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General Discussion / Re: Breva 1100 Gearbox Replacement - AKA the Guzzi from hell
« Last post by BrevaIsTheName on Today at 04:53:20 PM »Okay, since I have a bit of time today I wanted to address some points that are either not mentioned in the service manual or may catch someone off-guard, should they attempt this repair on their own.
Having an organized workstation helps a lot-- stay organized, go slow and think like an engineer. Then you will be fine.
...unless this job catastrophically fails. In which case I will be back here with even more updates and a much, much more frantic warning!
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- When removing the clutch slave cylinder, ENSURE you have a push rod from the old gearbox or on hand, ordered as a separate part. The two rear bushings near the thrust washer stack come out, but the far (cylindrical) bushing is retained in the gearbox.
- The gearshift linkage is awkwardly held hanging until the side cover/rearsets are reinstalled. There is no direction specified for what angle it should be installed along the gearbox splines. Make a note of where yours was installed or prepare to adjust the linkage as necessary. A linkage installed at too low of an angle will catch the frame, making it feel like 1st gear won't engage and leaving only half shifts. Addressing this early will spare you the heart attack of thinking your brand new eBay transmission is faulty!
- The thick part of the cardan unit attaches to the input shaft of the gearbox. The yoke has a retaining clip which affixes it to the shaft. You will know it's installed correctly when you hear a click, but taking it out can be a pain. The only effective way to remove the shaft is to have a friend hit the part of the yoke closest to the gearbox with a hammer or mallet while you pull simultaneously. Make sure to grease liberally upon reinstallation.
- Take photos and pay attention to the original routing of vacuum and fuel lines. The bike was assembled very carefully with attention to this detail, so you must do the same.
- Since this is such a big job, I implore you to I-Mark everything. Use a paint marker to draw lines across fasteners and their mounting points. Use a torque wrench. Go slow. Write everything down. This CANNOT be done in an afternoon by your average joe, so don't count on your memory as it will fail you.
Having an organized workstation helps a lot-- stay organized, go slow and think like an engineer. Then you will be fine.
...unless this job catastrophically fails. In which case I will be back here with even more updates and a much, much more frantic warning!
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