Wildgoose Chase Moto Guzzi

General Category => Bike Builds, Rebuilds And Restorations Only => Topic started by: Scout63 on February 22, 2020, 06:52:37 AM

Title: 79 G5 Build
Post by: Scout63 on February 22, 2020, 06:52:37 AM
First post for my G5 Build. Iím a new member and will be asking many questions.  I bought this G5 a little unwillingly about a year ago:
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/D196F63E-739C-45AB-B69D-5F08B9223E4B_zpsojbyf8ze.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/D196F63E-739C-45AB-B69D-5F08B9223E4B_zpsojbyf8ze.jpeg.html)
The original owner kept it in a shed unridden since 1987 and it was pretty rusty with about 17000 miles. I bought it for $200.00 and stuck it in my storage unit until I recently finished a Norton Commando restoration, which was my first full retro where I did all the work ( other than paint and head work) myself:
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/561304C5-2F06-4380-87BC-A162DE9C4004_zpsycaery7x.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/561304C5-2F06-4380-87BC-A162DE9C4004_zpsycaery7x.jpeg.html)

I tore the Guzzi apart over the past three weeks:
(https://i36.photobucket.com/albums/e27/Zehnderllc/80CB9546-04FA-46A2-A05C-78F5D22549FF_zpswrh8jmyb.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/80CB9546-04FA-46A2-A05C-78F5D22549FF_zpswrh8jmyb.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/4C61B2E4-BCD0-4252-AD8F-1A94CAA44E54_zps7yrsb3qq.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/4C61B2E4-BCD0-4252-AD8F-1A94CAA44E54_zps7yrsb3qq.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/70B73488-BF7E-4EF3-9037-B1ED78E2F4D3_zpsmj7f7yeq.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/70B73488-BF7E-4EF3-9037-B1ED78E2F4D3_zpsmj7f7yeq.jpeg.html)

Now the aluminum is at the vapor honer and all of the frame and steel parts have been blasted and are getting a light prime coat. The crank, rods, pistons, cylinders, heads and gears look great.  My plan is to mock-up the build in prime, sort tank and seat, battery and regulator etc. placement, de-tab unnecessary frame parts and then disassemble, paint the steel and re-assemble.  Iíve bought a Motogadget m-blue for electrics.

While finishing the Norton I got hooked on images of round case custom builds.  I just love the frames, wheels and engines.  But already owning some stock standard style bikes I want to try more of a cruiser. Iíve got a set of floorboard frame rails with boards and several fuel tanks ( Lemans III, Honda CB450 and 360 and the G5).  Iíd like to keep the frame seat mounts stock to maintain flexibility, may use a solo seat and bread loaf pillion.  I have in mind a mild custom version of a Dover White BMW /2 which sounds strange, but that is where I am now.  Also Iím going to weld in side car mounts before painting the frame.

My real problem is that right now I donít have a solid vision, only ideas.  Iíve found a lot of gorgeous round case builds on line but most are cafe bikes or restorations.  Hopefully I can find a look that works.

This all sounds ambitious, but Iíve found the Guzzi a dream to work on after the Norton.  The Guzzi is all metric and is built like a tank.  Assemblies make sense and fit well.  The engine is as gorgeous as the Norton but in a different way.

Iíll keep posting and asking.  Thanks everyone for watching. Ben
Title: Re: 79 G5 Build
Post by: ozarquebus on February 22, 2020, 11:16:31 AM
Very good. I will be following since I have G5 project too.
Title: Re: 79 G5 Build
Post by: Groover on February 22, 2020, 02:53:17 PM
Watching this as well. Huge fan of the G5 models. Looking forward in seeing the development. Good luck, and thanks for making a build thread.
Title: Re: 79 G5 Build
Post by: Rick4003 on February 24, 2020, 02:12:22 AM
+1 on thanks for the build thread!

I think if you are planning to actually use the bike you will be happy for not going the cafť racer route. I started mine out as a cafť racer with clip-ons and all the stuff, but it was unbearable to ride for very long. The footrest was just way too high in combination with the clip-ons. I changed my clip-ons to a proper handlebar and I have to say that other than being a lot more comfortable, the bike actually rides a lot better with the new riding position.

The cafť racers do look really cool, but unless you are planning to full on race it all the time, then you will have a much more useful motorcycle with a more upright seating position. And just because you have a more upright seating position doesn't mean that you can't make all the cool engine mods too :)

-Ulrik
Title: Re: 79 G5 Build
Post by: Scout63 on February 25, 2020, 08:52:19 PM
Thanks for the encouragement all - thanks Ulrik for saying what I think I think.  My 71 BMW /5 has perfect riding position as a standard with moderate pull back bars.  I had a Ď68 /2 with a solo saddle and bread loaf pillion that also looked and felt just right.  Iím just not sure I can get that look right on a tonti frame.  Steel parts are blasted and primed.  Iíll post a photo as soon as photobucket gets back on line. Ben
Title: Re: 79 G5 Build
Post by: Scout63 on February 25, 2020, 09:20:00 PM
Status update. Picked up the steel parts in primer tonight:

(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/9227813A-8CD7-4B6C-A001-BA98ACE1AC6A_zpsy3kbjtta.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/9227813A-8CD7-4B6C-A001-BA98ACE1AC6A_zpsy3kbjtta.jpeg.html)
Title: Re: 79 G5 Build
Post by: Antiquar on February 25, 2020, 10:01:02 PM
Looking really good! Remembering my own G5 project from a few years ago fondly.
Title: Re: 79 G5 Build
Post by: Scout63 on February 26, 2020, 09:38:23 PM
I need feedback. Here are some tank options:
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/B2AB5542-87AB-48E6-9556-6578551D850E_zpsoq9vc7jv.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/B2AB5542-87AB-48E6-9556-6578551D850E_zpsoq9vc7jv.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/09206BE7-7D51-47DC-A158-0E1FA5034F21_zpso6jtb8ij.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/09206BE7-7D51-47DC-A158-0E1FA5034F21_zpso6jtb8ij.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/A3B724FC-2A6B-4E23-891C-F62796DDB868_zpshaerjneo.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/A3B724FC-2A6B-4E23-891C-F62796DDB868_zpshaerjneo.jpeg.html)

I like the third one best. It is a CB360 tank.  It shows the frame rails best and seems like it will keep the build looking lithe. Here it is with a Dime City seat frame and padding, and an older sportster repro fender:

(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/D2D87357-D783-4899-9D0A-982DD80E546C_zpsnoafe0zm.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/D2D87357-D783-4899-9D0A-982DD80E546C_zpsnoafe0zm.jpeg.html)

Does it work?  Is the seat gap to the tank a problem?  If I go with this tank Iíll need to fill the badge mounts and weld in new petcock mounts, and Iíd like to replace the fill with a flush mount.  Keep the battery area open or install v7sport type triangular side covers?  Exposure of the frame is paramount but I feel that the see-through middle is a little done.  Thanks - Ben
Title: Re: 79 G5 Build
Post by: Scout63 on March 07, 2020, 10:55:38 PM
Finally had some time to work on the bike today. I cleaned up and checked the gearbox assemblies.  Everything looks good:
(https://i36.photobucket.com/albums/e27/Zehnderllc/0BF186A3-329A-43FF-87C1-B011BC38B742_zpsu2itokdy.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/0BF186A3-329A-43FF-87C1-B011BC38B742_zpsu2itokdy.jpeg.html)

I also removed the  brake disks, tires and tubes and stripped the wheels:
(https://i36.photobucket.com/albums/e27/Zehnderllc/9BCE23C5-FF37-49E3-B1FD-00195706409F_zpsxsgusgzh.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/9BCE23C5-FF37-49E3-B1FD-00195706409F_zpsxsgusgzh.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/D819E904-439B-4CEC-AAF9-5C54EE2EB249_zpscqyxh0bk.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/D819E904-439B-4CEC-AAF9-5C54EE2EB249_zpscqyxh0bk.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/814C1FEE-FD00-4642-9C59-20D12591E330_zps7dhtihb6.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/814C1FEE-FD00-4642-9C59-20D12591E330_zps7dhtihb6.jpeg.html)
On to the front wheel tomorrow.



