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General Category => Bike Builds, Rebuilds And Restorations Only => Topic started by: Dave Swanson on June 23, 2020, 06:23:39 PM

Title: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on June 23, 2020, 06:23:39 PM
I purchased a nice Lemans last fall.  It is a good solid unit.  It had some cosmetic issues.  The primary issue was damage to the fairing and instruments from having another bike knocked over into it.  The bike has a fairly interesting history that I will get into as the thread progresses.

The bike had been gone through by Joe Eish a number of years ago and ridden very little afterwards.  In fact the owner never transferred the Lemans into his name.  When I bought the bike it still had the prior owner's Arizona license plate with a 2004 sticker.  The prior (prior) owner from Arizona was Alan Trachtman.

Without any documents from the Eish regarding the work performed I guessed that the bike had a pretty thorough going over.

The engine cases had been cleaned up.

(https://i.postimg.cc/52wgy1dX/IMG-5652-2.jpg) (https://postimg.cc/bZwkV7vP)

And a Dyna III ignition had been installed.

(https://i.postimg.cc/Pr0VN2CR/IMG-5648-2.jpg) (https://postimg.cc/zVSFcwSC)

I had the fairing repaired and repainted.

Before

(https://i.postimg.cc/h4YwxY1G/thumbnail-IMG-5067-2.jpg) (https://postimages.org/)

After

(https://i.postimg.cc/BnqWP5HX/thumbnail-IMG-6131.jpg) (https://postimg.cc/9rNgv7xh)

And had Palo Alto Speedometer Service restore the clocks.

Before

(https://i.postimg.cc/CMPQpFSY/IMG-5650-2.jpg) (https://postimg.cc/z3hjnYyP)

After

(https://i.postimg.cc/QC14pBDk/clocks.jpg) (https://postimages.org/)

I also had flaws in the paint fixed.  This was not controversial because it had been resprayed at one time and it wasn't a top notch job.  If it had retained it's original paint I would have left it alone.

(https://i.postimg.cc/vHb4M0C0/thumbnail-IMG-6074.jpg) (https://postimages.org/)

(https://i.postimg.cc/KvG8CRgV/thumbnail-IMG-6079.jpg) (https://postimg.cc/8sYG6k4B)

(https://i.postimg.cc/0jxykNXz/thumbnail-IMG-6078.jpg) (https://postimages.org/)

(https://i.postimg.cc/cLKRm2Qj/thumbnail-IMG-6132.jpg) (https://postimg.cc/cvSt1DkM)

Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on June 23, 2020, 06:36:30 PM
I was actually trying to convince myself that I would not tear this bike completely apart.  The straw that broke that camel's back was finding transmission oil drips from the bell housing area.  I could tell it was transmission oil because, I am assuming, Joe Eish used a red gear lube.  The drips on the floor are definitely red.

Of course this means that I will be taking the engine and transmission out and as long as it is out of the frame to a right proper job of looking over everything!

Last night I removed the rear wheel and found the rear drive spline and mating wheel spline were worn beyond what I am comfortable putting back together. 

With the engine and transmission out there is no good reason not to perform a complete inspection.  It is a Lemans I after all.   :laugh:

Earlier I had no intention of creating a build thread for this because I thought it wouldn't be that extensive.  That has all changed. 

Here we go!

(https://i.postimg.cc/KzscJq7q/thumbnail-IMG-6958.jpg) (https://postimg.cc/tZWHgzMW)
Title: Re: 77 Lemans - Extensive Fettle
Post by: jas67 on June 24, 2020, 05:17:06 AM
 :popcorn:
Title: Re: 77 Lemans - Extensive Fettle
Post by: blu guzz on June 24, 2020, 05:43:42 AM
Keep the old Goose flying.  Thanks for doing it the right way.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Motorad64 on June 24, 2020, 12:54:34 PM
Love it
Title: Re: 77 Lemans - Extensive Fettle
Post by: blackcat on June 26, 2020, 09:41:10 AM
"Earlier I had no intention of creating a build thread for this because I thought it wouldn't be that extensive."

Well, best to do it now than wait. Does the engine have the original iron bores? And what did Palo Alto Speedometer charge you for doing the clocks?  I need to have the bezel changed in one of mine but it would be better if I had both of them changed and checked. 
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on June 26, 2020, 10:22:47 AM
Does the engine have the original iron bores? And what did Palo Alto Speedometer charge you for doing the clocks?  I need to have the bezel changed in one of mine but it would be better if I had both of them changed and checked.

Tom, yes, original iron bores.  I wasn't planning on tearing the engine down since it had all the earmarks of being thoroughly gone over, and assuming it was done by Joe Eish I am sure whatever was done to the engine was done competently.   Without receipts for the work it is still a mystery what work was performed, so in I go.  The bores still have cross hatch visible with absolutely no scoring.  The pistons appear to be new and I assume the rings are also.   I might as well keep going just to make sure there isn't any surprises.  The only surprise so far was a stray extra valve cover bolt in the cavity for the top head bolt.

