Wildgoose Chase Moto Guzzi

General Category => Bike Builds, Rebuilds And Restorations Only => Topic started by: rutgery on March 26, 2018, 06:28:45 AM

Title: Cali 3 to V7 Sport conversion
Post by: rutgery on March 26, 2018, 06:28:45 AM
I've bought a Cali III that needed some work. The bike had some very nice parts (spoke wheels, lafranconi exhaust, stainless bolts, alu alternator cover) which made it a very good deal. The plan is to convert this bike to a V7 Sport. I'm trying to get as close as possible to the original without breaking the bank. The braking system will be retained, as will the wide(r) tyres and front end.

The bike when I bought it:

(http://thumb.ibb.co/mEbEpn/IMG_1861.jpg) (http://ibb.co/mEbEpn)


(http://thumb.ibb.co/gkWVUn/IMG_1865.jpg) (http://ibb.co/gkWVUn)


As the front end is 40mm instead of 35mm on the V7, the replica V7 parts cannot be used. I've decided to change my parts to get the look of the V7 sport. One of these parts is the fork top clamp. The handlebar mounts are shaved off, holes welded shut, rounded and painted in a black wrinkle finish.

(http://thumb.ibb.co/dhuOh7/IMG_1936.jpg) (http://ibb.co/dhuOh7)


(http://thumb.ibb.co/jZ2yX7/IMG_2862.jpg) (http://ibb.co/jZ2yX7)


(http://thumb.ibb.co/fEp3X7/IMG_2874.jpg) (http://ibb.co/fEp3X7)


I've detabbed the frame, removed the footrests and removed a bit of the upper support for the steering head to make room for the fuel tank. My dad helped welding for the side covers, steering damper, seat and the upper steering head. 

(http://thumb.ibb.co/ebZbkS/IMG_2472.jpg) (http://ibb.co/ebZbkS)


(http://thumb.ibb.co/faa5en/IMG_2471.jpg) (http://ibb.co/faa5en)


While the frame was away for a fresh powder coat, I've rebuild the front end (the inner tubes were worn through the crome layer). My engine recieved a nice le mans camshaft to drive a mechanical speedo, because the original cam doesn't have the tacho drive at the end of the cam. A different distributor cover was also installed, for the same reason.

The frame powdercoated RAL 3020 red with the engine installed, and the cali 3 swingarm replaced with one from a LM1000.

(http://thumb.ibb.co/hHQkC7/IMG_2782.jpg) (http://ibb.co/hHQkC7)


(http://thumb.ibb.co/kZo5C7/IMG_2835.jpg) (http://ibb.co/kZo5C7)


I've decided to run a T3 front fender, as the 1000s fenders are inpossible to come by. The front fork is reversed to get the look of the older guzzi's with the callipers in front. To be able to mount the fender, some support brackets had to be made (I used 1mm stainless plate). The fender fits nicely underneath the fork stabiliser.

(http://thumb.ibb.co/i8jns7/IMG_2864.jpg) (http://ibb.co/i8jns7)


(http://thumb.ibb.co/cXT2QS/IMG_2866.jpg) (http://ibb.co/cXT2QS)


(http://thumb.ibb.co/gzofC7/IMG_2867.jpg) (http://ibb.co/gzofC7)


The handlebar mounts are currently in progress. A little sneak peak:

(http://thumb.ibb.co/ik4WKn/CBLB7805.jpg) (http://ibb.co/ik4WKn)



The braking system is installed on the frame, and I'm currently working on the wiring. The current issue is a place to relocate all relays to. The RH side cover also need modifying to fit over the braking system, and they both need mounting pins and holes drilled to fit them to the frame.

(http://thumb.ibb.co/kiStzn/foto_frame.jpg) (http://ibb.co/kiStzn)




Title: Re: Cali 3 to V7 Sport conversion
Post by: Antietam Classic Cycle on March 26, 2018, 08:24:32 AM
Interesting project!

That's the first time I've seen a "polizia" fairing meant for a Loopframe Guzzi mounted to a Tonti guzzi.
Title: Re: Cali 3 to V7 Sport conversion
Post by: siabeid on March 26, 2018, 02:12:51 PM
I have just spent the last 2 winters going over every piece of a v7 sport, and I must say that your top triple clamp modification  resembles one for a real v7 sport very closely.
Title: Re: Cali 3 to V7 Sport conversion
Post by: wirespokes on March 28, 2018, 03:13:03 AM
I LIKE it! But I think it would have been easier and cleaner leaving the calipers behind the forks, and not needed the extra fender brackets.
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on March 31, 2018, 09:20:37 AM
Interesting project!

That's the first time I've seen a "polizia" fairing meant for a Loopframe Guzzi mounted to a Tonti guzzi.

Yeah, I hadn't seen it before either. For anyone interested, The fairing was mounted with two brackets at the handlebars (see attached picture) and two simple L-shaped brackets at the headlight.

(http://thumb.ibb.co/i638Pn/image.png) (http://ibb.co/i638Pn)


I have just spent the last 2 winters going over every piece of a v7 sport, and I must say that your top triple clamp modification  resembles one for a real v7 sport very closely.
That's great to hear! Thanks

Title: Re: Cali 3 to V7 Sport conversion
Post by: ramarren on March 31, 2018, 09:57:27 AM
Fun project! I look forward to seeing the completed bike.

I've got one question, however: How do you have the frame powder-coated without taking the engine out of it? Far as I'm aware, to powder-coat something you have to spray it with paint powder after cleaning and treatment of the metal surfaces and then bake it until the paint-powder melts and fuses into a tough, bonded finish. I don't know how you can do that without taking the engine out!

I had my 850T frame, center stand, and swingarm powder-coated red once upon a time when I 'Sportified' it. It required a complete tear down, stripping to the metal, etc, and then a complete build up and reassembly. Came out great looking with a very very tough finish. I wasn't going for a full "V8 Sport" lookalike, however, just the ergonomics for the 850T since I liked the bike pretty much as it ran already and wanted something a bit more unique. :-)
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on March 31, 2018, 09:58:53 AM
A test fit of the tank, seat and side covers brought to light some small issues. All easely solvable though. The right side cover had to be cut at two places to make room for the rear brake master cylinder and the brake rod. The relays on the LH side of the bike have to be relocated, I'll probably attach them to the rear lower mudguard. The exhaust crossover had to be shortened a bit to bring the mufflers forward, and some stainless brackets have to be made to hold the mufflers to the rearsets (the original brackets are about 2cm too low).

(http://thumb.ibb.co/h5bCjn/IMG_2976.jpg) (http://ibb.co/h5bCjn)


(http://thumb.ibb.co/dpzhjn/IMG_2979.jpg) (http://ibb.co/dpzhjn)

(http://thumb.ibb.co/jWuRAS/IMG_2980.jpg) (http://ibb.co/jWuRAS)


The first clip-on part machined and fitted:

(http://thumb.ibb.co/iv27H7/IMG_2981.jpg) (http://ibb.co/iv27H7)


I'm also having some issues fitting the side stand, as the forward engine bolt isn't long enough. the engine bolt is about 27cm, and with the side stand fitted, the bolt is flush with the side stand bracket. Does anyone know where you can get a longer forward engine bolt (preferably in europe)?
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on March 31, 2018, 10:03:16 AM
Fun project! I look forward to seeing the completed bike.