Title: Re: 79 G5 Build
Post by: Calijackalbob on March 08, 2020, 04:09:22 AM
Wow! You are ambitious. I would be too chicken to attempt such a huge job.
Good luck with it. Hope your wallet matches your enthusiasm.
The Norton looks great. Im sure the G5 will too.
Personally I would keep the bike stock. There are precious few original Guzzis of the era left. And many that are have been butchered into cafe racers which probably has only devalued them,.... but its your bike. Do what you will. I see where youre going with it. I agree the cb tank looks good and will accentuate the engine, being so small, and the solo seat will make it look really retro, probably 20 years or so older than the G5.
Id suggest filling the tank badge brackets and fitting adhesive V7 badges. Then you have the freedom to put them where they look best. They come in various colours, so you can match the paint job. Check them out....(http://<br />[url=https://ibb.co/VHcfjqc][img]https://i.ibb.co/VHcfjqc/images-2.jpg)[/url]

(https://i.ibb.co/QFQ0W7F/images-1.jpg) (https://ibb.co/QFQ0W7F)


(https://i.ibb.co/LkRNpZ3/images.jpg) (https://ibb.co/LkRNpZ3)
[/img]
You might also choose just the eagle logo and not the name,, which will give the bike a bit more mystery.....

(https://i.ibb.co/Lhw1tFV/images-5.jpg) (https://ibb.co/Lhw1tFV)

(https://i.ibb.co/t4nv2D7/images-4.jpg) (https://ibb.co/t4nv2D7)

(https://i.ibb.co/rQ3Hn9S/images-3.jpg) (https://ibb.co/rQ3Hn9S)

best free online forum hosting (https://imgbb.com/)

(https://i.ibb.co/t4nv2D7/images-4.jpg) (https://ibb.co/t4nv2D7)

(https://i.ibb.co/LkRNpZ3/images.jpg) (https://ibb.co/LkRNpZ3)


Anyhow, best of luck with the bike. Keep posting pics!
Title: Re: 79 G5 Build
Post by: Scout63 on March 08, 2020, 08:13:38 AM
Thanks for the badge ideas. I like the gold eagles a lot.

Iím not doing a restoration because every surface and part of the bike is rusty from being stored in an outside shed.  I would have to source too many parts.  That and I think the tonti frame and round barrel engine are so pretty and I want to show them off.  I could probably get away with not stripping the engine, gearbox and wheels, but I like the look of vapor honing, and full disassembly is essential. I also enjoy riding older bikes more when I know and trust every system.

Plus Iíve never built a semi custom bike and want to see if I can do it. Itís less of a straight assembly and more cognitive. Thereís a lack of custom non-Cafť Guzzis on the net so Iím having to cross marques to get ideas.  Every problem, from wiring to tank selection to exhaust is new and exciting.  Rather than trying to get it ďcorrectĒ I can try to get it ďclean.Ē  Sounds a little overthought I know.

Title: Re: 79 G5 Build
Post by: Scout63 on March 17, 2020, 10:27:36 PM
More progress:
(https://i36.photobucket.com/albums/e27/Zehnderllc/37303A6F-6799-4B63-AB27-67573C329F9C_zpshaclr8dh.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/37303A6F-6799-4B63-AB27-67573C329F9C_zpshaclr8dh.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/D461F30E-B96E-4A3C-9895-A987B1D62378_zpsolkwgslp.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/D461F30E-B96E-4A3C-9895-A987B1D62378_zpsolkwgslp.jpeg.html)

I had to put the parts together without the internals to see what it looked like:
(https://i36.photobucket.com/albums/e27/Zehnderllc/834F20A5-92EE-4EB6-87F4-73948B987E05_zpsv8vqz32m.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/834F20A5-92EE-4EB6-87F4-73948B987E05_zpsv8vqz32m.jpeg.html)
Title: Re: 79 G5 Build
Post by: Rick4003 on April 02, 2020, 02:15:19 PM
Looks very nice, dry glass blasted?
Title: Re: 79 G5 Build
Post by: Scout63 on April 05, 2020, 06:33:17 PM
Thanks Rick. All aluminum parts were vapor honed. Iím lucky to have someone here in town that will do it very quickly for reasonable rates. I usually just wipe the parts down periodically with ACF-50 and they hold a good finish.

We had a gorgeous weekend here so I spent it in the garage.  After ruining one rear main bearing by installing it slightly cocked (and then having to helicoil one of the mounting holes in the case) I took my time with the second.  Crank, rods, timing gear, sump, pistons and cylinders are now installed:

(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/0CF7739D-AC3C-4903-AB1F-DDED3B113942_zpsbbyhfih4.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/0CF7739D-AC3C-4903-AB1F-DDED3B113942_zpsbbyhfih4.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/3C7EC2BF-2124-4567-AF99-DF253D360EAC_zpsles7zgza.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/3C7EC2BF-2124-4567-AF99-DF253D360EAC_zpsles7zgza.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/4EA1E925-5D82-4C09-A77F-5D8C32A75402_zps81cpmm6d.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/4EA1E925-5D82-4C09-A77F-5D8C32A75402_zps81cpmm6d.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/E44F0A6D-4F2B-4A0B-B2A3-AAD6EA819986_zps8nownasj.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/E44F0A6D-4F2B-4A0B-B2A3-AAD6EA819986_zps8nownasj.jpeg.html)

I hope everyone is doing well.
Title: Re: 79 G5 Build
Post by: Scout63 on April 10, 2020, 11:14:02 PM
Yesterday I installed the flywheel, set TDC with a dial gauge and checked timing with a degree wheel. The TDC and static timing marks were fine, but the fully advanced marks were 2-3 degrees more advanced than spec.  I filed and painted new marks and cleaned and painted the TDC and static marks.  Today I installed the distributor and ordered new points, plug wires and caps. 

I also shipped the brake disks off to Truedisk in Michigan (Shout out to Tom Tokarz who runs a great shop) for grinding, drilling and painting.  Next up install the clutch, helicoil the gearbox plug holes and reinstall the gears.

I also ordered new tires for mounting after building the wheels.  I had a hard time finding a matching set in stock sizes.  I went with IRC Duros.  I am a fan of Avon Roadriders and Bridgestone BT 45ís for other bikes, but the Duros looked good.  The low price point worries me so I will keep a close eye on them.
Title: Re: 79 G5 Build
Post by: Brilig on April 12, 2020, 01:46:47 PM
Hi Ben, your project is moving quickly and looking good.  I'll be interested to see how it looks with the Honda fuel tank.  Along with the solo seat that will show off that big V-twin.

My project (79 SP 1000) is not moving as quickly because I'm trying to decide how far to take the rebuild this time around.  I have been researching this business about the chrome cylinder linings and when I put a magnet in through the spark plug hole I get a very strong magnetic attraction to my cylinder walls.  This leads me to conclude they are not chrome.  Your engine is the same year as mine so I am wondering what your cylinders are lined with.  I also see a similarity with our engines in that they don't have the fold over tabs to prevent the bolts accidentally backing out on the front main bearing and the bolts holding the timing chain tensioner.  I was thinking of adding them if I go forward with a complete rebuild. You also seem to have confidence in the original chain tensioner.  That's another decision I'm debating weather to go with the big aftermarket tensioner.

Good luck.  The bike is looking great.

Mark
Title: Re: 79 G5 Build
Post by: Scout63 on April 12, 2020, 05:30:13 PM
Hi Mark and thanks.  It keeps speeding up then slowing down. I just over torqued a timing cover screw and snapped it off so spent half a day drilling and helicoiling.  One down side to vapor honing is that threads need to be chased carefully. Iím also replacing pretty much all fasteners with stainless and need to make sure that screws and threads fit well.

