Author Topic: 1977 Le Mans running and on the road  (Read 116945 times)

Offline Groover

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Re: 1977 Le Mans Rebuild getting started
« Reply #210 on: October 21, 2017, 03:38:36 PM »
Looking good!  :thumb:
1981 Moto Guzzi V1000G5
1987 Moto Guzzi LM1000SE, a
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Offline Huzo

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Re: 1977 Le Mans Rebuild getting started
« Reply #211 on: October 21, 2017, 04:24:58 PM »
Bloody genius !

Offline Psychopasta

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Re: 1977 Le Mans Rebuild getting started
« Reply #212 on: October 21, 2017, 09:34:41 PM »
Great work!
V50 Monza 1981
Moto Guzzi V7 Stone Special 2023
Honda Goldwing 2019
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Ancient A65 Bitsa, in pieces

Offline TRw1

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Re: 1977 Le Mans Rebuild getting started
« Reply #213 on: October 22, 2017, 06:17:14 AM »
Looks great Jim!

Wildguzzi.com

Re: 1977 Le Mans Rebuild getting started
« Reply #213 on: October 22, 2017, 06:17:14 AM »

canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #214 on: October 22, 2017, 06:56:52 PM »
Thanks for the kind words fellas.

Stripped the carbs down, not too bad inside.



Found a good use for an old strainer we were about to throw out



Suspended across the basket in my ultrasonic cleaner



While the carbs are soaking for a day or two I went back to the bike, assembling the seat, surprisingly a lot pf parts go into the seat assembly, fiberglass pan, seat pivot bracket, tail light, seat bumpers and the seat itself, signal lights and licence plate bracket.



Tail light has the outer black shell, lamp assembly, lens, steel bracket, wire harness and the fasteners with rubber washers





Harness has to be passed through the fender before the tail light is mounted, Greggory Bender built the main harness and all the sub harness components as well, excellent exact copies as usual



Then the harness through the cover and steel plate



Plug the harness three wires in to the lamp assembly



Fit the rubber washers onto the studs



And rubber washers on the inside of the fender as well



The other end of the plate has captive nuts and is secured with bolts, rubber washers each side of the fender



And a plastic wore clip to one of the bolts and it matches the original installation



Bulbs, gasket and lens and the tail light is done



Pivot bracket has a ground wire to the center bolt, scrape the powder off each hole



Bolt on the signal light brackets, they are both the same



I soldered on a dedicated ground wire to pass through the pivot bracket side holes



Crimped on eyelets to each signal light ground, used rubber washers on the fender side of the bracket bolts and large 6mm stainless steel fender washers



set the fender assembly onto the bike







And then ...... I removed the bubble warp from the seat I have been storing for the past couple years, its been moved a half dozen times and sadly its torn



Tape will not stick to this foam, I am going to try crazy glue but I think its a write-off, really, really pissed with this, what a shame.

I think I will look for another option for the seat, this formed foam is too fragile,

Any recommendations for an alternate seat that looks 'close' to the original?

canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #215 on: October 23, 2017, 10:22:57 PM »
Carb parts cleaned and dried



Clutch perch, front master cylinder and levers, rear caliper, flat powder coat, still has a wee bit of gloss,


Offline Huzo

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Re: 1977 Le Mans Rebuild getting started
« Reply #216 on: October 24, 2017, 01:30:45 AM »
I have a very good seat from a Mk1 or 2.
It's not perfect though and only that would be worthy of your bike.
Free if you want it.
I'll photo and e mail and post it for you if you want.
I know exactly the words I want to use to describe your work, but I'd bet the arse off the forum.
You and Old Jock, bloody peas in a pod.
« Last Edit: October 24, 2017, 01:34:06 AM by Huzo »

canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #217 on: October 24, 2017, 09:47:19 AM »
I have a very good seat from a Mk1 or 2.
It's not perfect though and only that would be worthy of your bike.
Free if you want it.
I'll photo and e mail and post it for you if you want.
I know exactly the words I want to use to describe your work, but I'd bet the arse off the forum.
You and Old Jock, bloody peas in a pod.

Thanks Huzo for the seat offer, let me see if I can find an adhesive to fix it, I have been given a couple good suggestions that I will try out.

Offline mgmark

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Re: 1977 Le Mans Rebuild getting started
« Reply #218 on: October 24, 2017, 10:07:29 AM »
Yes that molded seat edge is fragile, until it has been mounted to the base. There is a replica seat foam being made and I used it on my Lemans 1 type build a couple years back. The look is perfect although the foam is denser than the original and heavier. I bought mine from MG Cycle parts.

Your work is fantastic to watch and an inspiration to us all. Thanks for bringing another Guzzi back to life better than new!

Mark

This is that replacement foam mounted on an original seat base.