I've got one question, however: How do you have the frame powder-coated without taking the engine out of it? Far as I'm aware, to powder-coat something you have to spray it with paint powder after cleaning and treatment of the metal surfaces and then bake it until the paint-powder melts and fuses into a tough, bonded finish. I don't know how you can do that without taking the engine out!

I had my 850T frame, center stand, and swingarm powder-coated red once upon a time when I 'Sportified' it. It required a complete tear down, stripping to the metal, etc, and then a complete build up and reassembly. Came out great looking with a very very tough finish. I wasn't going for a full "V8 Sport" lookalike, however, just the ergonomics for the 850T since I liked the bike pretty much as it ran already and wanted something a bit more unique. :-)

Thanks for the kind words Ramarren! You are right about the powder coating. I had the engine removed and frame/swingarm plugged to get it coated, and installed the engine again before I took the picture. I've heard great things about the toughness of the powder coat finish! Your 850T sounds quite unique! Do you have a picture of it?
Title: Re: Cali 3 to V7 Sport conversion
Post by: ramarren on March 31, 2018, 02:18:54 PM
Thanks for the kind words Ramarren! You are right about the powder coating. I had the engine removed and frame/swingarm plugged to get it coated, and installed the engine again before I took the picture. I've heard great things about the toughness of the powder coat finish! Your 850T sounds quite unique! Do you have a picture of it?

LOL! Yea, it was just the wording you used that was ambiguous. The pedant in me cannot help it... :evil:

I'm hunting for pictures of my 850T. It was a lovely machine, and a delight to ride; probably my all time favorite motorcycle to date (although my Racer is coming on strong in that department now). The 850T is now moved one circle of hands past the folks I know so I don't know what's become of it since about 2015. Unfortunately, the photos of it that I once had were lost in an apartment renovation around 2002 or so, but I'm hopeful that a few have survived somewhere if I can only find them.
Title: Re: Cali 3 to V7 Sport conversion
Post by: gentlemanjim on March 31, 2018, 09:36:53 PM
Nice work.  Where did you get the fuel tank?  I'm doing a similar project on a V50.  Got my tank on eBay from India.  fairly poor quality, but is going to do.
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on April 02, 2018, 09:02:51 AM
Nice work.  Where did you get the fuel tank?  I'm doing a similar project on a V50.  Got my tank on eBay from India.  fairly poor quality, but is going to do.

Thanks! Your project's looking good! I've got my fuel tank from India as well.. Have to agree with the quality, but nothing that can't be fixed. Did you paint the tank yourself?
Title: Re: Cali 3 to V7 Sport conversion
Post by: gentlemanjim on April 02, 2018, 09:12:30 AM
Yes I do it all myself - That's the fun of it.
Title: Re: Cali 3 to V7 Sport conversion
Post by: Groover on April 03, 2018, 09:17:45 AM
Looking good, watching this now!
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on April 08, 2018, 12:13:46 PM
Looking good, watching this now!

Thanks Groover!

The wheels are installed, with some new, less bulky axle nuts. Rims and spokes cleaned and the calipers actuated by the foot brake installed. The front calliper brake line needs to be shortened to fit nicely.

(http://thumb.ibb.co/cfD5Zx/IMG_3017.jpg) (http://ibb.co/cfD5Zx)

(http://thumb.ibb.co/jfR3Mc/IMG_3009.jpg) (http://ibb.co/jfR3Mc)

(http://thumb.ibb.co/fRbESH/IMG_3010.jpg) (http://ibb.co/fRbESH)

(http://thumb.ibb.co/mgar7H/IMG_3011.jpg) (http://ibb.co/mgar7H)


As you can see in the picture, the inner fender doesn't quite fit right. It seems the upper frame ''brace'' was moved to a few cm the rear. I'll probably attach it with a bracket fit to the battery plate.

The clip-on parts are also machined and fitted, but I don't have handlebars so I can't install the switchgear just yet..

(http://thumb.ibb.co/hk69ux/IMG_3012.jpg) (http://ibb.co/hk69ux)


As for the speedo and tacho, the original items are very rare (and very expensive!) so I've bought a T3 dash and removed everything but the lower plate to attach the dials to. The rubber sleeves for the dials are still available, but a hole had to be made for the trip meter knob. The bolt holes of the instrument light panel from a V7 Sport where a bit further apart, so the lower plate holes are filed out to fit the panel bolts.

(http://thumb.ibb.co/nKjnEx/IMG_3013.jpg) (http://ibb.co/nKjnEx)

(http://thumb.ibb.co/hEs7Ex/IMG_3015.jpg) (http://ibb.co/hEs7Ex)


The front engine bolt was too short to fit through the frame/engine and a side stand, and longer replacement bolts were rediculously expensive, so my dad helped by welding a piece of steel in between the bolt. This piece is welded in a part covered by the frame and engine, so you can't see it when it's installed. The side stand is mounted and the bolt just clears the exhaust downpipe.

(http://thumb.ibb.co/gcb0Zx/IMG_3019.jpg) (http://ibb.co/gcb0Zx)

(http://thumb.ibb.co/bTDEux/IMG_3018.jpg) (http://ibb.co/bTDEux)


The lafranconi exhausts need new brackets to fit them to the new footpegs, so I've installed the exhaust system and supported it with some wood. The brackets will be made from 3mm thick Stainless.

(http://thumb.ibb.co/j1ipux/IMG_3021.jpg) (http://ibb.co/j1ipux)

(http://thumb.ibb.co/gCVDMc/IMG_3022.jpg) (http://ibb.co/gCVDMc)


A Guzzi dealer in the Netherlands organised a bbq for Guzzi riders yesterday, and while I was there I had a look in the workshop. There was a very nice original V7 Sport in for maintenance with almost the exact same colour sceme I'm using for my build. It even had the rare aprilia turn signals in perfect condition!

(http://thumb.ibb.co/cNOHgc/IMG_3034.jpg) (http://ibb.co/cNOHgc)

(http://thumb.ibb.co/mi9ZSH/IMG_3037.jpg) (http://ibb.co/mi9ZSH)

 
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on April 30, 2018, 04:49:55 AM
Progress has been slow the last couple of weeks, but the exhaust is now attached properly with the brackets to the rearsets. Which means there's no more wood underneath the bike to support anything!

(https://thumb.ibb.co/mSPS4H/IMG_3134.jpg) (https://ibb.co/mSPS4H)

(https://thumb.ibb.co/h80dBx/IMG_3135.jpg) (https://ibb.co/h80dBx)


I fitted the instruments, but when looking at the bike from the side they didn't look very good. So I've lowered them to fit more closely to the headlight. this is the old setup:

(https://thumb.ibb.co/g3R1Wx/IMG_3138.jpg) (https://ibb.co/g3R1Wx)


Aand with the instruments lowered:

(https://thumb.ibb.co/f72EjH/IMG_3204.jpg) (https://ibb.co/f72EjH)


I got some nice bell crank phf 36 carbs to put on the bike, they were in rough condition so cleaning them will take some time. I also got some le mans 3 heads with bigger valves (44/37 valves) to go with the carbs, So the engine will essentially become a 950cc LM3. I still need the pistons though..

(https://thumb.ibb.co/kg84jH/IMG_3080.jpg) (https://ibb.co/kg84jH)

(https://thumb.ibb.co/cOh3dc/IMG_3083.jpg) (https://ibb.co/cOh3dc)

(https://thumb.ibb.co/mnx8Bx/IMG_3123.jpg) (https://ibb.co/mnx8Bx)


Those ''medium'' valves look quite big!