Both instruments were thoroughly gone over.  The price was $700.  When you look at the invoice for work performed it makes sense.  Since there aren't any NOS instruments available, it is worth it, at least to me.  Hartmut's (PAO's proprietor)  craftsmanship is top notch.  Your bill should be much less for just clean/lube and bezel change.
Title: Re: 77 Lemans - Extensive Fettle
Post by: blackcat on June 26, 2020, 12:03:32 PM
Given all the money I've just spent on mine, I'm not in the mood to spend another $700 bucks but it looks like they did a great job. I will give them a call and see what they want to just replace one bezel and clean up both of them as they don't need to be recalibrated.

Do you think it has the stock cam?
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on June 27, 2020, 08:41:07 AM
The brake rotors are off to TrueDisk today. 
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on June 27, 2020, 08:41:53 AM

Do you think it has the stock cam?

Yes, I am all but 100% certain it has the stock cam. 
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on June 28, 2020, 07:46:10 PM
The major disassembly is over.  Now to organize.  Rusty hardware will be cadmium plated.  Just too much rust on the hardware for me to put it back together that way.

(https://i.postimg.cc/J0mMHGHb/IMG-6984.jpg) (https://postimg.cc/CBvWWMN1)

The forks were in great shape.  And the fork lowers are in great condition.

(https://i.postimg.cc/Pq2xjbCB/IMG-6979.jpg) (https://postimg.cc/2qLmdZFw)
Title: Re: 77 Lemans - Extensive Fettle
Post by: LesP on June 28, 2020, 08:41:29 PM
Wow  :thumb: :thumb:
I would take a week + to make the wooden stand.  :laugh:

It will be back on the road in no time and pristine.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on June 29, 2020, 05:30:52 AM
Wow  :thumb: :thumb:
I would take a week + to make the wooden stand.  :laugh:


But what a stand it would be!  It would probably have a built in espresso maker!   :bow:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on June 29, 2020, 06:12:37 AM
The wheels are in great shape.  Big relief.   New rubber and converted to tubless.   The early Lemans all had tubes for some reason. 

This was my first experience using RuGlide for a tire lubricant.  I can highly recommend it.  And it is the perfect time of year to leave the tires in the sun for a few hours to warm them up.  The tires went on easier than any other. 

(https://i.postimg.cc/7688RvWL/thumbnail-IMG-6985.jpg) (https://postimages.org/)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on June 29, 2020, 06:40:50 AM
The rear wheel has a new plate with drive spline.  I sprung for new cush rubbers to go with it.


(https://i.postimg.cc/63r3jfzD/thumbnail-IMG-6985.jpg) (https://postimages.org/)
Title: Re: 77 Lemans - Extensive Fettle
Post by: mcdammitt on June 29, 2020, 09:39:46 AM
Lovely bike,thanks
Title: Re: 77 Lemans - Extensive Fettle
Post by: blackcat on June 29, 2020, 03:45:03 PM
RuGlide is the best.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Klinkhammer on June 30, 2020, 02:27:56 PM
Lovely bike! Good catch!
Title: Re: 77 Lemans - Extensive Fettle
Post by: Motorad64 on July 01, 2020, 08:45:26 AM
Dave...how did you go about the tubeless conversion?  I'd like to go the same route eventually with '78.   I picked up tubeless valves from Harpers.   Figured with alloy's it should be fairly easy.  Especially with clean, repainted wheels.   

Bike looks great...
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on July 01, 2020, 09:17:19 AM
Dave...how did you go about the tubeless conversion?  I'd like to go the same route eventually with '78.   I picked up tubeless valves from Harpers.   Figured with alloy's it should be fairly easy.  Especially with clean, repainted wheels.   

Bike looks great...

The conversion is very straight forward.  Once the RuGlide fully dried I haven't lost a lb of pressure.   
Title: Re: 77 Lemans - Extensive Fettle
Post by: blackcat on July 05, 2020, 07:46:21 AM
I did the conversion to my Lemans and CX with no issues. I did apply some silicone around the stems when installing the valve stems. Not that it matters now that you have purchased the stems but they can be had from your local Napa dealer for a lot less money.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on July 10, 2020, 03:46:54 PM
I mailed my rotors to TrueDisk on 5/27 via USPS Priority Mail.  USPS LOST THEM!.  The package hasn't been scanned since 7/1.  I stopped at the Post Office and had a trace started but nothing so far.  I may have to buy another set of rotors! :sad: :cry:
Title: Re: 77 Lemans - Extensive Fettle
Post by: SED on July 10, 2020, 07:10:35 PM
I bet they find them.  Eveything I thought had been lost by the USPS eventually showed up.   Had some Ariel engine bearings go missing and the originals showed up a week after the replacements - pretty sure they were actually stuck in US Customs tho...
Smart to file the paperwork early.
Good Luck
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on July 12, 2020, 09:28:36 AM
11 days later the package is moving again.  So much for "Priority" mail.   :lipsrsealed:
Title: Re: 77 Lemans - Extensive Fettle
Post by: LesP on July 13, 2020, 07:14:28 AM
Good to see they are safe and moving Dave.
The cost will be interesting, I payed $128 (US$82) (and three months) to have the rotor ground on the Norton.