1984 LeMans > 1985 LeMans + 1978 LeMans > 1989 Lemans > 20 years later, 1985 Lemans > 1980 SP1000
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Offline Huzo

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Re: 1977 Le Mans Rebuild getting started
« Reply #219 on: October 24, 2017, 02:57:19 PM »
Mine might be a replica reproduction. It's as hard as a bull's arse!

canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #220 on: October 24, 2017, 10:08:45 PM »
assembled the rear caliper



new rigid rear brake line





attached the zinc plated cable guide



assembled the clutch perch / lever



grease the spring and ball







handlebar lock screw





switches cleaned up



sanded off some of the powder coat on the bar, too tight for the switches to pass over



There are two cut outs under the left hand handlebar, forward one for the headlight switch



Scrape down the paint for the ground lug in the switch to make contact





Assembled the front master cylinder





Master cylinder. switch and throttle slide over the right hand bar










Offline TRw1

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Re: 1977 Le Mans Rebuild getting started
« Reply #221 on: October 25, 2017, 05:31:01 AM »
Beautiful work.  Thanks for all of the pictures!

Offline Huzo

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Re: 1977 Le Mans Rebuild getting started
« Reply #222 on: October 25, 2017, 05:34:08 AM »
I haven't been around this scene as long as some of you guys, but if there's a better source of information and guidance as to how to restore your Mk 1 or 2 then I'll bare my arse.
Words (for once) fail me, but at the risk of embarrassing Canuck, I'm in awe of your workmanship and dedication. There is NO excuse for doing less than a beautiful job if you follow this story.
This guy could probably build a piano if he wanted to.
Thank you very much. Huzo. :bow:

Offline Psychopasta

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Re: 1977 Le Mans Rebuild getting started
« Reply #223 on: October 25, 2017, 09:10:51 AM »
Hey Huzo, I agree there's probably no finer build, but if there is, would you mind eating your hat instead of baring your arse?

Your friend,

Pasta
V50 Monza 1981
Moto Guzzi V7 Stone Special 2023
Honda Goldwing 2019
Aprilia Tuareg 660 2023
Ancient A65 Bitsa, in pieces

Offline Huzo

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Re: 1977 Le Mans Rebuild getting started
« Reply #224 on: October 25, 2017, 03:33:35 PM »
Hey Huzo, I agree there's probably no finer build, but if there is, would you mind eating your hat instead of baring your arse?

Your friend,

Pasta
I'd love to mate, but I haven't told you what I did with my hat the time I got caught short in the small plane !!! :embarrassed:

canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #225 on: October 25, 2017, 09:56:08 PM »
I'd love to mate, but I haven't told you what I did with my hat the time I got caught short in the small plane !!! :embarrassed:

I don't think the moderators would let an arse shot get by and I can't be supporting any hat eating either! :wink:

Small jobs that took a long time this evening, I looked back at the pictures SwooshDave took of the Le Mans in the Barber museum, I noticed I has shiny bolts where they should be frame black.

Got out the Eastwood powder gun again, more flat black. I prefer powder to a rattle can, the finish is much more durable, cures as soon as the part cools, no overspray or odours and no runs. Its so simple and easy.





Spray and bake at 375 F for 20 minutes and the finish should last a lifetime





Replaced the frame bolts, triple clamp uppers, fork pinch bolts and the tank rubber cushion bolts





Switch housing was pretty rusty inside, bead blasted it and powder coated it,







The frame tab for the ignition is the same as on the V7 Sport that used a thick cast aluminum switch housing, to keep the switch centered on the frame Guzzi added a thick spacer that goes between the tab and switch

I coated the carb cable guides in cast aluminum powder since I don't want to bother the cad plating shop with a couple little pieces and four tiny bolts



Waiting on a few more small parts to arrive that I need to get installed before I get onto the wire harness including the rear inner splash guard some electrical bits, brake hoses, ...... I always think I have sourced everything and then realize I forgot another parts or two.

canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #226 on: October 26, 2017, 10:23:39 PM »
Starter motor rebuild, I bought a new field coil, solenoid and a brush / spring / bushing set from Euro Moto Electric

https://www.euromotoelectrics.com/



Kit comes with new bushings for the cap and nose piece



Press in easily in a bench vice





fit the new filed coils and the coil retainers, powder coat was a mistake, I had to sand off the powder on the radius face and use a big flat blade socket and 1/2" ratchet to torque down the retainer screws



soldered on the new brushes



pass the armature through the body and hold back the brushes to seat the armature end



Fit the three shims and lock ring, then the cap and cap screws





On the other end the flipper has to fit over the solenoid, then guide the solenoid in to place, fit the rubber bung between the nose and body and press the nose on while setting the flipper pivot bolt, pain in the a$$





Fitting the long through bolts takes some fiddling and then its done

Financially it doesn't make sense to rebuild these to this extent, you can buy a new cheap starter from MG Cycle for less than the repair parts I put into this one, the only reason I rebuilt this starter is that it's the original one off the Le Mans and I want to keep the bike as stock as possible.




canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #227 on: October 29, 2017, 06:26:43 PM »
Rebuilt the rear master cylinder with rebuild kits from MG Cycle, both the piston and control arm, replated steel rod down to the brake pedal,