(https://thumb.ibb.co/hTdyTc/JRHH5338.jpg) (https://ibb.co/hTdyTc)


The original v7 sport indicator lights are both way to expensive, and impossible to get all the colours of. So I chose an alternative to install on my replica, Lucas indicator lights! They look very simmilar to the original lights but are much cheaper. My supplier unfortunately sent me one red light in stead of two, but The other light should arrive later.

(https://thumb.ibb.co/ffhTuH/IMG_3202.jpg) (https://ibb.co/ffhTuH)

(https://thumb.ibb.co/nKj8uH/IMG_3200.jpg) (https://ibb.co/nKj8uH)


Those voxbell horns on the original v7 look very nice, and I'd like to use em on my replica. But they are surprisingly expensive, and I've already got a set of working horns so I chose to install my horns on the same location of the original voxbells.

(https://thumb.ibb.co/dEiF8c/IMG_3206.jpg) (https://ibb.co/dEiF8c)


The tank and side covers didn't have the mounting hardware (correctly) installed on them, but that's another thing that's fixed now. Two mild steel plates are welded to the front part of the tank to ''hook'' it to the frame, and the rear will be attached with a rubber band (the same way as on the original). To attach the side covers to the frame, I turned four brass pins. These are silver soldered to the inside of the covers, and hook to the tabs extending from the frame (with rubbers in them to dampen vibrations). I still need to drill one hole in each side cover to attach them more permanently.

(https://thumb.ibb.co/dumUZH/IMG_3209.jpg) (https://ibb.co/dumUZH)


(https://thumb.ibb.co/icyhoc/IMG_3210.jpg) (https://ibb.co/icyhoc)





Title: Re: Cali 3 to V7 Sport conversion
Post by: canuck750 on April 30, 2018, 05:01:39 PM
The bike looks great, very well done.   :bow: :bow: :bow:
Title: Re: Cali 3 to V7 Sport conversion
Post by: Turin on May 01, 2018, 12:15:37 AM
That looks great!
Title: Re: Cali 3 to V7 Sport conversion
Post by: helmetbolt on May 04, 2018, 01:42:14 AM
That really is looking good.
Title: Re: Cali 3 to V7 Sport conversion
Post by: mgmark on May 04, 2018, 09:29:44 PM
Your bike looks really good, excellent progress! I did almost the same thing with my Ď85 Lemans, and used Cal III forks to get the front wire wheel. I went with the 70s short swing arm to get the rear wheel centered under the rear fender. I used an early rear wire wheel and laced up a matching rim for the Cal front wheel. Your 40mm swan neck mounts look a lot like the Verlicchi ones I found used for my bike, well done, you. I removed all of the Lemans foot pegs and controls, and went with the early style more forward parts.
I really like the stainless front fender on your bike. Iím going to do that to mine so it matches the rear!

Here is the link for my bike if youíre interested.
http://wildguzzi.com/forum/index.php?topic=88567.0


(https://thumb.ibb.co/k6ZJm7/15_EB5104_40_F1_4_D7_E_8_FB7_DB67_DE6_AEDE1.jpg) (https://ibb.co/k6ZJm7)
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on May 05, 2018, 04:41:29 PM
Thanks for the kind words guys!

Your bike looks really good, excellent progress! I did almost the same thing with my �85 Lemans, and used Cal III forks to get the front wire wheel. I went with the 70s short swing arm to get the rear wheel centered under the rear fender. I used an early rear wire wheel and laced up a matching rim for the Cal front wheel. Your 40mm swan neck mounts look a lot like the Verlicchi ones I found used for my bike, well done, you. I removed all of the Lemans foot pegs and controls, and went with the early style more forward parts.
I really like the stainless front fender on your bike. I�m going to do that to mine so it matches the rear!

Here is the link for my bike if you�re interested.
http://wildguzzi.com/forum/index.php?topic=88567.0


(https://thumb.ibb.co/k6ZJm7/15_EB5104_40_F1_4_D7_E_8_FB7_DB67_DE6_AEDE1.jpg) (https://ibb.co/k6ZJm7)


That's a real nice project bike! cool to see all the different makeovers it has had. Did you install the older type swingarm for the slightly shorter length? because my wheel seems quite centered underneath the fender? The older swingarms also don't support as wide rear tyres, what rim size did you use for the rear?

The 36' dell'orto carbs are installed and barely fit, I had to use the left carb on the right side and vise versa because the throttle levers hit my fuel taps. Also the RH fuel tap had to be rotated to make some more room. I do plan on using some oval air filters (like Mark) to reduce engine wear. Also, I need cable actuated chokes, because the flip up levers I installed cannot be used when the throttle cables are installed...

(https://thumb.ibb.co/gx0UuS/IMG_3225.jpg) (https://ibb.co/gx0UuS)

(https://thumb.ibb.co/gNK017/IMG_3226.jpg) (https://ibb.co/gNK017)

(https://thumb.ibb.co/g6e017/IMG_3227.jpg) (https://ibb.co/g6e017)


One of the hardest parts to get for a reasonable price was the rear fender. Some stainless repro fenders were made but unfortunately are unavailable as the manufacturer stopped making them.. Because of that, I had to import one from the US. This fender now is the only true original V7 sport part on my bike, so I guess that's kinda cool. The fender I bought was slightly damaged and was missing the ''box'' thingy that attaches to the rear seat. So just like many other brackets, I made my own. The bracket is made from 1mm thick stainless steel, just like the rest of the fender. The repro rear light and light holder fit nicely as well. I do need to add the weird thumbscrews, the fender is now secured with normal bolts.

(https://thumb.ibb.co/c7yDon/IMG_3230.jpg) (https://ibb.co/c7yDon)

(https://thumb.ibb.co/nvAton/IMG_3231.jpg) (https://ibb.co/nvAton)

(https://thumb.ibb.co/ee1r8n/IMG_3232.jpg) (https://ibb.co/ee1r8n)


Title: Re: Cali 3 to V7 Sport conversion
Post by: mgmark on May 06, 2018, 02:44:50 PM

(https://thumb.ibb.co/b8giOn/IMG_2128.jpg) (https://ibb.co/b8giOn)

(https://thumb.ibb.co/f8QA3n/IMG_2129.jpg) (https://ibb.co/f8QA3n)
I used the short �70s swingarm for the shorter wheelbase. If I remember I tried my original Lemans mag rear wheel with a 130/80 rear tire and it just cleared this swingarm. The Lemans swingarm is shorter than the California swingarm and is popular with guys wanting to convert Cals to a retro look bike. I first mocked up my bike with the stock Lemans swingarm and the rear wheel was maybe 1-1/2� too far back for the wheel to be centered under the fender.
I�m running 2.15� rims front and back on my bike, like in the 70s.

Yes, the carbs are a very tight fit with everything else on these bikes. Mine has all the original Lemans parts, so I�m running the stock 40mm carbs and cables. I changed my chokes from cable to lever just to simplify things. I�m thinking maybe the fuel taps on your tank are moved a bit from an original Guzzi tank. I have an 850 Lemans I tank on my bike. The throttle cables are routed poorly as original, but there are no other options in that tight space.

Mark
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on June 02, 2018, 07:00:32 AM
It's been a while, so I guess it's time for an update! The wiring is all done now, and the lighting works! The handlebars still had to be made, so a friend of mine helped me get some 22mm stainless tubes and had the bending equipment. A little while later and I'm very pleased with the result!