I didnít really think out the chain tensioner until after getting the chain and sprockets on. Iíll watch it during break in. The stock setup is not ideal though.  If I had it to do again I would install the spring tensioner.

If I remember, the front main bearing had wave washers on it when I took it apart. I used fresh bolts and reused the washers.

The cylinder liners are iron.  They were well within spec and I just gave them a light honing and new rings.  Iím hoping yours are iron also.

Nest up gearbox assembly and then wheel assembly.  Im thinking of flipping the brakes to the rear of the fork legs.  Iíll post that question.

Best of luck.  Iíll be watching your progress.

Also today I helicoiled the 10mm gearbox shell holes per Guzziology.  Seems like Pretty simple insurance.
Title: Re: 79 G5 Build
Post by: Scout63 on April 13, 2020, 09:14:56 PM
Rear wheel assembled and loose laced.

(https://i36.photobucket.com/albums/e27/Zehnderllc/02F93BD9-F060-41FA-BA82-0964C6F3FEC2_zpszdvcxvwf.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/02F93BD9-F060-41FA-BA82-0964C6F3FEC2_zpszdvcxvwf.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/C89DF1BE-AC23-4704-95BA-919585AC245F_zpsul8sxong.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/C89DF1BE-AC23-4704-95BA-919585AC245F_zpsul8sxong.jpeg.html)
Title: Re: 79 G5 Build
Post by: Scout63 on April 20, 2020, 06:51:58 AM
I opened the timing chest up again and installed a spring type cam chain tensioner (Thanks for the nudge Mark). Fitted new stainless cap screws to the sump and timing covers. Assembled the forks with FAC dampers and Wirth springs. Installed new points and condensers. Waiting on clutch pushrod seals so I can keep working to the rear.  Brake disks out to Tom at Truedisk for grinding and drilling.
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/80457F7A-7D2B-41DF-9A17-165A6D1F10F2_zpsgrylxwej.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/80457F7A-7D2B-41DF-9A17-165A6D1F10F2_zpsgrylxwej.jpeg.html)
(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/05F99D70-FBF8-460B-9E5A-0BD1CEAADACE_zpsi2h7k0xz.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/05F99D70-FBF8-460B-9E5A-0BD1CEAADACE_zpsi2h7k0xz.jpeg.html)
Title: Re: 79 G5 Build
Post by: Brilig on April 24, 2020, 12:12:05 PM
Looking sharp Ben.
Did you decide which way you are going to face the forks?
Only drawback I can see to having your calipers to the rear is that your drain plugs will be on the front.  If it was me, I wouldn't let that stop me from putting the calipers where I wanted them.
Wheels are looking great.  I wish I had spoke wheels.  Maybe my next project!

Mark
Title: Re: 79 G5 Build
Post by: ozarquebus on April 25, 2020, 06:22:09 PM
I am doing a timing chain replacement on my G5 and am at the point where the timing cover is being removed, but the engine is still on the bike. Can anyone tell me what the trick is to remove it now that the rotor is removed and the cover is loose? If it is just a matter of brute force, I can do that, but was wondering if there is something holding it place I can't see besides the many bolts.
Does the tachometer cable stay in place as cover is removed? All thew articles and manuals only address this on a removed engine.
Title: Re: 79 G5 Build
Post by: Scout63 on April 25, 2020, 07:28:20 PM
Remove the tach drive as it is engaged with the cam. The oil seal may be a tight fit on the rotor shaft as well. I would gently pull it off. Also make sure you have all of the screws out.
Title: Re: 79 G5 Build
Post by: Scout63 on April 25, 2020, 07:38:38 PM
Hi Mark. Neat job with the cam sprocket tool. I donít have those skills. 

I am going to flip the fork legs.  Waiting for disks to come back ground and drilled by Truedisk.  Also waiting on a front hub so that I can lace and true the wheel and install the carriers and disks.  Gearbox shift drum clearance check is waiting on a shift pawl from Harpers.  Then I can button up the gearbox and install the clutch.  This is the expensive part of a rebuild. I also just agreed on a purchase of a nice Matchless single so Iím hoping I wonít lose focus and will have enough discretionary funds to keep this moving.

What are you doing for exhaust.  Iím thinking either LaFranconi replacements or else gut, blast, shorten, re-core and ceramic coat my old ones. Maybe about six inches shorter just to throw off the traditional look.
Title: Re: 79 G5 Build
Post by: ozarquebus on April 25, 2020, 08:17:28 PM
Thank you Ben.
Title: Re: 79 G5 Build
Post by: Dave Swanson on April 26, 2020, 06:45:01 AM
Wow!  This is really turning out nice!  Props to you!
Title: Re: 79 G5 Build
Post by: Brilig on April 26, 2020, 07:37:37 AM
I am doing a timing chain replacement on my G5 and am at the point where the timing cover is being removed, but the engine is still on the bike. Can anyone tell me what the trick is to remove it now that the rotor is removed and the cover is loose? If it is just a matter of brute force, I can do that, but was wondering if there is something holding it place I can't see besides the many bolts.
Does the tachometer cable stay in place as cover is removed? All thew articles and manuals only address this on a removed engine.
Did you remember the big bolt that runs across the front of the engine that holds the engine to the frame?  I recently watched a U-TUBE video removing the timing cover on a LeManns.
Title: Re: 79 G5 Build
Post by: ozarquebus on April 26, 2020, 12:53:37 PM
yessir, big bolt came out slickly.
Don't let me hi jack this post.
Title: Re: 79 G5 Build
Post by: Scout63 on April 27, 2020, 08:41:00 PM
No sweat Ozarquebus.  We are all just building one perfect bike together.   Disks came back from Truedisk yesterday.

(https://i36.photobucket.com/albums/e27/Zehnderllc/Mobile%20Uploads/8E981F3D-47D1-4FED-869B-C166D96D1F5D_zps07rapkqf.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/Mobile%20Uploads/8E981F3D-47D1-4FED-869B-C166D96D1F5D_zps07rapkqf.jpeg.html)

They went out looking like this:

(https://i36.photobucket.com/albums/e27/Zehnderllc/9BCE23C5-FF37-49E3-B1FD-00195706409F_zpsxsgusgzh.jpeg) (https://s36.photobucket.com/user/Zehnderllc/media/9BCE23C5-FF37-49E3-B1FD-00195706409F_zpsxsgusgzh.jpeg.html)

Turn around time about two weeks. I mailed them on 4/10 got them back 4/26. Total cost for blasting, grinding, drilling, painting and shipping back three disks was just under $350 US.  I highly recommend Tom.
Title: Re: 79 G5 Build
Post by: berniebee on May 05, 2020, 10:58:03 AM
Nice job! I'm well into an SP1000 project myself and I've just repainted the frame, which appears to be identical to yours. I just noticed that in your primered frame pics, there are a couple of rubber plugs still in place.  Two on each side of the bike. See the pic below.
(https://i.ibb.co/9cdnNCL/guzzi-plugs.jpg) (https://ibb.co/9cdnNCL)
Title: Re: 79 G5 Build
Post by: Scout63 on May 06, 2020, 10:02:58 PM
Hi Berniebee:

I found the plugs after I got the frame back, as well as the big hole in the center stand where the left tang must have gotten ripped off. Iím mocking everything up in primer so Iíll have a chance to hit the plug areas again.

Stalled waiting for a shift drum pawl to get here from Italy.  My front hub came in from the Netherlands today so I can lace the front hub this weekend.

