youtube.com/watch?v=ucknxyRcRAw
>

Check out this helmet cam video of a Maico 700 in the desert.  Make sure you
have the sound on, it sounds like a Maico:

http://www.youtube.com/watch?v=ucknxyRcRAw

Rage Racing (maico9v@...) has sent you an ecard.

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Your friends at Yahoo! Greetings

Hey Doug, never, poorly worded. "I think this Maico would eat your rat for
supper even with a stiff clutch" was where I was going with that." Talk to you
tomorrow.

Gerry.

--- In MAICOMOTORCYCLES@yahoogroups.com, Doug Gardner <flyingdg480@...> wrote:
>
> I don't get it are you making fun of me!
>
>
> ________________________________
> From: booth_racing <booth_racing@...>
> To: MAICOMOTORCYCLES@yahoogroups.com
> Sent: Tue, November 24, 2009 12:08:05 PM
> Subject: [MAICOMOTORCYCLES] Re: How to Improve Clutch Pull on 81 490
>
>  
> Is that a Super or "supper" rat? :)
>
> --- In MAICOMOTORCYCLES@ yahoogroups. com, Doug Gardner <flyingdg480@ ...>
wrote:
> >
> > Gerry, I will trade you a Super Rat for that Junk Maico you have, clutch
pull on the Rat is sweet. Think about it and email me. DG
> >
> >
> > ____________ _________ _________ __
> > From: travisagle <travisagle@ ...>
> > To: MAICOMOTORCYCLES@ yahoogroups. com
> > Sent: Tue, November 24, 2009 10:46:32 AM
> > Subject: [MAICOMOTORCYCLES] Re: How to Improve Clutch Pull on 81 490
> >
> >  
> > The main tip on removing the clutch is to use a puller to compress the stack
before your remove the round clips. If you don't compress it you are sure to
bend a clutch plate.
> >
> > --- In MAICOMOTORCYCLES@ yahoogroups. com, "booth_racing" <booth_racing@
...> wrote:
> > >
> > > Thanks everyone, looks like I have some work to do. This will be my first
time in the engine, so I have a few questions:
> > >
> > > * What schematic or manual is best to use?
> > >
> > > * the washers start with two down, then pairs up and down after that,
correct?
> > >
> > > * Special tips or tricks for removing the clutch and disassembling?
> > >
> > >
> > >
> > > --- In MAICOMOTORCYCLES@ yahoogroups. com, "bigmaico" <hlobel@> wrote:
> > > >
> > > > OK Guy's:
> > > >
> > > > Here's the real trick, next time you pull your clutch apart you need to
take the inner clutch guide & polish the tool marks out of it until it looks
like it been chromed.
> > > >
> > > > If you look at the inner clutch part you will see that the steel plates
will grab the deep tool marks as you pull the clutch.
> > > >
> > > > I use a black 3M scotch bright wheel on my 6" bench grinder to do this.
> > > >
> > > > My clutch now feels almost as good as the hydraulic clutch on my KTM,
it's just 1 finger now!
> > > >
> > > > Howard
> > > >
> > > > --- In MAICOMOTORCYCLES@ yahoogroups. com, "Walter Nash" <wbnash@>
wrote:
> > > > >
> > > > > The ASV levers did the trick on my '78 250 (w/'81 motor) and my '81
490.
> > > > >
> > > > > 5e. Re: How to Improve Clutch Pull on 81 490 <http://groups.
yahoo.com/ group/MAICOMOTOR CYCLES/message/ 32004;_ylc= X3oDMTJyYXUxYmRx
BF9TAzk3MzU5NzE1 BGdycElkAzQ5MTk0 ODcEZ3Jwc3BJZAMx NzA2MTYyMDc2BG1z
Z0lkAzMyMDA0BHNl YwNkbXNnBHNsawN2 bXNnBHN0aW1lAzEy NTkwNTI1MTY- >
> > > > > Posted by: "mike conley" conleymike7777@ <mailto:conleymike7
777@?Subject= Re: How to Improve Clutch Pull on 81 490> conleymike7777
<http://profiles. yahoo.com/ conleymike7777>
> > > > > Mon Nov 23, 2009 7:49 pm (PST)
> > > > > I allso changed my magura lever to an ASV "unbreakable" setup, the
feel is much better!!, The position of the perch and curvature of the after
market lever make that stiff clutch feeling all but disappear.
> > > > >
> > > >
> > >
> >
>