(https://thumb.ibb.co/gQZ4Fy/IMG_3358.jpg) (https://ibb.co/gQZ4Fy)

(https://thumb.ibb.co/jhzFNd/IMG_3359.jpg) (https://ibb.co/jhzFNd)

(https://thumb.ibb.co/ikpAoJ/IMG_3361.jpg) (https://ibb.co/ikpAoJ)


Because I find it very important the bike can actually be used instead of just looking pretty I installed the mirrors of my old Honda CB400f. They offer very good visibility and I think they fit the bike well. The handlebars can be lowered quite a bit, but that can be adjusted later. I'll do that when the bike's roadgoing again.

Some pod filters are also added, I used DNA filters (ID 49mm) because they seem to be well built with good reviews and were half the price of K&N's (!!). I should also mention I've stashed the 36mm carbs for now, and installed the 30's that came with the bike. When I get the higher domed pistons I'll install the bigger valve heads with the carbs.

(https://thumb.ibb.co/db4Day/IMG_3368.jpg) (https://ibb.co/db4Day)


The rear footrests are also finally installed. These are tarozzi folding units which I think are way too expensive, but they match my rearsets and are very high quality. The threads don't run the full length of the rearsets, so I've drilled 20mm of the treads out of the rearset brackets to be able to install them properly.

(https://thumb.ibb.co/eWu1TJ/IMG_3369.jpg) (https://ibb.co/eWu1TJ)


For the blinkers I've chosen to install the Hella ox eye blinkers, even though I have the original aprillia type blinkers used on the original V7 available. The reason for this is that the bike isn't original anyway, the hella blinkers are period correct and the aprillia's chrome is flaked so it'll take a lot of work to refurbish them.

I also had the bike out of the shed to give it a bit of a tan ;) Also I could test how the riding position was, the side stand, etc. During this I found the center stand cannot retract fully because it hits my rear brake caliper, and the crossbar hits the wheel. Apperently the center stands of the cali 3 and le mans bikes are different? In the pictures you can see the center stand sitting lower than it shoud. I plan on removing the center stand, but if anyone has a good suggestion to fix this my ears are open! The center stand cannot be modified anymore because that'll ruin the powdercoating..

(https://thumb.ibb.co/cKxwTJ/IMG_3402.jpg) (https://ibb.co/cKxwTJ)

(https://thumb.ibb.co/mGNrvy/IMG_3403.jpg) (https://ibb.co/mGNrvy)

(https://thumb.ibb.co/bDzbTJ/IMG_3404.jpg) (https://ibb.co/bDzbTJ)

(https://thumb.ibb.co/cZhfoJ/IMG_3423.jpg) (https://ibb.co/cZhfoJ)

(https://thumb.ibb.co/ir3LoJ/IMG_3424.jpg) (https://ibb.co/ir3LoJ)


The last of the small parts I recieved were some thumbscrews for the rear fender, domino handgrips, ignition lock holder and 90 degree elbows for the carbs. With them installed, my to do list is becoming very short. I need to check the ignition timing, turn some spacers for the rear handgrips (as the rear shocks have different mounting points than the le mans) and, of course, the fuel tank and side covers still need paint. I've not yet decited if I want to use paint from the V11, use Kia AE3 acid green (the same colour as gentlemanjim), order a paint sample from stein dinse and use that as an example or go to someone who has painted a green V7 sport before..

(https://thumb.ibb.co/jKNS2d/IMG_3462.jpg) (https://ibb.co/jKNS2d)

(https://thumb.ibb.co/f2arTJ/IMG_3463.jpg) (https://ibb.co/f2arTJ)

(https://thumb.ibb.co/ighfoJ/IMG_3464.jpg) (https://ibb.co/ighfoJ)

(https://thumb.ibb.co/fprUhd/IMG_3465.jpg) (https://ibb.co/fprUhd)

(https://thumb.ibb.co/nDX22d/IMG_3468.jpg) (https://ibb.co/nDX22d)

 

Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on June 20, 2018, 04:06:36 PM
The paint for the v7 is almost done. I got some decals which were very close to the original v7 sport telaio rosso decals (the eagle is white in stead of gold) from ''https://pelders.nl/'' (this is a dutch site so maybe use google translate  :wink:) and v11 sport green paint from ''https://www.caferacernet.nl/'' (also dutch). The paint consists of two layers, the base is metallic silver, and the top coat is kinda transparent green. I used some spraymax 2k primer for the base layers, and will use spraymax 2k clear coat to cover the tank/side covers with decals. I've used spraymax clear before, and it seemed quite fuel resistant..


(https://thumb.ibb.co/j0kuKo/IMG_3535.jpg) (https://ibb.co/j0kuKo)

(https://thumb.ibb.co/mjXwX8/IMG_3544.jpg) (https://ibb.co/mjXwX8)

(https://thumb.ibb.co/cJuoeo/IMG_3547.jpg) (https://ibb.co/cJuoeo)

(https://thumb.ibb.co/nb0uKo/IMG_3549.jpg) (https://ibb.co/nb0uKo)

(https://thumb.ibb.co/iwLpkT/IMG_3548.jpg) (https://ibb.co/iwLpkT)

(https://thumb.ibb.co/keGjKo/IMG_3550.jpg) (https://ibb.co/keGjKo)


I also got a nice visit from someone with a real v7 sport, and couldn't resist taking a few pictures with both bikes!

(https://thumb.ibb.co/hJJLs8/IMG_3563.jpg) (https://ibb.co/hJJLs8)

(https://thumb.ibb.co/mdJLs8/IMG_3565.jpg) (https://ibb.co/mdJLs8)

(https://thumb.ibb.co/eDCoC8/IMG_3566.jpg) (https://ibb.co/eDCoC8)

(https://thumb.ibb.co/ftUUKo/IMG_3567.jpg) (https://ibb.co/ftUUKo)

(https://thumb.ibb.co/dzOjkT/IMG_3568.jpg) (https://ibb.co/dzOjkT)
Title: Re: Cali 3 to V7 Sport conversion
Post by: Rick4003 on June 21, 2018, 12:30:37 AM
Looking very good Rutgery!

I like the home made swan neck clip-ons, that's a nice touch. All in all the bike looks really good! Well done!

A bit late, but before mine had decals put on the base coat was sanded so the clear coat would have a good bond to the paint. It is a bit hard to sand it properly around the decals.
Title: Re: Cali 3 to V7 Sport conversion
Post by: Groover on June 21, 2018, 08:11:20 AM
That looks great! How does it ride? Does the shorter LM swingarm play well with the Cal III forks?
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on June 25, 2018, 06:58:20 AM
thanks for the kind words, the clear coat is drying as I write this. The handling should be like the LM1000's, as they use the same front end and swingarm. But I'll post here when I've tried it myself ;)
Title: Re: Cali 3 to V7 Sport conversion
Post by: Guzzi relic on July 01, 2018, 04:11:28 PM
Beautiful work.    :bow:

Thanks for documenting and sharing your project.

Ken
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on August 31, 2018, 05:41:44 AM
After testing the bike the last few weeks some problems have occurred and have been fixed, I thought I should add those here for someone doing a similar project.