Best of luck with the SP. Ben
Title: Re: 79 G5 Build
Post by: Antietam Classic Cycle on May 07, 2020, 08:34:58 AM
"Shift drum pawl". Not sure part you mean for sure, but I have a bin full of used 5 spd. parts.
Title: Re: 79 G5 Build
Post by: Scout63 on May 08, 2020, 09:45:09 PM
Hi Charlie. The pawl that spring loads into the shift drum detents to positively index each gear. Part no. 55234700. I ordered from overseas after striking out here. I should have called you. I am sorry. Ben
Title: Re: 79 G5 Build
Post by: Antietam Classic Cycle on May 08, 2020, 09:50:05 PM
Hi Charlie. The pawl that spring loads into the shift drum detents to positively index each gear. Part no. 55234700. I ordered from overseas after striking out here. I should have called you. I am sorry. Ben

I've always called that the "detent plunger". I have a few. Must have missed your request for one here.
Title: Re: 79 G5 Build
Post by: Scout63 on May 09, 2020, 09:48:24 PM
You didnít miss it. I didnít think to post a request.  I struck out on the larger parts suppliers although Curtis Harper was gracious enough to be willing to locate one.  I jumped the gun and ordered overseas and so paid an exorbitant amount for one Iíll probably get in three weeks or so. Iím new to Guzzis and the forum. Iíll know next time. Thanks anyway.
Title: Re: 79 G5 Build
Post by: Scout63 on May 29, 2020, 11:04:50 PM
I picked up my heads today. That will move the Guzzi firmly into the on deck circle.  I alao picked up the rebuilt mag for my Matchless single, installed it and timed the mag.  First start - hopefully- tomorrow.  Than reassemble the Commando primary and go to town on the Guzzi.   Best to everyone. 
Title: Re: 79 G5 Build
Post by: Scout63 on February 13, 2021, 10:13:38 PM
Finally back to the G5.  I havenít been near it since early last Spring. Tonight I loose laced the front hub with ss spokes from Buchananís. One of the few things I dare doing inside the house since the only messy part is the thread anti seize.  It is so nice working near my wife, plus it is about 30 in the garage.

(https://i.ibb.co/QFC6L69/B92-B0-FCF-2-D50-4-E96-A133-1-BEB08-E0-F363.jpg) (https://ibb.co/QFC6L69)

(https://i.ibb.co/JnbR5Vg/0-A8-EA06-B-6419-4-D31-AE3-F-A5-B498-A39-AA6.jpg) (https://ibb.co/JnbR5Vg)
a

Next up truing the wheels. Iím so glad to be back working on this bike.  It would be so nice to have it running by Memorial Day.
Title: Re: 79 G5 Build
Post by: Scout63 on February 14, 2021, 05:07:51 PM
Front wheel bearing carriers and disks installed. I reversed the circlip for installation of the calipers behind the forks.

(https://i.ibb.co/yppsGhq/AB57-CCCA-3301-49-B1-A542-6391-CFDB6-BA0.jpg) (https://ibb.co/yppsGhq)
a
Title: Re: 79 G5 Build
Post by: Scout63 on February 14, 2021, 11:13:48 PM
Front wheel trued to about .030Ē. Iím going to finish it tomorrow to get runout as low as I can,  then work on the rear wheel.

(https://i.ibb.co/vmhbXVD/373-A9-C25-1166-40-E1-879-A-B01-D9-FFAAF36.jpg) (https://ibb.co/vmhbXVD)
a
Title: Re: 79 G5 Build
Post by: Scout63 on February 15, 2021, 10:17:50 PM

(https://i.ibb.co/1RvC348/66-AEAB60-1-E60-4-F07-9423-6-AB33-DC6-BA0-B.jpg) (https://ibb.co/1RvC348)


Wheels are done. They will never look this good again.
Title: Re: 79 G5 Build
Post by: Antietam Classic Cycle on February 16, 2021, 09:11:22 AM
 :thumb: :thumb:
Title: Re: 79 G5 Build
Post by: Groover on February 16, 2021, 09:52:28 AM
Nice work, love seeing those rims restored. Is there a reason for moving the calipers to the rear, personal preference?
Title: Re: 79 G5 Build
Post by: Dave Swanson on February 16, 2021, 10:21:18 AM
Nice job on those wheels!  My T3 California rims were in similar shape.  Its amazing how much work just the wheels can be!! 
Title: Re: 79 G5 Build
Post by: Scout63 on February 17, 2021, 07:09:48 AM
Nice work, love seeing those rims restored. Is there a reason for moving the calipers to the rear, personal preference?

Iím just musing Grover.  Iíve been all over the map on the build.  Now itís going to be stock seat and tank, police bars, floorboards, white frame and light blue bodywork.  I still think the forward calipers look kind of clunky.  I can always swap the bearing carriers and fork legs back.  Iím also plotting a solo seat and (gasp) CB360 tank which will sit on top of the frame rails. Iím not going to alter any frame mounts so that I can revert to stock anytime.
Title: Re: 79 G5 Build
Post by: Scout63 on February 28, 2021, 02:24:12 PM
Progress without progress. I got space cleared and all of the parts organized.  Once I install the steering stem and U-Joint carrier bearings I can get the steel painted.  Also sorted parts to go to the plater.  I still need to disassemble the shift and brake pedals for plating.

(https://i.ibb.co/Nm5TJnJ/E6-BE46-EE-0-DBF-4079-B659-9154-A36-C0-EED.jpg) (https://ibb.co/Nm5TJnJ)

(https://i.ibb.co/5RKLpbX/71-EBBC9-B-7-C61-4-B7-E-8-A74-1-B83-A38-E7391.jpg) (https://ibb.co/5RKLpbX)
Title: Re: 79 G5 Build
Post by: Scout63 on March 01, 2021, 10:08:51 PM
Installed steering stem, U-Joint and swingarm bearings and taped off and bolted the frame and swing arm for painting.  Circling the gearbox warily before a second attempt at assembly and shimming.
Title: Re: 79 G5 Build
Post by: Scout63 on March 06, 2021, 10:42:16 PM
Frame etc. delivered to the painter yesterday.  Two week time frame hopefully.  Small parts off to Intíl. Chromium Plating in Providence today. Headlight rim, fender mounts, shift and brake levers, headlight ears.  Large parts like engine guards, tail rack and my Norton headlight will go with the next batch.
Title: Re: 79 G5 Build
Post by: Scout63 on March 07, 2021, 08:59:16 AM
...and he called this morning to tell me the painted parts are ready. 24 hour turnaround.  I always overpay him in cash.  Now if only the weather would get over 40F so I can spend more than a half hour in the garage.
Title: Re: 79 G5 Build
Post by: Scout63 on March 07, 2021, 05:09:38 PM
Steel parts painted before and after:


(https://i.ibb.co/8mKFqbD/AB55-ECFF-B510-48-B4-AFCF-E7-A0-A2-DFE698.jpg) (https://ibb.co/8mKFqbD)

(https://i.ibb.co/NV6rrhk/C0-F341-FF-E358-41-AE-B37-B-AE2535-DAD5-E0.jpg) (https://ibb.co/NV6rrhk)
Title: Re: 79 G5 Build
Post by: Groover on March 07, 2021, 07:59:40 PM
Looking great! Which finish did you decide on? Looks like a satin?
Title: Re: 79 G5 Build
Post by: Scout63 on March 07, 2021, 09:17:44 PM
Looking great! Which finish did you decide on? Looks like a satin?

Satin two part.  It came out great. Ken told me the two coats took almost two quarts.  He gave me the excess paint and hardener so that I can touch up. Iím sure I will need to after the engine installation.
Title: Re: 79 G5 Build
Post by: Scout63 on March 08, 2021, 09:58:26 PM
Gearbox disassembled again, shimmed and assembled.  Now itís shifting fine on the bench.
Title: Re: 79 G5 Build
Post by: Scout63 on March 14, 2021, 05:21:40 PM
Tires and tubes installed today. IRC Durotours and IRC regular weight tubes.  Iíve used their tubes for years and like them. I bought a gallon of Slip Tac tire lubricant and it worked great.


(https://i.ibb.co/g7THRN0/D8-DBC74-B-D8-BB-4644-9-FF3-D2-AF18-F55-C5-A.jpg) (https://ibb.co/g7THRN0)
Title: Re: 79 G5 Build
Post by: Antietam Classic Cycle on March 14, 2021, 07:06:05 PM
Tires and tubes installed today. IRC Durotours and IRC regular weight tubes.  Iíve used their tubes for years and like them. I bought a gallon of Slip Tac tire lubricant and it worked great.