It seems the way now, I posted a NOS 1978 Ducati 900SS clutch cover to Belgium in late April ($80 for 2 kg (iirc) Express)... The flight was cancelled and it is still in Sydney so coming up 3 months to go 900 kms of 17000.  :laugh:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on July 18, 2020, 08:54:06 AM
Good to see they are safe and moving Dave.
The cost will be interesting, I payed $128 (US$82) (and three months) to have the rotor ground on the Norton.


$161 US including shipping for all 3 rotors.  On their way back UPS this time!   :grin:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Motorad64 on July 18, 2020, 09:19:07 AM
That's pretty darned reasonable.  I may send an old set I have on the shelf for a rainy day.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Canuck750 on July 20, 2020, 05:02:15 PM
I have had great service from TruDisc, return shipping to Canada in about three weeks and I had a couple drilled as well in the same turn around period.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on July 24, 2020, 05:12:01 PM
The wayward brake discs made it back after a long delay by USPS.  So much for Priority!  :laugh:  I am just glad they made it safely back.

Tom at Truedisk did a great job on them.  It will almost be a shame to rub them with brake pads.   :smiley:  Very reasonable price, $135 plus shipping.

(https://i.postimg.cc/5NP3bdKS/IMG-7120.jpg) (https://postimg.cc/fJ9XfFNV)
Title: Re: 77 Lemans - Extensive Fettle
Post by: blackcat on July 24, 2020, 06:10:02 PM
Hmmm....maybe I should do that to mine too. They seem perfectly fine to me but I guess it wouldn't hurt.

Those look very nice.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on July 31, 2020, 06:11:50 PM
I always love having the wheels done, done.  It feels like the project is really getting somewhere. 

New rubber, drive spline and cush rubbers,  disks ground by TrueDisk, and set up for tubeless. 

(https://i.postimg.cc/Hxqbnr6C/IMG-7149.jpg) (https://postimg.cc/phBm1LN0)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on August 31, 2020, 07:54:17 PM
As I teardown the engine for inspection I have had my doubts, thinking that I should just leave it alone.  But since it is out and on the bench I am going to go through it to satisfy my curiosity and to make sure all is right with the world.

I found a problem when removing the tachometer drive.  The tach drive appeared to have only one washer!  The pocket was missing the drive washer.

(https://i.postimg.cc/L4tdfFtY/IMG-7339.jpg) (https://postimg.cc/5j2kdGkb)

I checked everywhere for the washer, and then upon looking closely the one washer did look a bit thick!

I am happy I solved the mystery of the "missing" hard washer.  Since this engine was run very little after it was gone through the lower pocket in the outer cover still looks serviceable.

(https://i.postimg.cc/t4g8L1LW/IMG-7342.jpg) (https://postimg.cc/LnryPs48)

Quite a pleasant surprise was to find this!!  A nice set of aluminum timing gears.

(https://i.postimg.cc/0NzRJ6nP/IMG-7338.jpg) (https://postimg.cc/NyvP3jZz)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 05, 2020, 06:13:15 PM
Engine inspection complete.  The rear was seal replaced as a precaution as long as the engine was out.

I also upgraded to a deep spline clutch with the good bonded, and riveted clutch plates. 

Going back together.  Next is going through the transmission. 

I am having my right hip replaced October 5th, and hope to have most of it together before the saw bones comes after me!! 

(https://i.postimg.cc/65z6Xqft/IMG-7351.jpg) (https://postimg.cc/YhGBNpPs)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Canuck750 on September 05, 2020, 07:48:25 PM
 :thumb:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 06, 2020, 05:05:04 PM
I disassembled the transmission, scrubbed the housings, replaced the front and rear main seals.  The front seal had been leaking quite a bit.  Bench checked the shifting before joining to the engine.  It seems to shift quite nicely.

Now it is time to get serious!!