The rear wheel kept hitting the rear inner fender (that plastic bit) because the Cali 3 has the attach points moved rearwards for the longer swingarm. That's fixed by attaching the fender on the upper part of the frame, and "pulling" the fender towards the battery tray. A bracket is used to hold the lower part of the fender in place.

As the bike was fitted with pod filters, the jetting was way off. to counter this, the main jets went from 125 to 135, and the needle was raised one notch. The jetting definitely is not perfect, but especially from 3k on it pulls very well and it runs clean and smooth.

The starter motor had some startus interruptis problems, where it was clicking but not turning the engine. That was easely fixed by changing the wires to the starter relay, which supplies the starter solenoid. One wire on the relay was both the supply and switch current. Changing this to a setup with a supply current directly from the battery fixed this.

The least technical problem were the clip-ons. I copied the design of the v7 sport clip-ons where the rise is about 16cm. Because the headlight brackets do not allow the handlebars to be lower than the brackets on my bike, the handlebars were too high and the seating position awkward. I've cut the handlebar tubes about 10cm, making the rise 6cm. This would be very sporty on a real v7 sport, but the Cali 3 steering head is longer making the handlebars about 5cm higher as well. This makes for a nice semi-sporty seating position.

The paint on the side covers turned out very nice, but the paint on the tank has some weird wrinkling/ orange peel going on. This most likely is because the paint is of a different kind or I added the clearcoat too soon. Either way, I'll try sanding those spots down and repaint. If that doesn't turn out well I'll take it to a pro and add the correct telaio Rossi tank decals.

The ride is very nice, as the bike runs well and the steering is slightly slower than my G5 but sporty. The front end does leave something to be desired however, as it is surprisingly bumpy. I'll look into improving this.
(https://thumb.ibb.co/nmDdtU/image.jpg) (https://ibb.co/nmDdtU)

(https://thumb.ibb.co/f3pwf9/image.jpg) (https://ibb.co/f3pwf9)
Title: Re: Cali 3 to V7 Sport conversion
Post by: canuck750 on August 31, 2018, 02:15:07 PM
The bike looks great, real nice work!
Title: Re: Cali 3 to V7 Sport conversion
Post by: Turin on August 31, 2018, 08:46:30 PM
What length of shock are you running? The bike looks a little low compared to the V7 sport. A longer shock will also quicken up the steering. I believe the lemans 1000 runs a 13.5" .
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on September 01, 2018, 09:43:55 AM
What length of shock are you running? The bike looks a little low compared to the V7 sport. A longer shock will also quicken up the steering. I believe the lemans 1000 runs a 13.5" .

The standard KONI shocks from the cali 3 are 337 mm (or about 13.2'') so a little shorter, and the mounting points on the frame are slightly rearward compared to the LM frames. I hadn't thought of that as a possible difference!
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on November 13, 2018, 03:14:16 PM
The bike still isn't done. I wanted to fit a center stand but the original cali 3 unit didn't fit anymore as the swingarm is now shorter than original. The solution to this would be fitting a T3 center stand, but that hits the rear calliper.. So some welding had to be done! The left leg is moved about 3cm outwards. A piece of the left foot is removed, and the feet extended to just lift the rear wheel off of the ground.

(https://thumb.ibb.co/cK0JC0/IMG-4567.jpg) (https://ibb.co/cK0JC0)

(https://thumb.ibb.co/nCNgX0/IMG-4568.jpg) (https://ibb.co/nCNgX0)

(https://thumb.ibb.co/cmXkaL/IMG-4593.jpg) (https://ibb.co/cmXkaL)

Fitted on the bike:

(https://thumb.ibb.co/mEaMFL/L1010261.jpg) (https://ibb.co/mEaMFL)

(https://thumb.ibb.co/edVovL/L1010262.jpg) (https://ibb.co/edVovL)


I also got some high round valve covers, they needed some work so they are sandblasted and sprayed with silicone spray to keep them clean. Just waiting on the adapter plates before they can be installed on the bike..

(https://thumb.ibb.co/kFMvaL/ONRE1482.jpg) (https://ibb.co/kFMvaL)


The Indian repro fuel tank just isn't as nice as the original on the real V7 Sport.. So I've finally decided to buy a real repro from Italy! quite expensive, but the tank is way nicer and fits more closely on the frame and cylinder heads. The only problem is that the fuel tank rubbers are attached about 2cm higher on the new type frame, so I'll make some rubbers to close this gap and hold the fuel tank secure
 
(https://thumb.ibb.co/jyJDUf/IMG-4802.jpg) (https://ibb.co/jyJDUf)

(https://thumb.ibb.co/dkcwh0/IMG-4744.jpg) (https://ibb.co/dkcwh0)


And last but not least, I got tired of the tarozzi rearsets. In my opinion they are way to far back. I've bought a brake and shift lever, and am currently working on a set of new footrest plates which will use the tarozzi hardware as the T3 units are unobtainium.. The picture shows the difference between the levers

(https://thumb.ibb.co/eGhF9f/IMG-4803.jpg) (https://ibb.co/eGhF9f)

(https://thumb.ibb.co/csiu20/IMG-4804.jpg) (https://ibb.co/csiu20)


Title: Re: Cali 3 to V7 Sport conversion
Post by: Rick4003 on November 21, 2018, 12:35:56 AM
It will for sure be a sweet bike when you are done.  :thumb:

I agree completely on the rearsets, I have the Agostini kit and it is way to high up and maybe too far back too. Maybe they didn't get the footpeg location all wrong at the factory after all  :wink:

One of the projects for my bike is certainly a relocation of the footpegs. Lower down for sure and maybe a bit further forward too. I will make a few different mounting plates to find the best location.
- Ulrik
Title: Re: Cali 3 to V7 Sport conversion
Post by: Fnq1000 on November 24, 2018, 11:56:04 PM
Progressing very nicely, well done!

You mention that you bought a repro tank from Italy. Where did you source it?

Cheers
Jason
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on December 06, 2018, 02:27:08 PM
It will for sure be a sweet bike when you are done.  :thumb:

I agree completely on the rearsets, I have the Agostini kit and it is way to high up and maybe too far back too. Maybe they didn't get the footpeg location all wrong at the factory after all  :wink:

One of the projects for my bike is certainly a relocation of the footpegs. Lower down for sure and maybe a bit further forward too. I will make a few different mounting plates to find the best location.
- Ulrik

a mounting plate with multiple holes to be able to adjust the position definitely isn't a bad idea, I might steal that for my own project :laugh:

Progressing very nicely, well done!

You mention that you bought a repro tank from Italy. Where did you source it?

Cheers
Jason

Thanks Jason! I got the fuel tank from TLM Nijmegen (the netherlands) as I live close by. The same tank is available at stein-dinse. Don't forget that there are two versions, they have the fuel cap flipping to a different side
Title: Re: Cali 3 to V7 Sport conversion
Post by: canuck750 on December 06, 2018, 07:42:34 PM
Looking real nice and it will be much more powerful than the original V7 Sport with superior brakes as well. :thumb:
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on May 10, 2019, 02:39:35 AM
Well it's been quite a while, but the project still is ongoing. As mensioned before, I wasn't impressed with the front fork, that's why I decided to swap the internals of a Honda RC36 (Showa) into the 40mm bitubo forks.