(https://i.ibb.co/g7THRN0/D8-DBC74-B-D8-BB-4644-9-FF3-D2-AF18-F55-C5-A.jpg) (https://ibb.co/g7THRN0)


My favorite tubes as well. Never tried their tires though.
Title: Re: 79 G5 Build
Post by: Scout63 on March 14, 2021, 09:17:12 PM
I backed into IRC Duro tires for my Matchless Charlie.  They were the only 19Ē Trials tires I could find and the tread matched the old Dunlops pretty well. The quality seems good.  Their tubes hit just right on price and quality and Iíve never had a failure other than installation pinching.
Title: Re: 79 G5 Build
Post by: Scout63 on March 20, 2021, 05:30:21 PM
Engine is ready for installation in the frame.  After ruining two intermediate plates I figured out how to use the MG Cycle clutch alignment tool. The gearbox install was surprisingly easy.


(https://i.ibb.co/VShfqTV/E2-D6-BB3-E-F29-F-4-F94-8944-B8301480-CAFF.jpg) (https://ibb.co/VShfqTV)
Title: Re: 79 G5 Build
Post by: Groover on March 21, 2021, 08:27:17 AM
Nice work! :thumb:
Title: Re: 79 G5 Build
Post by: Kane on April 19, 2021, 03:44:42 PM
Very nice.
Your Norton looks great, too!
Title: Re: 79 G5 Build
Post by: Scout63 on April 19, 2021, 10:10:33 PM
Thanks Kane. The Norton is running beautifully at least for the next few days.  Then something will fall off.  I got the engine and frame together today between trips to the office and hauling mulch.  I hung the frame from above and pumped up the lift table.  It worked pretty well.


(https://i.ibb.co/LY8T9f4/AC468-BA2-6-A37-4764-A034-B2-E49-C8-A5490.jpg) (https://ibb.co/LY8T9f4)


Groover - youíll be glad to know I decided to keep the bike black with white striping.  Iím going with a T3 dual seat, dual gauges with white faces, civilian bars and floorboards. I have a nice G5 seatcover from England but need to find a good pan as mine is pretty well rusted out.  I also have a solo seat to try out. Iím keeping all the parts to put it back to a pure G5 if need be.
Title: Re: 79 G5 Build
Post by: Groover on April 21, 2021, 03:08:14 PM
G5-specific restoration quality inspector here reviewing your plan with a big checkmark of approval - you may proceed, but don't go crazy. Those white face clocks.... that is pushing the limit, but sure.. go ahead..  :azn: 


Kidding - all sounds like a great plan!
Title: Re: 79 G5 Build
Post by: Scout63 on April 21, 2021, 10:14:58 PM
Roger that Groover. The stock monogauge just feels like a bridge too far for me.  Here are the gauges. 

https://shop.revivalcycles.com/motogadget-motoscope-classic-tachometer/

Very expensive at $579 each.  They are designed for solo use but Iím going to install a speedo and a tach and water jet cut a mounting plate.   Itís strange to have one gauge cost almost three times the bike price.

Ben
Title: Re: 79 G5 Build
Post by: 1down5up on April 21, 2021, 10:36:23 PM
The motogadget stuff is very nice but eyewateringly expencive.  (I have a munit installed)

Have you considered the acewell spredo/tacho, they are Chinese (and don't let the chinglish put you off), but I have one on a Honda twin project andnI can't fault it.


http://www.acewell-meter.com/wp-content/uploads/2017/07/2017-P03-ACE-CA85SPDRPM-SERIES.jpg

Title: Re: 79 G5 Build
Post by: Groover on April 22, 2021, 06:48:46 AM
Nice gauges for sure. I think there are some 90's Ducati white face gauges that might work on these bikes, but not 100% sure. Was looking into this a while ago, that's what I remember.
Title: Re: 79 G5 Build
Post by: rutgery on April 22, 2021, 02:33:34 PM
Nice gauges for sure. I think there are some 90's Ducati white face gauges that might work on these bikes, but not 100% sure. Was looking into this a while ago, that's what I remember.

The ducati 900ss white face speedometer works on a guzzi for sure, I've got one on my Sport. The tacho uses a different ratio which will always show more than the Guzzi engine is turning over (Don't know the ratio but shouldn't be much of a problem to find)
Title: Re: 79 G5 Build
Post by: grdstudios@gmail.com on April 25, 2021, 04:10:34 PM
I have a 80 G5 EML Sidecar Conversion that just being freshened up. It sat our side for decades. Just did the top end and it's coming along when I have the time
(https://i.ibb.co/zm2Gd5C/80-EML-shop-Loop-Ft-wheel.jpg) (https://ibb.co/zm2Gd5C)

(https://i.ibb.co/B6sRZdL/80-G5-Home-for-finishing.jpg) (https://ibb.co/B6sRZdL)

(https://i.ibb.co/cxfbgXN/80-G5-Home-for-finishing-rear.jpg) (https://ibb.co/cxfbgXN)
Title: Re: 79 G5 Build
Post by: Scout63 on April 30, 2021, 06:05:06 PM
I have a 80 G5 EML Sidecar Conversion that just being freshened up. It sat our side for decades. Just did the top end and it's coming along when I have the time
(https://i.ibb.co/zm2Gd5C/80-EML-shop-Loop-Ft-wheel.jpg) (https://ibb.co/zm2Gd5C)

(https://i.ibb.co/B6sRZdL/80-G5-Home-for-finishing.jpg) (https://ibb.co/B6sRZdL)

(https://i.ibb.co/cxfbgXN/80-G5-Home-for-finishing-rear.jpg) (https://ibb.co/cxfbgXN)


The bike has great bones and will bruise your wallet. Mine certainly has. Do you have a chair for it?
Title: Re: 79 G5 Build
Post by: Scout63 on May 08, 2021, 10:21:53 PM
I had a free afternoon and got the swingarm, rear drive and rear wheel installed.

(https://i.ibb.co/yq14Dkd/43030730-CBFF-47-E9-8-EA3-BE578-EE30-CD7.jpg) (https://ibb.co/yq14Dkd) (https://i.ibb.co/pwQ8GJP/8-D1-AD892-5-B3-A-4-D62-8-AD2-5-D5-DCC8-E4-D7-A.jpg) (https://ibb.co/pwQ8GJP) (https://i.ibb.co/ypHJWPQ/C5-F003-DD-A86-E-44-EC-A336-513-B42469101.jpg) (https://ibb.co/ypHJWPQ) (https://i.ibb.co/2PLf4Gk/15560138-C9-D5-4-F33-9-ECB-7606-E9-DB8-C5-F.jpg) (https://ibb.co/2PLf4Gk) (https://i.ibb.co/8z83nSP/DDBB6840-776-D-4540-B1-FB-49212-EFCE1-F8.jpg) (https://ibb.co/8z83nSP) (https://i.ibb.co/5s384nx/1-B3-AF168-9927-4-CFF-B69-A-E9-D5-A722-AC98.jpg) (https://ibb.co/5s384nx) (https://i.ibb.co/ZHPJqV6/34-B91681-90-CD-4-A12-8-CAD-0-A38-ED8-DC311.jpg) (https://ibb.co/ZHPJqV6)
Title: Re: 79 G5 Build
Post by: berniebee on May 09, 2021, 09:32:11 AM
Looking good. Wow, you've got several nice bikes in your stable.
Title: Re: 79 G5 Build
Post by: Scout63 on May 09, 2021, 09:37:56 PM
Thanks Bernie. Every one of them came to me needing pretty much everything and costing little.  By the time I was done with parts and my labor they each have cost more than theyíre worth. Stray dogs all but I love them.
Title: Re: 79 G5 Build
Post by: Scout63 on May 12, 2021, 10:16:39 PM
Front end is back together so now I have a rolling chassis.  Itís going slow since I have to tap every mounting hole in the cases, fork legs, triple trees etc. after the vapor blasting. I also installed the circlip on the wrong side of the front wheel. It has to go on the side opposite the big end of the axle.  Get that wrong and nothing fits. Luckily I could remove the circlip, drive both bearings and the inner spacer over a little and install the circlip on the other side. 