Is that a Super or "supper" rat?  :)


--- In MAICOMOTORCYCLES@yahoogroups.com, Doug Gardner <flyingdg480@...> wrote:
>
> Gerry, I will trade you a Super Rat for that Junk Maico you have, clutch pull
on the Rat is sweet. Think about it and email me. DG
>
>
> ________________________________
> From: travisagle <travisagle@...>
> To: MAICOMOTORCYCLES@yahoogroups.com
> Sent: Tue, November 24, 2009 10:46:32 AM
> Subject: [MAICOMOTORCYCLES] Re: How to Improve Clutch Pull on 81 490
>
>  
> The main tip on removing the clutch is to use a puller to compress the stack
before your remove the round clips. If you don't compress it you are sure to
bend a clutch plate.
>
> --- In MAICOMOTORCYCLES@ yahoogroups. com, "booth_racing" <booth_racing@ ...>
wrote:
> >
> > Thanks everyone, looks like I have some work to do. This will be my first
time in the engine, so I have a few questions:
> >
> > * What schematic or manual is best to use?
> >
> > * the washers start with two down, then pairs up and down after that,
correct?
> >
> > * Special tips or tricks for removing the clutch and disassembling?
> >
> >
> >
> > --- In MAICOMOTORCYCLES@ yahoogroups. com, "bigmaico" <hlobel@> wrote:
> > >
> > > OK Guy's:
> > >
> > > Here's the real trick, next time you pull your clutch apart you need to
take the inner clutch guide & polish the tool marks out of it until it looks
like it been chromed.
> > >
> > > If you look at the inner clutch part you will see that the steel plates
will grab the deep tool marks as you pull the clutch.
> > >
> > > I use a black 3M scotch bright wheel on my 6" bench grinder to do this.
> > >
> > > My clutch now feels almost as good as the hydraulic clutch on my KTM, it's
just 1 finger now!
> > >
> > > Howard
> > >
> > > --- In MAICOMOTORCYCLES@ yahoogroups. com, "Walter Nash" <wbnash@> wrote:
> > > >
> > > > The ASV levers did the trick on my '78 250 (w/'81 motor) and my '81 490.
> > > >
> > > > 5e. Re: How to Improve Clutch Pull on 81 490 <http://groups. yahoo.com/
group/MAICOMOTOR CYCLES/message/ 32004;_ylc= X3oDMTJyYXUxYmRx BF9TAzk3MzU5NzE1
BGdycElkAzQ5MTk0 ODcEZ3Jwc3BJZAMx NzA2MTYyMDc2BG1z Z0lkAzMyMDA0BHNl
YwNkbXNnBHNsawN2 bXNnBHN0aW1lAzEy NTkwNTI1MTY->
> > > > Posted by: "mike conley" conleymike7777@ <mailto:conleymike7
777@?Subject= Re: How to Improve Clutch Pull on 81 490> conleymike7777
<http://profiles. yahoo.com/ conleymike7777>
> > > > Mon Nov 23, 2009 7:49 pm (PST)
> > > > I allso changed my magura lever to an ASV "unbreakable" setup, the feel
is much better!!, The position of the perch and curvature of the after market
lever make that stiff clutch feeling all but disappear.
> > > >
> > >
> >
>

Going from a Magura to a Moose easy-pull lever made a huge difference on my '81.

--- In MAICOMOTORCYCLES@yahoogroups.com, "booth_racing" <booth_racing@...>
wrote:
>
> Hi guys - my first 490 and the clutch is very stiff.  Fresh motor and clutch,
no oil in since rebuild.  What can be done to improve the pull?
>
> Thanks,
> Gerry.
>

The main tip on removing the clutch is to use a puller to compress the stack
before your remove the round clips.  If you don't compress it you are sure to
bend a clutch plate.