(https://i.ibb.co/GWhKG7h/IMG-5191.jpg) (https://ibb.co/GWhKG7h)

(https://i.ibb.co/bXCKThM/IMG-5192.jpg) (https://ibb.co/bXCKThM)

(https://i.ibb.co/LgQFpbm/IMG-5193.jpg) (https://ibb.co/LgQFpbm)

(https://i.ibb.co/JjXLjFm/IMG-5236.jpg) (https://ibb.co/JjXLjFm)

(https://i.ibb.co/zxZQ32M/IMG-5238.jpg) (https://ibb.co/zxZQ32M)

It was quite a straightforward swap, only the bolts to hold the damper units in place are 8mm items for the bitubo's and 6mm for the Showa's. I turned a small cylinder to fit around the bolt and press fit into the tubes so that the seal will hold the fork oil. The showa caps threaded straight onto the bitubo forks, but their end cap diameter was 41mm so I turned it down to 40 to fit through the triple three.

The fuel tank is painted and decals applied:

(https://i.ibb.co/ccWDXQj/IMG-5505.jpg) (https://ibb.co/ccWDXQj)


To make the bike more comfortable, I made some new footrest brackets which use the tarrozi rubber parts. The  base is milled out of steel, and two cylinders are welded on to fit the tarrozi items.

(https://i.ibb.co/71YbFyz/DE86-B1-FA-FF59-4-AED-9-EE8-64-D90-FEE38-E8.jpg) (https://ibb.co/71YbFyz)


I want to be able to run tubeless tires, and thought a bit more black on the bike would benefit the looks as well, so I decided to try to adapt the older type snowflake rims. The main issue were the brake disks, the new floating disks use five mounting bolts, and the old type used originally on these rims use six mounting bolts. I originally wanted to use adapters with a five and a six bolt pattern on either side, but there wasn't enough space for this, that's why I opted to make new disk holders. These use the six bolt pattern for the wheels and hold the ''floaters'' for the brake disk. They are turned from one block of aluminium. For the front, one side is countersunk for hex bolts, and the other side I cut thread to accept and hold the bolts.

(https://i.ibb.co/7YwdFpj/4633-EEF0-AF75-4-DF8-A172-EB18446-A7879.jpg) (https://ibb.co/7YwdFpj)

(https://i.ibb.co/qMxy59S/797180-EB-4429-48-BD-B5-B0-007-E91312012.jpg) (https://ibb.co/qMxy59S)

(https://i.ibb.co/v3V1JKp/98-A86393-F2-C4-419-C-ACBB-AE0-F93-F2-A049.jpg) (https://ibb.co/v3V1JKp)


wheels are powder coated semi-gloss black and valves threated into the rim

(https://i.ibb.co/WKfcT4k/E9-F7-D71-D-D5-AC-4553-9-BBC-53-E8749-BA534.jpg) (https://ibb.co/WKfcT4k)


everything added to the bike:

(https://i.ibb.co/Xx24Cn3/9-F876-C0-D-D39-A-4-A34-A1-E9-828819-A5-E9-F7.jpg) (https://ibb.co/Xx24Cn3)

upload foto gratis (https://nl.imgbb.com/)


The front callipers will be replaced by brembo p04 calipers, which should improve the breaking a lot. The front master is replaced by a ps16 unit. The rear f08 calliper is maintained, but uses a new brake master to achieve the correct ratio.
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on May 10, 2019, 02:42:22 AM
The eagle eyes among you might have noticed I fitted 36mm carbs as well. I had some interferance problems with the replica thank, but this Italian made tank doesn't have these problems. I modified the splitter to fit onto the throttle just like the 1000s has, and made a custom adjuster.
Title: Re: Cali 3 to V7 Sport conversion
Post by: Frenchfrog on May 10, 2019, 08:40:54 AM
Nice work , especially on the forks !
Title: Re: Cali 3 to V7 Sport conversion
Post by: Don G on May 10, 2019, 10:41:50 AM
Very nice indeed! :thumb: DonG
Title: Re: Cali 3 to V7 Sport conversion
Post by: s1120 on May 12, 2019, 10:59:50 AM
Im used to seeing the California III bikes having a rear frame rail kick up. Is that just on the later ones, or did you remove the kick up on yours?
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on May 14, 2019, 01:36:24 AM
Im used to seeing the California III bikes having a rear frame rail kick up. Is that just on the later ones, or did you remove the kick up on yours?

As far as Iím aware, only the Le Mans 1000 series have a kick-up in the frame. My frame is, except from the mods shown in this blog, stock.
Title: Re: Cali 3 to V7 Sport conversion
Post by: Mike Strong on May 18, 2019, 06:39:09 AM
Very nice work - I have a T3 project that I'm planning some similar themes for. I'm looking for some side covers at the moment - where did you source yours?
Cheers,
Mike
Title: Re: Cali 3 to V7 Sport conversion
Post by: wirespokes on May 18, 2019, 07:43:01 PM
The 97 Cali I sourced parts from has the kicked up frame rails.

Looking good rutgery.  :thumb:
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on May 20, 2019, 03:24:06 PM
Very nice work - I have a T3 project that I'm planning some similar themes for. I'm looking for some side covers at the moment - where did you source yours?
Cheers,
Mike
The side covers are made by Winny in Belgium, he has a facebook page ''silverrock motorcycle'' with his contact info. As far as I know, he's the only one making them in steel

Title: Re: Cali 3 to V7 Sport conversion
Post by: Rick4003 on May 23, 2019, 03:31:40 AM
Hi Rutgery,

Very nice work on the disk carriers! And the rest of the bike of course, it doesn't look bad with the black rims at all!
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on November 06, 2019, 09:25:45 AM
I guess it's time for the final update on this build log. It's been sitting unedited for quite a while but the bike's been driven a lot during this time. I'm happy to report that the RC36 damper rods inside of my 40mm forks fork perfectly. The bike has covered about 5500 km without any major issues in its current trim with the black wheels (and metzeler Roadtec 01s), new footrests and italian tank. The handeling is slightly slower than my G5 but that's to be expected as the wheelbase is slightly longer.

The new brembo P04 callipers mated to a ps16 master brake superbly but the rear P08 calliper linked to a 13mm Nissin master with custom linkage is slightly too wooden for me, I might change that in the future.

The Ducati 900ss white face dials look great on the bike but I've changed the tacho to a cheap replica model as the ducati one doesn't have the right gearing and was reading about 20% higher all the times. The current Vega tacho has the correct ratio and is very very simmilar in appearance, but if you look at the details, it does look cheaper made. It also doesn't read the revs quite as fast ast the veglia does weirdly enough.