Also I installed stainless Mistral head pipes and crossover and new LaFranconi mufflers. Theyíve been in the box for a long time. Slow install also.

New Brembos installed in the forward position to please Groover.


(https://i.ibb.co/86y2Cj3/DB0-D3749-2-D15-46-AA-9798-AD68718-D8183.jpg) (https://ibb.co/86y2Cj3)

(https://i.ibb.co/fxYv32b/4-B6-F85-D6-19-C4-497-B-B9-A9-C7805-AE5066-A.jpg) (https://ibb.co/fxYv32b)

(https://i.ibb.co/8NDj7Cf/B12-FE4-B4-EB51-48-CB-AC07-34-A51-F97146-B.jpg) (https://ibb.co/8NDj7Cf)
Title: Re: 79 G5 Build
Post by: Groover on May 13, 2021, 07:12:50 AM
 :thumb:
Title: Re: 79 G5 Build
Post by: berniebee on May 13, 2021, 06:49:13 PM
Well, if you are going to please  people - I'd like to see these on your handlebars.. :evil:


(https://i.ibb.co/Bt067QX/Streamers-Bicycle-Grips.jpg) (https://ibb.co/Bt067QX)
Title: Re: 79 G5 Build
Post by: Pescatore on May 14, 2021, 10:02:38 AM
Nice job.  :bow:
I Love those disk brakes.  As a traditionalist, I would install the original tank.
New exhaust, huh?  My header pipes are rusted, but still whole.  I think I will wrap them for now.
How much did the whole exhaust go for?
Title: Re: 79 G5 Build
Post by: Scout63 on May 14, 2021, 09:03:52 PM
Nice job.  :bow:
I Love those disk brakes.  As a traditionalist, I would install the original tank.
New exhaust, huh?  My header pipes are rusted, but still whole.  I think I will wrap them for now.
How much did the whole exhaust go for?

So much. Head pipes, flanges and crossover are Mistral stainless.  The mufflers are LaFranconis.  The whole system was about $1100.00 not counting shipping.  Seems like a lot until I total up the stacks of Motogadget boxes waiting to be opened. This the most expensive $200.00 motorcycle Iíve ever owned.  It is the bike building that I love, and the money is really just paying for a hobby, like airline tickets for traveling or lift tickets for skiing.
Title: Re: 79 G5 Build
Post by: Pescatore on May 14, 2021, 10:21:48 PM
  It is the bike building that I love, and the money is really just paying for a hobby, like airline tickets for traveling or lift tickets for skiing.

...and the occasional new tool.

I might be down the Cape this summer and perhaps we can meet.
Have fun. 
Title: Re: 79 G5 Build
Post by: Scout63 on May 14, 2021, 10:54:25 PM
We just started a Saturday morning coffee shop ride group.  PM me when you are coming down.
Title: Re: 79 G5 Build
Post by: Pescatore on May 17, 2021, 08:59:23 AM
 :thumb: :thumb:
Title: Re: 79 G5 Build
Post by: Scout63 on May 20, 2021, 05:41:21 AM
Rear fender installed.  I went with a T3 tail light and grab rail:


(https://i.ibb.co/gmQBfh8/1-F267-FCF-7-EC2-4770-885-E-A5-EAE1-BD6781.jpg) (https://ibb.co/gmQBfh8)

purano sei diner kotha lyrics (https://poetandpoem.com/purano-sei-diner-kotha)


Heel-Toe shifter fitted.  It is a gorgeous piece:


(https://i.ibb.co/LdJ1NXw/63-B12-FD6-BD18-43-DA-9-C52-46-E5-BAB01-B5-C.jpg) (https://ibb.co/LdJ1NXw)


Carbs disassembled.  They were pretty bad, but arenít they always:


(https://i.ibb.co/1nnXTTM/37-C714-B8-AC7-D-4-B42-84-D2-9002-E3941-DB8.jpg) (https://ibb.co/1nnXTTM)


The tank and side covers are painted black and off to the striper.
Title: Re: 79 G5 Build
Post by: Groover on May 21, 2021, 09:59:30 AM
Did you get your chrome pieces back? How did they turn out?
Title: Re: 79 G5 Build
Post by: Scout63 on May 22, 2021, 07:16:56 AM
They gave me a quote of 2400 for about 7 of the smaller pieces. It was too much for me and I asked them to mail them back. Iím working around it and cleaning everything up the best I can Groover. The one part I canít seem to find is a good chrome headlight trim ring.
Title: Re: 79 G5 Build
Post by: Scout63 on May 23, 2021, 10:17:18 PM
Handlebars drilled and switches installed.  Iím not sure I like how the Domino throttle works with the right switch.  The throttle is too big and makes the switches hard to operate. The stock clutch mount fits the left switch nicely.


(https://i.ibb.co/PFRvdTP/81-BEEBE2-FA57-4-E84-BF50-D7-E3-EABDBD31.jpg) (https://ibb.co/PFRvdTP)

(https://i.ibb.co/1GS8rkV/DC23-BE7-C-4-FC6-4-B30-BB0-D-733473-CA2764.jpg) (https://ibb.co/1GS8rkV)
Title: Re: 79 G5 Build
Post by: Rick4003 on May 24, 2021, 12:22:50 AM
Hi Ben,

I have a domino throttle and a motogadget button set (m12 size). Frankly I dislike the system of having the right hand indicator switch on the right hand. I too thought that it was a neat system but have found it to be very annoying in actual use.
The best example is when you are accelerating out of a right hand corner, as when exiting a roundabout (left then quick right). Here you need to hold the throttle very stable to ride smoothly but at the same time you have to move your right hand off the throttle to reach the indicator button. Then back on the throttle to pull out of the roundabout. Then while accelerating out you again have to move your hand off the throttle to cancel the indicator.

I am working to change the indicator back to a three way toggle shift (on)-off-(on) on left side of the handlebar. If I had to use the buttons I would use two buttons on the left as indicators. (might take a while to get use to which one is which side though.) This way your right hand would be free to handle the throttle without having to reach over and indicate also.

-Ulrik

Title: Re: 79 G5 Build
Post by: Scout63 on May 24, 2021, 06:03:35 AM
Thanks Ulrik. I was thinking of putting both switch sets on the left. It would look much cleaner.  More drilling and fishing.
Title: Re: 79 G5 Build
Post by: Rick4003 on May 24, 2021, 07:21:39 AM
No problem.

I plan to stick with two buttons on the right, but change the indicator button to starter button and keep the top button as the mode button.
Also when you run the cables through the handlebars make sure that you deburr and round the inside edges of the holes the very best you can. Any kind of sharp corner will cut your wires over time.

-Ulrik
Title: Re: 79 G5 Build
Post by: Scout63 on May 24, 2021, 02:50:10 PM
Hi Ulrik:

I moved both switches to the left side. I like the look better and they are easier to reach.  I did debur.  I also went a few sizes larger on holes to make routing easier. I found that if I lubed the wires with silicone grease they routed much more easily. I think my switch functions will be:

Top left - headlight
Top right - auxiliary
Middle left - left turn
Middle right - right turn
Bottom left - horn
Bottom right - starter


(https://i.ibb.co/1XHk9Cp/E76-F1260-0-DB2-4-B68-9-A3-C-68-B4537-A4-AD1.jpg) (https://ibb.co/1XHk9Cp)

(https://i.ibb.co/GWD4L6Q/80-E07-EBA-4-C7-D-4-C1-F-A651-3-D5-F28636-DAF.jpg) (https://ibb.co/GWD4L6Q)

(https://i.ibb.co/N6FdFjR/6070-AC3-A-AB3-B-4-D50-802-E-5011-EF889785.jpg) (https://ibb.co/N6FdFjR)
q
Title: Re: 79 G5 Build
Post by: Rick4003 on May 24, 2021, 08:36:10 PM
Hi Ben,

Looks good, I believe you will be much happier with this setup than the other one. Button configuration also seems to be spot on. But that's always easy to say before you have ridden the bike for a while. At first I thought the right/left button indicator was fine.