--- In MAICOMOTORCYCLES@yahoogroups.com, "booth_racing" <booth_racing@...>
wrote:
>
> Thanks everyone, looks like I have some work to do.  This will be my first
time in the engine, so I have a few questions:
>
>  * What schematic or manual is best to use?
>
> * the washers start with two down, then pairs up and down after that, correct?
>
>  * Special tips or tricks for removing the clutch and disassembling?
>
>
>
> --- In MAICOMOTORCYCLES@yahoogroups.com, "bigmaico" <hlobel@> wrote:
> >
> > OK Guy's:
> >
> > Here's the real trick, next time you pull your clutch apart you need to take
the inner clutch guide & polish the tool marks out of it until it looks like it
been chromed.
> >
> > If you look at the inner clutch part you will see that the steel plates will
grab the deep tool marks as you pull the clutch.
> >
> > I use a black 3M scotch bright wheel on my 6" bench grinder to do this.
> >
> > My clutch now feels almost as good as the hydraulic clutch on my KTM, it's
just 1 finger now!
> >
> > Howard
> >
> > --- In MAICOMOTORCYCLES@yahoogroups.com, "Walter Nash" <wbnash@> wrote:
> > >
> > > The ASV levers did the trick on my '78 250 (w/'81 motor) and my '81 490.
> > >
> > > 5e. Re: How to Improve Clutch Pull on 81 490
<http://groups.yahoo.com/group/MAICOMOTORCYCLES/message/32004;_ylc=X3oDMTJyYXUxY\
mRxBF9TAzk3MzU5NzE1BGdycElkAzQ5MTk0ODcEZ3Jwc3BJZAMxNzA2MTYyMDc2BG1zZ0lkAzMyMDA0B\
HNlYwNkbXNnBHNsawN2bXNnBHN0aW1lAzEyNTkwNTI1MTY->
> > > Posted by: "mike conley" conleymike7777@ <mailto:conleymike7777@?Subject=
Re: How to Improve Clutch Pull on 81 490>  conleymike7777
<http://profiles.yahoo.com/conleymike7777>
> > > Mon Nov 23, 2009 7:49 pm (PST)
> > > I allso changed my magura lever to an ASV "unbreakable" setup, the feel is
much better!!, The position of the perch and curvature of the after market lever
make that stiff clutch feeling all but disappear.
> > >
> >
>

Thanks everyone, looks like I have some work to do.  This will be my first time
in the engine, so I have a few questions:

  * What schematic or manual is best to use?

* the washers start with two down, then pairs up and down after that, correct?

  * Special tips or tricks for removing the clutch and disassembling?



--- In MAICOMOTORCYCLES@yahoogroups.com, "bigmaico" <hlobel@...> wrote:
>
> OK Guy's:
>
> Here's the real trick, next time you pull your clutch apart you need to take
the inner clutch guide & polish the tool marks out of it until it looks like it
been chromed.
>
> If you look at the inner clutch part you will see that the steel plates will
grab the deep tool marks as you pull the clutch.
>
> I use a black 3M scotch bright wheel on my 6" bench grinder to do this.
>
> My clutch now feels almost as good as the hydraulic clutch on my KTM, it's
just 1 finger now!
>
> Howard
>
> --- In MAICOMOTORCYCLES@yahoogroups.com, "Walter Nash" <wbnash@> wrote:
> >
> > The ASV levers did the trick on my '78 250 (w/'81 motor) and my '81 490.
> >
> > 5e. Re: How to Improve Clutch Pull on 81 490
<http://groups.yahoo.com/group/MAICOMOTORCYCLES/message/32004;_ylc=X3oDMTJyYXUxY\
mRxBF9TAzk3MzU5NzE1BGdycElkAzQ5MTk0ODcEZ3Jwc3BJZAMxNzA2MTYyMDc2BG1zZ0lkAzMyMDA0B\
HNlYwNkbXNnBHNsawN2bXNnBHN0aW1lAzEyNTkwNTI1MTY->
> > Posted by: "mike conley" conleymike7777@ <mailto:conleymike7777@?Subject=
Re: How to Improve Clutch Pull on 81 490>  conleymike7777
<http://profiles.yahoo.com/conleymike7777>
> > Mon Nov 23, 2009 7:49 pm (PST)
> > I allso changed my magura lever to an ASV "unbreakable" setup, the feel is
much better!!, The position of the perch and curvature of the after market lever
make that stiff clutch feeling all but disappear.
> >
>

