Partsmart Update February 2004

1563 R condenser ?5.75
This replacement condenser will fit on the existing mounting on the side of the voltage regulator (SIBA type) or on the special bracket (Bosch type). It is similar to the original type and here is just one fixing screw hole (the original has two). Be sure to use a spring washer and tighten the fixing screw securely. For SIBA types, make sure that the voltage regulator cover is fastened with two screws. Good ground (earth) connections are essential for correct operation. Take care not to bend the metal bracket – the spot welds may break. Connect the two black wires together in the connector provided (wire 1 from the ignition coil and wire 1 from the reversing relay).

0002 R cylinder head gasket.
There have been some failures of the cylinder head gaskets supplied by Partsmart and we have been working with our parts supplier to identify the cause. Instances of failure have occurred where the engine is working hard for extended periods and the reason is now clear from the supplier’s research. The original gaskets had a woven metal mesh between the fibrous gasket material. Our gasket supplier used to supply cut gaskets of 1mm wire reinforced Unilion, a Compressed Asbestos Fibre material, as cylinder head gaskets to MOC. This fibrous material had a woven wire mesh between and is very similar to the original part supplied by Fichtel & Sachs. Some years ago, an expanded graphite material, Supagraf N7 was supplied as an asbestos free alternative. They have to withstand the engine compression pressures and relatively high temperature up to 250C in addition to being exposed to the combustion flame. The failures are probably caused by the material density and composition of the existing gasket that is eroded by the combustion flame. We have now ordered a new batch of gaskets in a new high-pressure material that is better suited to the application. While not as durable as asbestos gaskets, we are expecting the new batch to operate trouble free. We apologise for any inconvenience caused gasket failure that was created by the change to asbestos free type.

0128 shim set – gear box layshaft and mainshaft. ?15.85/set
Comprising 7 shims of for each shaft in the range 0.05mm to 1.00mm thickness. With this shim set it should be possible to create a combination for the correct end float as specified in the engine manual. For specific advice on end float and gearbox set-up, refer to Partsmart #1807 engine manual ?5.50.

0130 Shim set ?17.80 comprising the following items:-
Sachs # 0020 shims for crankshaft. Comprising 2 each of the following thicknesses:- 0.10mm, 0.15mm, 0.20mm, 0.25mm, 0.30mm, 0.40mm, 0.50mm, 1.00mm. With this shim set it should be possible to create a combination for the correct end float as specified in the engine manual. For specific advice on crankshaft set-up, refer to Partsmart #1807 engine manual ?5.50.

Sachs # 0024 shims for crankshaft chainwheel (SIBA crankshaft only).
Comprising 1 each of the following thicknesses:- 0.10mm, 0.15mm, 0.20mm, 0.25mm, 0.30mm, 0.40mm, 0.50mm, 1.00mm. This shim set is required to align the crankshaft chain wheel drive to to the clutch hub. Insert or remove shims to achieve alignment as shown in the manual.

Sachs # 0171 eccentric shims for gearchange mechanism
Comprising 1 each of the following thicknesses:- 0.10mm, 0.20mm, 0.30mm, 0.40mm, 0.50mm, This shim set is required to align the gearshift mechanism relative to the gear cluster. Insert or remove shims to achieve alignment as shown in the manual. For specific advice on gear shift set-up, refer to Partsmart #1807 engine manual ?5.50.

Sachs # 0161 shims for gearchange mechanism
Comprising 1 each of the following thicknesses:- 0.10mm, 0.20mm, 0.30mm, 0.40mm, 0.50mm, This shim set is required to align the gearshift assembly and shims fitted behind the circlip that secures the shifter to the splined shaft. Many shifters are worn now and inserting the appropriate shims can eliminate the slop that can contribute to inefficient gear changing. For specific advice on gear shift set-up, refer to Partsmart #1807 engine manual ?5.50.

Note: Sachs numbers are the parts manual illustration numbers and not the part number.

0999 Rear wheel Important safety reminder
Kabinews readers have been warned frequently in recent years about the consequences of sudden, catastrophic failure of the rear wheel. This is caused by metal fatigue and affects all KR 200 models of all model years. Those built after 1960 with hub-cap retainer clips are particularly prone to failure. Normally, only the rear wheel is affected as the front is lightly loaded and anyway would give adequate warning of failure. MOC offers a new wheel designed to cope with everyday driving but this is offered with 10mm stud holes to suit cars built after 1959. To use this stronger wheel assembly in early cars with 8mm wheel studs, the rear axle must be modified using the procedure published on MOC website. (Look in KR200 articles). If you are not sure about any of the engineering terms and procedures described, do not attempt this job. Remember, the rear wheel and axle is a crucial safety item!