Looking forward to see how it ends up. I also have an extra tonti frame, and all the parts needed apart from the seat and painted parts. Hopefully I will get around to build it up at some point  :azn:
Title: Re: 79 G5 Build
Post by: Scout63 on May 25, 2021, 10:10:49 PM
Carbs vapor honed and rebuilt with new main jets, throttle springs, gaskets and air and throttle stop screws. installed with Emgo pods:


(https://i.ibb.co/qFvgJGP/74657760-734-B-46-C4-B996-E531-BBD8-FDD4.jpg) (https://ibb.co/qFvgJGP)

(https://i.ibb.co/yVtrtGZ/64-CED1-CC-F335-49-EE-9625-70-C7-C2-E10-A15.jpg) (https://ibb.co/yVtrtGZ)


and then disassembled again since I was worried that I didnít get all of the honing media out. Everything is going back into the ultrasonic cleaner, then more soap and water and compressed air.


(https://i.ibb.co/FK2n4s0/8-F3-A3514-C50-E-434-C-BB33-20-AE3-BEB1438.jpg) (https://ibb.co/FK2n4s0)

bmw 328i quarter mile (https://statewideinventory.org/bmw-0-60-times)


Rotor and stator installed:


(https://i.ibb.co/CPfpcLs/4-B76-D4-F0-A172-4-A83-9-C2-E-B4617-B582-DF2.jpg) (https://ibb.co/CPfpcLs)
Title: Re: 79 G5 Build
Post by: Scout63 on May 30, 2021, 02:10:07 PM
RME LI compatible Reg/rec installed.  I hope the location works.  Wired it to the alternator with a disconnect plug.


(https://i.ibb.co/L6Xyp7S/4-E2182-E3-33-AD-43-E6-BC34-60-E2-C95504-BC.jpg) (https://ibb.co/L6Xyp7S)

(https://i.ibb.co/F8yVrkn/165874-F4-09-DB-4-A83-A4-F6-F9-D1-F5080-E71.jpg) (https://ibb.co/F8yVrkn)

(https://i.ibb.co/3CHbSvC/E8459078-5175-4428-812-C-19-F19-FA5094-A.jpg) (https://ibb.co/3CHbSvC)
o
Title: Re: 79 G5 Build
Post by: Scout63 on May 31, 2021, 01:11:00 PM
Positives and Grounds and Motogadget installed and powered with temp key. Outputs and inputs not wired.

(https://i.ibb.co/VxyvNN5/189758-BD-F400-4348-BCAF-983-AFED31-F38.jpg) (https://ibb.co/VxyvNN5)

(https://i.ibb.co/4TZGTJJ/554342-EE-5-FDC-4770-ACB6-AFCC0-EAF0942.jpg) (https://ibb.co/4TZGTJJ)

(https://i.ibb.co/3hmQHhW/F2-A54175-0-BDB-4-BFB-AC0-C-245-FC424-FCE2.jpg) (https://ibb.co/3hmQHhW)
Title: Re: 79 G5 Build
Post by: Groover on June 02, 2021, 12:51:41 PM
Looking great!
Title: Re: 79 G5 Build
Post by: Scout63 on July 03, 2021, 06:04:58 PM
Thanks Groover.

Garage time today. The Motogadget is almost completely wired. Itís a blast to play with. New seat installed. Horns (very important) installed. Cranked the engine for the first time. No spark Yet. Tomorrow Iíll wire in the gauges.


(https://i.ibb.co/cwzBPCY/17725-A8-B-BF44-4-A18-9194-D10-FEF0-EE08-B.jpg) (https://ibb.co/cwzBPCY)

(https://i.ibb.co/zNtY4vb/25865-D47-EB5-A-4-C23-AA70-E10798-F50883.jpg) (https://ibb.co/zNtY4vb)

(https://i.ibb.co/D9zbpRq/A23-B1-F4-D-634-C-4-E84-AEAC-55-C19-A93-A1-D7.jpg) (https://ibb.co/D9zbpRq)

(https://i.ibb.co/dkTYPWX/C3-B0-CE1-F-DE4-F-4-C34-8-CB5-C1-D13-C04-D3-A7.jpg) (https://ibb.co/dkTYPWX)
Title: Re: 79 G5 Build
Post by: Scout63 on July 10, 2021, 07:56:54 PM
I test fit the side covers and fitted the breather box.  I covered it with a section of inner tube to hopefully prevent any contact vibration. Sandblasted, painted and installed the sidecover mounting brackets. Thanks Charlie for the photos.


(https://i.ibb.co/wBggtYP/A486-AB72-BDB5-47-A0-B317-0-ECA2-F87484-D.jpg) (https://ibb.co/wBggtYP)

(https://i.ibb.co/CML6DP3/41-AAD637-01-D2-4974-84-F1-84084747-C1-BD.jpg) (https://ibb.co/CML6DP3)

(https://i.ibb.co/6RdV500/B6-F53-D9-A-B8-BF-4081-B297-AF54-B97-D0-E81.jpg) (https://ibb.co/6RdV500)

(https://i.ibb.co/ZMQSVrV/DE62882-F-8209-4789-B015-24-AC5-DA139-E0.jpg) (https://ibb.co/ZMQSVrV)

(https://i.ibb.co/vwtHjzC/42-DAB501-6-A26-44-B9-BD72-F72-F645501-B7.jpg) (https://ibb.co/vwtHjzC)



(https://i.ibb.co/8xPnwFH/75335-A03-1758-4-F31-873-E-1-EB16-A50-F673.jpg) (https://ibb.co/8xPnwFH)
Title: Re: 79 G5 Build
Post by: ozarquebus on July 10, 2021, 08:31:45 PM
What a beautiful job coming together.
Title: Re: 79 G5 Build
Post by: Scout63 on July 14, 2021, 10:49:51 PM
Tank and side covers fitted. Itís a little weird looking having G5 badges and T3 tank seat and bars.  Iíll stick with it a bit.

The fuel cap needs to be fettled, fuel light new installed, brake rebuilt and installed, gauges installed, throttle fixed and installed, front forks fettled, everything checked for tightness. Etc.

(https://i.ibb.co/TB8GKMx/56-F7-C5-D2-C24-F-4642-B161-659882-CB143-C.jpg) (https://ibb.co/TB8GKMx)

(https://i.ibb.co/QYpXWXq/6-B8-C9-A59-7-C1-E-4851-BEC4-359-DF4-E81-DEF.jpg) (https://ibb.co/QYpXWXq)
Title: Re: 79 G5 Build
Post by: berniebee on July 15, 2021, 08:02:38 AM
Great progress on the bike!

Isn't it strange how the breather box just sits on the two rubber hoses- no mounting bracket or tab so it can be secured to a frame tube. But I guess it works.  I'm off to buy hose clamps to install mine today.

Title: Re: 79 G5 Build
Post by: Antietam Classic Cycle on July 15, 2021, 08:25:26 AM
Great progress on the bike!

Isn't it strange how the breather box just sits on the two rubber hoses- no mounting bracket or tab so it can be secured to a frame tube. But I guess it works.  I'm off to buy hose clamps to install mine today.