Servicing out the Clutch Basket/Hub sounds like a great idea - I hadn't thought
of that.

The Zip Tie idea is good - but here's what I learned from looking at Herbert
Shmitz' set-up:

Cut some fresh fuel line to get a small ring about 3/8" thick, then loop the zip
tie through the hole, around the cable, then back through the hole and secure to
the down tube.  Do this in two places.  Secure firmly, but not too tight -
enough slip to be able to slide the cable/ring assembly around the tube (not up
and down).  You might also do this to your stator lead cable on the other down
tube.

Lube the cable LIBERALLY and often - I use a commercial HD All-Purpose Lube. 
BUT... I also wash my bikes after every ride, so BEFORE YOU LUBE, use a Can of
Compressed Air and a Cable Lube Attachment and BLOW OUT ANY WATER & CRUD, then
Lube.  Ideally you should see an oil puddle or drip at the opposite end.  I
shoot about 8 - 10 quick squirts using a Cable Lube attachment.  AND - I like
the All Purpose stuff instead of the Cable Lube - it is cheaper and works great.

I have also seen some guys using a Modern, multi-position EZ Pull lever to max
the leverage.  You can get them with or without a Hot Start lever, but you'll
need to re-do your Comp. Release cable to use it.

I know that you can also Radius the actuator cam, but I have no direct
experience doing that - only have seen it done at a shop.  It seems pretty much
an eye-ball type deal and you should know what you are doing to try it.  That is
the biggest single improvement I have seen.

Lastly, if you have the clutch cover off and the actuator arm removed, grease
the "bushing" the arm pivots in LIBERALLY.

The goal is to reduce any and all points where the mechanism can bind.  Doing
all of the above will improve the action remarkably.

OK Guy's:

Here's the real trick, next time you pull your clutch apart you need to take the
inner clutch guide & polish the tool marks out of it until it looks like it been
chromed.

If you look at the inner clutch part you will see that the steel plates will
grab the deep tool marks as you pull the clutch.

I use a black 3M scotch bright wheel on my 6" bench grinder to do this.

My clutch now feels almost as good as the hydraulic clutch on my KTM, it's just
1 finger now!

Howard

--- In MAICOMOTORCYCLES@yahoogroups.com, "Walter Nash" <wbnash@...> wrote:
>
> The ASV levers did the trick on my '78 250 (w/'81 motor) and my '81 490.
>
> 5e. Re: How to Improve Clutch Pull on 81 490
<http://groups.yahoo.com/group/MAICOMOTORCYCLES/message/32004;_ylc=X3oDMTJyYXUxY\
mRxBF9TAzk3MzU5NzE1BGdycElkAzQ5MTk0ODcEZ3Jwc3BJZAMxNzA2MTYyMDc2BG1zZ0lkAzMyMDA0B\
HNlYwNkbXNnBHNsawN2bXNnBHN0aW1lAzEyNTkwNTI1MTY->
> Posted by: "mike conley" conleymike7777@...
<mailto:conleymike7777@...?Subject= Re: How to Improve Clutch Pull on 81 490> 
conleymike7777 <http://profiles.yahoo.com/conleymike7777>
> Mon Nov 23, 2009 7:49 pm (PST)
> I allso changed my magura lever to an ASV "unbreakable" setup, the feel is
much better!!, The position of the perch and curvature of the after market lever
make that stiff clutch feeling all but disappear.
>

Ditto what Bret said.