(https://i.ibb.co/YPbHS1F/IMG-7478.jpg) (https://ibb.co/YPbHS1F) (https://i.ibb.co/MRtsXvs/IMG-7477.jpg) (https://ibb.co/MRtsXvs)(https://i.ibb.co/1nzs0Kw/IMG-5688.jpg) (https://ibb.co/1nzs0Kw) (https://i.ibb.co/QFkD9bM/IMG-5700.jpg) (https://ibb.co/QFkD9bM) (https://i.ibb.co/fvn9M2r/IMG-6879.jpg) (https://ibb.co/fvn9M2r) (https://i.ibb.co/1fgsV3M/IMG-5635.jpg) (https://ibb.co/1fgsV3M) (https://i.ibb.co/LPZd4rZ/IMG-5636.jpg) (https://ibb.co/LPZd4rZ) (https://i.ibb.co/9sjp05Z/IMG-5638.jpg) (https://ibb.co/9sjp05Z) (https://i.ibb.co/ZmSP2dM/IMG-5677.jpg) (https://ibb.co/ZmSP2dM) (https://i.ibb.co/B6s4N5v/IMG-5686.jpg) (https://ibb.co/B6s4N5v)


Really the only downside I can currently think of for this build is that the green colour seems to attract a lot of flies, which I thought was kinda weird :rolleyes:
Title: Re: Cali 3 to V7 Sport conversion
Post by: Vwtee2 on July 08, 2020, 12:17:36 PM
Great job, looks fantastic, i have a v7 sport from 1973 but previous owner made it in to a le man 1 look a like. I've been looking at v7 parts to rebuild it but its like you said its like gold dust.. weldone with your bike, i love it
Title: Re: Cali 3 to V7 Sport conversion
Post by: Canuck750 on July 08, 2020, 08:46:02 PM
Beautiful bike  :thumb:
Title: Re: Cali 3 to V7 Sport conversion
Post by: Don G on July 09, 2020, 08:43:02 AM
I have an 2001 V11 Sport in Green, I have noticed that in the evenings the Aphids are attracted to it, I mean it will be covered with them.  DonG
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on August 22, 2020, 03:47:20 PM
Thanks for the kind words! It's been a while since the last update on this build log but I've been riding the bike quite a lot in the meanwhile. It's been a real treat with the stock cali 3 engine. However, as it it a Sport conversion, I did find the power a bit lacking in comparison with it's looks. That's why over the last year I've been collecting items to improve this. These are the following;

A lightened flywheel.
The stock flywheel of a cali 3 is one of the heavy types weighing in at 4200 grams excluding a stock ring gear weight of 2650 grams. To improve the throttle response I wanted to fit a lighter flywheel. As I'm still a student there's a budget to work with so when a second hand lightened (and balanced) flywheel and ring gear off of a 1000S became available I bought it.
This ''new'' flywheel weighs 2200 grams excluding the 1950 gram of the lightened ring gear.
Here's a picture of the lightened flywheel and ring gear.

(https://i.ibb.co/17f2gZ5/IMG-9734.jpg) (https://ibb.co/17f2gZ5)


The only issue with a used flywheel (used for about 70.000 kms) is that the clutch plate teeth will notch the flywheel. This can make the clutch notchy to engage/disengage. As can be seen in the picture below a slight notching is visible.

(https://i.ibb.co/bKZXHnX/IMG-9735.jpg) (https://ibb.co/bKZXHnX)


To prevent the clutch engagement being notchy only a few km after installation, I decided to file every inner tooth surface of the flywheel by hand. It was a terrible job and wouldn't recommend anyone to do it.. BUT, it did work very well and after way to many hours the notches were gone. The picture is taken in progress btw, so don't flame me for not filing every tooth :tongue:

(https://i.ibb.co/sFCN5zq/IMG-9744.jpg) (https://ibb.co/sFCN5zq)


Bigger Carbs
More air = more power right? Also, bell crank PHF 36's are in my opinion the best looking carbs ever made. However, as the engine is a small valve 950CC square fin, just sticking on the bigger carbs won't do much good. To make them a bit more useful, I replaced the stock 33mm intake manifolds for a set of 36mm manifolds off of a SP3. By scribing the heads the exact material to remove to flow the heads can be determined (as shown in the pictures). I made sure to remove the material evenly and gradually.

(https://i.ibb.co/zhBDXzN/image.png) (https://ibb.co/zhBDXzN)


(https://i.ibb.co/HGNt5jK/IMG-9761.jpg) (https://ibb.co/HGNt5jK)


next up was replacing the new white carb floats with the old black ones from my 30mm units as these are way less prone to leaking.

(https://i.ibb.co/K5Bqz84/IMG-9786.jpg) (https://ibb.co/K5Bqz84)

Up next the jets were installed. No point in telling what I started with but the jetting I ended up with after the assembly with each of the components listed were the following:
pilot jet- 60
atomizer - 265
needle - K-9 (clip in the upper groove)
slide - 60-3
main jet - 135
Note that this is in the Netherlands so basically sea level.

(https://i.ibb.co/drWsH29/IMG-9784.jpg) (https://ibb.co/drWsH29)


A faster cam
As is covered many times on this forum, installing 36 mm carbs without changing the camshaft doesn't yield many gains. Also, a cam a bit ''hotter'' than the standard cam (or lawnmower cam as it's often called) can give a big improvement in both torque and top end power. As I wanted a cam with proven longevity, relatively cheap and a nice combo of rideability and power, and a tacho drive on the nose, the most logical choice was a B10 cam used in the LM 1000 series. I found a second-hand one for relatively cheap and it was in very good condition. The B10 cam can be indentified by the ''K'' stamping in the end of the cam.

(https://i.ibb.co/jgzNPBS/IMG-9766.jpg) (https://ibb.co/jgzNPBS)


Next to the change in the camshaft, I changed out the valve springs as a B10 cam engine stock has stiffer valve springs. Replacing the valve springs is relatively simple but I made sure to check the spring shimming to ensure proper valve spring pressure. Also, a ''special tool'' which is just a glue clamp with a welded on bracket was used to easily remove the C clamps from the valve tips.
Removal of the valves.

(https://i.ibb.co/3sn5gFN/IMG-9757.jpg) (https://ibb.co/3sn5gFN)

checking the valve shimming, all shimming was within factory specs.

(https://i.ibb.co/hKjXNRm/IMG-9758.jpg) (https://ibb.co/hKjXNRm)

New valve springs installed.

(https://i.ibb.co/s2mw0jB/IMG-9762.jpg) (https://ibb.co/s2mw0jB)


I'll follow up on this post soon with the disassembly and assembly of the sport with these components. Hopefully, I'll have tires for the high shoulder spoked rims. If that's the case it will be included in the build log post.

(https://i.ibb.co/W0HbzTf/IMG-9719.jpg) (https://ibb.co/W0HbzTf)

Title: Re: Cali 3 to V7 Sport conversion
Post by: wirespokes on August 25, 2020, 11:53:24 AM
I can't imagine anyone else filing those flywheel teeth! What a miserable job! I think I spent four or five hours over a couple days when I did it. I was concerned I might not have gotten the teeth smooth enough or uniform enough, but the clutch seems to be working perfectly. I don't think they need to be perfect - I've heard since, that the flywheel teeth aren't as critical as the hub.

Looking forward to the ride report after it's all buttoned up.
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on September 04, 2020, 10:33:42 AM
I can't imagine anyone else filing those flywheel teeth! What a miserable job! I think I spent four or five hours over a couple days when I did it. I was concerned I might not have gotten the teeth smooth enough or uniform enough, but the clutch seems to be working perfectly. I don't think they need to be perfect - I've heard since, that the flywheel teeth aren't as critical as the hub.

Looking forward to the ride report after it's all buttoned up.

Interesting that the flywheel teeth aren't as critical as the hub, why would that be the case?
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on September 04, 2020, 11:53:07 AM
The disassembly of the bike was quite straight forward as all work to be done was only to the engine. Because of this I removed the rear wheel, exhausts and swingarm and ''wheelbarrowed'' the top part of the motorcycle away. After that, I made sure the engine was nice and stable before removing the lower frame rails, gearbox and centerstand leaving them attached to eachother.