Back around '70-'71 the Ambo breather box did have a bracket that secured it to one of the distributor bolts. On V700s, the fuel line crossover bolted to a stub on the top of the breather box.
Title: Re: 79 G5 Build
Post by: Scout63 on July 19, 2021, 09:12:46 PM
Gauges and original switch.
(https://i.ibb.co/DKhpdzc/3-FEC776-F-7-D96-4-BE4-B8-E8-5-F3-BB6-BE712-F.jpg) (https://ibb.co/DKhpdzc)
Title: Re: 79 G5 Build
Post by: berniebee on July 21, 2021, 09:02:38 AM
 The gauges are the perfect combo of black print on a white face with a slim red pointer. And a just right sized digital display at the bottom. Beautiful!
Title: Re: 79 G5 Build
Post by: Scout63 on July 23, 2021, 07:51:47 AM
Thanks Berniebee. The gauges are really designed for single use so Iím having to split wires if I want info on both gauges. Once itís set up I might try to water jet a custom plate. This one from MG is great for sorting but not quite what I want.
Title: Re: 79 G5 Build
Post by: Scout63 on August 19, 2021, 09:39:02 PM
Slow progress. I have finished wiring the gauges.  Drilled the gauge plate to fit a mode button for each gauge at the bottom. Also installed led idiot lights for oil pressure, turn, alternator and high beam.

(https://i.ibb.co/pKDkc1Y/93468-BBE-C52-C-4-C62-B569-415-EA66-A364-C.jpg) (https://ibb.co/pKDkc1Y)
Title: Re: 79 G5 Build
Post by: Scout63 on September 23, 2021, 01:14:06 PM
Almost done with this bike.  I had to tear it back to the flywheel since I installed the ring gear backwards. All that is left is installing a Dyna III, sorting the throttle cables and test firing and riding.

Groover - my apologies for the deviations. I have all the stock parts so I can bring it back to proper spec if necessary.

(https://i.ibb.co/g3jPtST/74-BD486-D-8-BEE-4-E74-8-D11-70-D0-E9886808.jpg) (https://ibb.co/g3jPtST)

(https://i.ibb.co/t4CLJRg/17586-A78-28-E2-4-C9-E-9-D56-4001-B74-A6-AEE.jpg) (https://ibb.co/t4CLJRg)

(https://i.ibb.co/8NnF2RZ/7-D6-A4043-679-F-4221-8-BE6-861-DEBC33074.jpg) (https://ibb.co/8NnF2RZ)

(https://i.ibb.co/B4N0ycf/F9-F77-E9-D-A539-48-E3-B5-AA-21-CDFD6-DC732.jpg) (https://ibb.co/B4N0ycf)
Title: Re: 79 G5 Build
Post by: twodogs on September 23, 2021, 01:28:43 PM
That looks great, can't wait to hear your ride report  :boozing:
Bruce
Title: Re: 79 G5 Build
Post by: Groover on September 23, 2021, 02:33:44 PM
All the modifications were approved earlier-on, you are in the clear  :azn:

The bike looks great, well done!

Quote from: Scout63 on Today at 02:14:06 PM (https://wildguzzi.com/forum/index.php?topic=104521.msg1780254#msg1780254)
Groover - my apologies for the deviations. I have all the stock parts so I can bring it back to proper spec if necessary.
Title: Re: 79 G5 Build
Post by: Canuck750 on September 24, 2021, 05:37:31 PM
Looks great, super clean and classy bike  :thumb: :thumb:
Title: Re: 79 G5 Build
Post by: Scout63 on September 24, 2021, 09:36:08 PM
The Dyna III came in today.  Great instructions and easy install. More importantly a big fat spark. I custom built throttle cables for the Domino throttle, checked all the nuts and bolts and fueled it up. Here is the first start:

https://youtu.be/3FqY6K9jvZY

It ran great around the block a few times.  It was my first ride on a big block.  Very smooth and torquey and I instantly liked the heel toe shifter.  Iím really going to like the bike.

There is a lot of sorting to do and I need to install the front fender, retorque the heads, adjust the carbs etc.

 I feel a little empty when I finish a project.
Title: Re: 79 G5 Build
Post by: Rick4003 on September 27, 2021, 03:22:50 AM
The Dyna III came in today.  Great instructions and easy install. More importantly a big fat spark. I custom built throttle cables for the Domino throttle, checked all the nuts and bolts and fueled it up. Here is the first start:

https://youtu.be/3FqY6K9jvZY

It ran great around the block a few times.  It was my first ride on a big block.  Very smooth and torquey and I instantly liked the heel toe shifter.  Iím really going to like the bike.

There is a lot of sorting to do and I need to install the front fender, retorque the heads, adjust the carbs etc.

 I feel a little empty when I finish a project.

Is it the quick pull double cable Domino throttle you have? I have that one two and found that it has a tendency to go out of sync after a while. I guess when you have two throttle cables moving back and forth every time you turn the bars they will creep a little bit. And never the same amount. I think I will go back to a single cable throttle and a splitter at some point.

"I feel a little empty when I finish a project." - You can always start a new one right away :grin: Or have several in the backlog, that's what I do. Then it feels great when one is finished, then on to the next one after!
Title: Re: 79 G5 Build
Post by: Scout63 on September 27, 2021, 09:54:30 PM
Is it the quick pull double cable Domino throttle you have? I have that one two and found that it has a tendency to go out of sync after a while. I guess when you have two throttle cables moving back and forth every time you turn the bars they will creep a little bit. And never the same amount. I think I will go back to a single cable throttle and a splitter at some point.

"I feel a little empty when I finish a project." - You can always start a new one right away :grin: Or have several in the backlog, that's what I do. Then it feels great when one is finished, then on to the next one after!
It is the quick pull Domino Rick.  It works fine now. I had to build custom cables for it, which will get old if it tends to break them. I use the stock cables and cut them back a bit and solder in the adjusters and nipples that fit the Domino.  I do have a very nice 1977 R100S and a 1973 SL125 waiting for restoration.  I usually take a few months and get some maintenance done on the running bikes. I also have most of the parts for a VW dune buggy build that Iíve been putting off.
Title: Re: 79 G5 Build
Post by: Rick4003 on October 01, 2021, 07:08:51 AM
It is the quick pull Domino Rick.  It works fine now. I had to build custom cables for it, which will get old if it tends to break them. I use the stock cables and cut them back a bit and solder in the adjusters and nipples that fit the Domino.  I do have a very nice 1977 R100S and a 1973 SL125 waiting for restoration.  I usually take a few months and get some maintenance done on the running bikes. I also have most of the parts for a VW dune buggy build that Iíve been putting off.

Then it should be the same as I have, It is a bit hard on the throttle hand even with light springs in the carbs. But I have kind of gotten used to it. I don't think about it much apart from really long rides.

I made my own cables to fit the throttle as well, I haven't had any problem with snapping the cables, but it tends to work itself out of synchronization after a while. But works fine other that that. Maybe it is only mine that does that.
Title: Re: 79 G5 Build
Post by: kidsmoke on October 01, 2021, 08:44:58 AM
The Dyna III came in today.  Great instructions and easy install. More importantly a big fat spark. I custom built throttle cables for the Domino throttle, checked all the nuts and bolts and fueled it up. Here is the first start:
https://youtu.be/3FqY6K9jvZY
It ran great around the block a few times.  It was my first ride on a big block.  Very smooth and torquey and I instantly liked the heel toe shifter.  Iím really going to like the bike.
There is a lot of sorting to do and I need to install the front fender, retorque the heads, adjust the carbs etc.
 I feel a little empty when I finish a project.

Well done, and congrats! Just did my first considerable mileage weekend on my '79. 687 miles over 4 days and one of those a very spirited 156 miles on Kentucky twisties. What wonderful machines, and mine's not 'fresh' like yours is. I imagine you're gonna love it. Cheers!
Title: Re: 79 G5 Build
Post by: Chuck in Indiana on October 22, 2021, 07:00:48 AM
Well done, and congrats! Just did my first considerable mileage weekend on my '79. 687 miles over 4 days and one of those a very spirited 156 miles on Kentucky twisties. What wonderful machines, and mine's not 'fresh' like yours is. I imagine you're gonna love it. Cheers!

Awesome.  :thumb: The G5 rocks..