Fritz
--- In MAICOMOTORCYCLES@yahoogroups.com, "BretB" <bretbonham@...> wrote:
>
> There are a few things:
>
> -Proper stacking order of Bellville washers. ))(())(())(())(())
>
> -Resist the urge to zip tie the cable tightly against the frame. Instead, zip
tie a zip tie to the frame and make a guide loop for the cable to go through.
This will prevent much of the binding that occurs. The key is no sharp bends and
that the cable can flop around without getting caught on anything.
>
> -Lube the cable. You can use a cable lube tool or you can tape a funnel to the
cable and let gravity do the work. My preference for cable lube is Tri-Flow.
>
> -Clutch actuator arm and cable should form a 90 degree angle at the midpoint
of the travel.
>
> -The clutch actuator arm should have only a slight bend to it. Bend it back
close to straight for more leverage. The cable might rub the cases if you go
completely straight.
>
> -Magura lever.
>
> -Lube the cable and the lever after each ride.
>
> Bret
>
>
> --- In MAICOMOTORCYCLES@yahoogroups.com, "booth_racing" <booth_racing@> wrote:
> >
> > Hi guys - my first 490 and the clutch is very stiff.  Fresh motor and
clutch, no oil in since rebuild.  What can be done to improve the pull?
> >
> > Thanks,
> > Gerry.
> >
>

There are a few things:

-Proper stacking order of Bellville washers. ))(())(())(())(())

-Resist the urge to zip tie the cable tightly against the frame. Instead, zip
tie a zip tie to the frame and make a guide loop for the cable to go through.
This will prevent much of the binding that occurs. The key is no sharp bends and
that the cable can flop around without getting caught on anything.

-Lube the cable. You can use a cable lube tool or you can tape a funnel to the
cable and let gravity do the work. My preference for cable lube is Tri-Flow.

-Clutch actuator arm and cable should form a 90 degree angle at the midpoint of
the travel.

-The clutch actuator arm should have only a slight bend to it. Bend it back
close to straight for more leverage. The cable might rub the cases if you go
completely straight.

-Magura lever.

-Lube the cable and the lever after each ride.

Bret


--- In MAICOMOTORCYCLES@yahoogroups.com, "booth_racing" <booth_racing@...>
wrote:
>
> Hi guys - my first 490 and the clutch is very stiff.  Fresh motor and clutch,
no oil in since rebuild.  What can be done to improve the pull?
>
> Thanks,
> Gerry.
>

Hi guys - my first 490 and the clutch is very stiff.  Fresh motor and clutch, no
oil in since rebuild.  What can be done to improve the pull?

Thanks,
Gerry.

Woods bike, hmmmm...sounds familiar -- LOL!

John

--- In MAICOMOTORCYCLES@yahoogroups.com, "bill_eyler" <billeyler@...> wrote:
>
> Yes, shipping charges always factor in. Want to make this 1 a woods bike .
> Bill
>
> --- In MAICOMOTORCYCLES@yahoogroups.com, "kawtriple" <kawtriple@> wrote:
> >
> > Damn Bill, its going to cost you as much to ship it as what you paid for it.
You will be happy with it.
> >
> > --- In MAICOMOTORCYCLES@yahoogroups.com, "bill_eyler" <billeyler@> wrote:
> > >
> > > SOLD..TY
> > >
> > > --- In MAICOMOTORCYCLES@yahoogroups.com, "bigmaico" <hlobel@> wrote:
> > > >
> > > > Ya that is a good deal, it looks clean & those little 83' 250 are fast
little buggers!
> > > >
> > > > --- In MAICOMOTORCYCLES@yahoogroups.com, "kawtriple" <kawtriple@> wrote:
> > > > >
> > > > > This one seems like a very fair deal ...
> > > > >
> > > > > http://seattle.craigslist.org/see/mcy/1472592446.html
> > > > >
> > > >
> > >
> >
>

Not mine  http://seattle.craigslist.org/see/bik/1477660944.html