MG Cycle sent me a box of new brake hoses as well

I fitted a new main steel brake line that runs up to the front left caliper







Fed the front hoses through the grommets and added rubber washers against the fiberglass fender



I removed the calipers, was not happy with the bright black powder finish, I stripped the calipers and used powder stripper to get the paint off then recoated them in flat black, they didn't come out flat but I like the finish, they were originally anodized



Rear rubber hose to the steel line

I fit a short length of rubber hose to replace the rotted insulator that fits into the steel clamp on the rear caliper bracket



Its a tight fit and it helps to open up the clamp a bit, pass the hose through and then squeeze the clamp tight







This is the front left hand brake hose support that attaches to the frame



And further up this bracket holds the rubber hose / steel hose joint



And I got the plate holder powder coated and mounted



Signal flasher holder bracket and rubber



and the breather hose

« Last Edit: October 30, 2017, 02:04:04 PM by canuck750 »

Offline balvenie

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Re: 1977 Le Mans Rebuild getting started
« Reply #228 on: October 29, 2017, 06:46:25 PM »
Lovely :grin: I can almost smell the newness :thumb:
Oz
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Online Chuck in Indiana

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Re: 1977 Le Mans Rebuild getting started
« Reply #229 on: October 30, 2017, 07:36:46 AM »
Most excellent as usual, Jim.  :bow:
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Offline Groover

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Re: 1977 Le Mans Rebuild getting started
« Reply #230 on: October 30, 2017, 09:21:14 AM »
I did not know MGCyle started carrying the OEM style brake hoses. Good to know.

All looks great!
1981 Moto Guzzi V1000G5
1987 Moto Guzzi LM1000SE, a
1987 Moto Guzzi LM1000SE, b
1980 Piaggio Vespa P200E
1980 Piaggio Vespa P125X
1980 Vespa Grande Moped
1980 Vespa SI Moped
http://scooteropolis.com/

canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #231 on: October 30, 2017, 09:58:40 AM »
I did not know MGCyle started carrying the OEM style brake hoses. Good to know.

All looks great!

Yep, I have had hoses made for me locally, pretty accurate ends as well, but the MG prices were so close that I just order new from MG Cycle.

canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #232 on: October 30, 2017, 09:27:24 PM »
Fairing and headlight fitted



took a lot of fiddling of the brackets to get it all to fit
















Offline smdl

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Re: 1977 Le Mans Rebuild getting started
« Reply #233 on: October 30, 2017, 10:27:30 PM »
Beautiful!
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canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #234 on: October 30, 2017, 11:47:54 PM »
Thanks Shaun, what you been building these days?

Offline smdl

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Re: 1977 Le Mans Rebuild getting started
« Reply #235 on: October 31, 2017, 12:32:17 AM »
Hi, Jim.

I actually made some good progress on my 750S tribute just before I moved back to BC.  I had to get it to roller status in order to transport it on the trailer across Canada.  I'm just working on my Triumph TR4A so I can get it registered in BC, and then I'll be back to the bike project.  I have a great new heated shop here, so I should be able to be quite productive over the winter (for a change), and my goal is to get it done for Spring.  When I get a chance, I will update my build thread to recover the photos, and add some of the more recent updates.

Thanks for the continued inspiration!

Cheers,
Shaun
« Last Edit: October 31, 2017, 01:09:57 AM by smdl »
'74 Eldorado Civilian
'17 V7 III Stone
'21 Aprilia Tuono 660
'22 V85TT Guardia D'Onore
'22 V85TT Guardia D'Onore (Yep, two)

Offline TRw1

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Re: 1977 Le Mans Rebuild getting started
« Reply #236 on: October 31, 2017, 06:39:20 AM »
Jim,

Looking good!  It's getting there.

Ted

canuck750

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Re: 1977 Le Mans Rebuild getting started
« Reply #237 on: October 31, 2017, 09:35:23 PM »
A couple corrections, I had fitted rubber bumpers to the bottom tabs adjacent to the battery that the side cover pins pass through (bumpers on the V7 Sport), there should be just nuts and ground wired connect to the pin  / nuts

1st I sanded off the powder on the tabs





Same on the opposite side



Fitted a used inner splash fender, can't get new repros right now so this will do for the time being

Rubber washers



and the wire retainer on the wheel side



I had the rear master cylinder to splitter hose incorrectly routed, should be just behind the battery





and fitted the transmission breather hose



Now to finish the carbs and fit the distributor / electronic ignition, install the dash and instruments, wire harness,........

Offline balvenie

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Re: 1977 Le Mans Rebuild getting started
« Reply #238 on: October 31, 2017, 10:00:26 PM »
Love your "show", thanks Jim :grin:
Oz
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As ye practice, so do ye teach.

Offline Huzo

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Re: 1977 Le Mans Rebuild getting started
« Reply #239 on: November 01, 2017, 03:42:28 AM »
I really like that "velvety" look on the satin black you did for the frame.
So much better than the gloss look of some lesser efforts.

 

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