(https://i.ibb.co/K9jJvxh/IMG-9740.jpg) (https://ibb.co/K9jJvxh)

(https://i.ibb.co/59HKFbW/IMG-9741.jpg) (https://ibb.co/59HKFbW)

(https://i.ibb.co/7pXWGmk/IMG-9745.jpg) (https://ibb.co/7pXWGmk)


Next up the clutch ringgear was removed. Note that the current flywheel inner teeth are ''notched'' similar to the lightened flywheel. I was surprised to see this as the clutch actuation was as smooth as could be so the notches apparently aren't that big of a deal. The old flywheel was easily removed with the help of an impact driver, but the new flywheel was hold in place while tightening the bolts with a very special tool shown in the picture. This works just as well as any special tool which will hold the flywheel at the ring gear teeth.

(https://i.ibb.co/Htwq9MK/IMG-9748.jpg) (https://ibb.co/Htwq9MK)

(https://i.ibb.co/Msfn8Q8/IMG-9750.jpg) (https://ibb.co/Msfn8Q8)


Being the cheapskate that I am, to install the clutch plates (I reinstalled the old plates as these where barely worn, they must've been replaced by the previous owner before I got the bike) I 3D printed a clutch alignment tool. A little figuring out what tooth spacing I had to use lead to this tool shown in the picture.

(https://i.ibb.co/4Yrk20D/IMG-9770.jpg) (https://ibb.co/4Yrk20D)


This tool combined with an extra bolt and a few washers laying around made the clutch installation quick and easy. I didn't even forget to reinstall the ''puck'' inside the flywheel after removing the alignment tool. The ring gear can easily be torqued to spec while holding the ring gear with the other hand. So no other special tools required.  :thumb:

(https://i.ibb.co/1XJLtJD/IMG-9773.jpg) (https://ibb.co/1XJLtJD)

(https://i.ibb.co/THSNsHd/IMG-9775.jpg) (https://ibb.co/THSNsHd)

(https://i.ibb.co/rpw1vLJ/IMG-9776.jpg) (https://ibb.co/rpw1vLJ)

(https://i.ibb.co/6wLxY79/IMG-9777.jpg) (https://ibb.co/6wLxY79)

(https://i.ibb.co/tKPT14w/IMG-9780.jpg) (https://ibb.co/tKPT14w)


After the clutch and flywheel, I removed the heads from the engine. I was surprised to see a lot of ''mayo'' inside the valve covers as I thought the engine would get plenty warm as it sees longer distances quite often. It might be due to the colder climate of the Netherlands.. Anyhow, it's not that big of a deal so I just removed it with a cloth.

(https://i.ibb.co/wWB3fyC/IMG-9752.jpg) (https://ibb.co/wWB3fyC)

I didn't take too much extra pictures of removing the head as it's quite straight forward.

(https://i.ibb.co/3MqryFt/IMG-9753.jpg) (https://ibb.co/3MqryFt)

(https://i.ibb.co/3FVPPYN/IMG-9755.jpg) (https://ibb.co/3FVPPYN)

(https://i.ibb.co/x1vzRqH/IMG-9756.jpg) (https://ibb.co/x1vzRqH)

(https://i.ibb.co/pQtnt9L/IMG-9757.jpg) (https://ibb.co/pQtnt9L)


While the heads are off, replacing the camshaft is way easier as you don't have to worry about the pushrods and/or cam followers. So the crank nut was removed with an impact driver and the ''old'' cam was removed. I didn't take many pictures here either as I needed all hands. I asked two people to hold the cam followers in place with magnets on a stick while I removed the old cam and reinserted the ''new'' B10 cam (indentified with the ''K'' mark at the end of the cam). Taking a picture of the distributor will help checking if the new cam is installed properly and the timing hasn't ''jumped'' a tooth with the removal/installation.

(https://i.ibb.co/PF6RkSV/IMG-9763.jpg) (https://ibb.co/PF6RkSV)

(https://i.ibb.co/51pkxc3/IMG-9766.jpg) (https://ibb.co/51pkxc3)

(https://i.ibb.co/Sf9spQF/IMG-9768.jpg) (https://ibb.co/Sf9spQF)


Now the heads and valve train can be reinstalled, torquing everything to the correct specs as the base and head gaskets are replaced. This will need a re-do after a few heat cycles and again after 1000 kms.

(https://i.ibb.co/KXKTWrQ/IMG-9769.jpg) (https://ibb.co/KXKTWrQ)


Next up was a very nice trip to Austria with my trusty V1000 G5, racking up just over 2500kms in slightly over a week.

(https://i.ibb.co/kxjJRWn/IMG-0027.jpg) (https://ibb.co/kxjJRWn)


After the trip the tires where delivered and thus installed on the wheels. This meant the Sport would finally have her spoke wheels back! :thumb:

(https://i.ibb.co/d2sYFTh/IMG-0214.jpg) (https://ibb.co/d2sYFTh)

(https://i.ibb.co/Dr7jHwH/IMG-0217.jpg) (https://ibb.co/Dr7jHwH)

Unfortunately, I must have done something wrong as the rear wheel was 13mm off center.. This was a huge bummer but fortunately it could be resolved by adjusting the spokes. The front wheel installation went smoothly and this is how she stands now:

(https://i.ibb.co/s9xXDGY/IMG-0227.jpg) (https://ibb.co/s9xXDGY)


The ride is very different than before, acceleration feels way faster and shifting smoother (presumably due to the lighter flywheel). Also the bike seems to have much more power above 5000 RPM than before. I haven't had the change to try the freeway but I'm sure it'll drive smoother and quicker there as well. I haven't noticed faster stalling off idle due to the lighter flywheel either.


Title: Re: Cali 3 to V7 Sport conversion
Post by: wirespokes on September 06, 2020, 08:20:20 AM
Love it, Rutger!  :thumb:

Yeah, I'm curious why the flywheel teeth don't impact clutch operation to any great extent. Nice getting your experience as well.

For a clutch alignment tool I turned down some hardwood to the correct diameter and then used some drill bits to align the teeth. Nice that you've got access to a 3D printer. I'm jealous.
Title: Re: Cali 3 to V7 Sport conversion
Post by: rutgery on September 07, 2020, 12:49:47 PM
Love it, Rutger!  :thumb:

Yeah, I'm curious why the flywheel teeth don't impact clutch operation to any great extent. Nice getting your experience as well.

For a clutch alignment tool I turned down some hardwood to the correct diameter and then used some drill bits to align the teeth. Nice that you've got access to a 3D printer. I'm jealous.

That alignment tool is a very creative idea! As far as 3D printers go, it really isn't a huge investment. I bought mine for about 300 usd and the learning curve (especially if you can draw in CAD) is very easy.
Title: Re: Cali 3 to V7 Sport conversion
Post by: wirespokes on September 18, 2020, 10:48:44 PM
I'm horrible with stuff like computer programs. Not intuitive at all. Maybe I could learn - but it might be super painful.

Yeah, making a clutch tool seemed difficult until I realized I didn't have to mate with the splines. The spline inner diameter is enough.
Title: Re: Cali 3 to V7 Sport conversion
Post by: Mad Welshman on September 06, 2021, 04:49:59 PM
Hi there cracking build I am in the process of doing a very similar build any idea where can I get a pair of those steel side panels?, Jon.
(https://i.ibb.co/tw6txmc/EB8-F5-B9-C-2-B19-4150-8050-E2-E9-F6-BE4-DAF.jpg) (https://ibb.co/tw6txmc)

random animation generator (https://freeonlinedice.com/)