(https://i.postimg.cc/bvWzdq8Z/IMG-7353.jpg) (https://postimg.cc/rdG6PXDT)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 07, 2020, 12:55:45 PM
(https://i.postimg.cc/RCDFp3Fn/IMG-7358.jpg) (https://postimg.cc/5j8b628x)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Klinkhammer on September 08, 2020, 01:02:35 PM
Oh, this is probably my favorite phase of a rebuild. Everything is still perfect -in your mind. Soon all the compromises start...
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 09, 2020, 09:05:57 PM
It is always a nice step in the right direction when the wooden support box comes out and it is standing on it's own.

(https://i.postimg.cc/dQ8hnVYw/IMG-7364.jpg) (https://postimg.cc/K48c8FjH)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 11, 2020, 05:02:33 PM
It is time to mount the swingarm so I was giving the ujoint carrier bearing a once over.  It felt a bit rough when turning.   When looking at it closely I could see 5 cracks in the inner bearing race!

(https://i.postimg.cc/pL3cjzXt/IMG-7371.jpg) (https://postimg.cc/bZHRcGt6)

(https://i.postimg.cc/6p81TYK0/IMG-7370.jpg) (https://postimg.cc/w1dkG57y)

I had conjured up disaster in my mind that the inner race would fall apart while pounding on it with a long drift and then force me to find a good Tig welder to weld a bar on the outer race in an attempt to save my swingarm.  I then remembered reading Charlie's method of using a blind bearing puller and pushing it out with a press from the other end!  PERFECT!  The collet when expanded kept the broken inner race from coming apart and the bearing pushed out with no drama!

Thanks Charlie, you didn't know it but you saved the day again!   :bow:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Antietam Classic Cycle on September 11, 2020, 07:00:16 PM

I had conjured up disaster in my mind that the inner race would fall apart while pounding on it with a long drift and then force me to find a good Tig welder to weld a bar on the outer race in an attempt to save my swingarm.  I then remembered reading Charlie's method of using a blind bearing puller and pushing it out with a press from the other end!  PERFECT!  The collet when expanded kept the broken inner race from coming apart and the bearing pushed out with no drama!

Thanks Charlie, you didn't know it but you saved the day again!   :bow:

 :grin: Glad my bass-ackwards method of doing things sometimes, helped someone.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 12, 2020, 08:18:48 AM
:grin: Glad my bass-ackwards method of doing things sometimes, helped someone.

Yes it certainly did.

The carrier bearing is the biggest problem I have come upon that would have become a large problem if I hadn't torn this bike down.  Needless to say I am happy I went the longer teardown route. 

So far this has been what I have found.

Rear spline wear beyond my comfort level.

Carrier bearing cracked.

One of the shock studs on the frame had the 8mm bolt hole stripped out.  I was happy to find a 8mm set of helicoils that I stashed away. 

Improper washer installation on tachometer drive

Washers missing from  many of the 6mm socket head bolts.

Some bodgy wiring. 

Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 12, 2020, 04:35:14 PM
I made some good progress today.  I always look forward to having it standing on it's own 2 wheels!

(https://i.postimg.cc/15VY6dS4/IMG-7379.jpg) (https://postimg.cc/w7HVY07d)

(https://i.postimg.cc/13pC7NfQ/IMG-7375.jpg) (https://postimg.cc/FYHV7zyW)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Canuck750 on September 14, 2020, 08:31:47 AM
Looking great resting on its own two wheels👍
Title: Re: 77 Lemans - Extensive Fettle
Post by: Antietam Classic Cycle on September 14, 2020, 08:51:48 AM
I'm hoping to reach that point today or tomorrow on the V7 Sport. Been far too long...
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 14, 2020, 05:38:34 PM
I bought these head guards awhile back on Ebay.  I think they look pretty good!

(https://i.postimg.cc/gjZw4X3Z/IMG-7391.jpg) (https://postimg.cc/gLGk20Sz)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 19, 2020, 12:59:00 PM
Brakes are good to go.  Bleeding went well with no drama.  Exhaust back on.  I marvel at the condition of this original exhaust!  I guess spending most of it's life in Arizona, and then post AZ was stored kept in living quarters helped.

(https://i.postimg.cc/XNgn6F6x/IMG-7406.jpg) (https://postimg.cc/9zz6GDMq)

(https://i.postimg.cc/qMM4JRkr/IMG-7407.jpg) (https://postimg.cc/DmDt57Jp)

(https://i.postimg.cc/fT2ZJNL9/IMG-7410.jpg) (https://postimg.cc/D8XRMR1v)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 19, 2020, 05:11:53 PM
(https://i.postimg.cc/5N8VxCz6/IMG-7415.jpg) (https://postimg.cc/qzBYwgjT)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 20, 2020, 04:50:01 PM
The skeleton is now fully formed.  The carbs look like they mean business!

I know the market heavily favors the 77  Ducati 900 SS over a 77 Lemans but I have always very much preferred the MG Lemans.  To me it has it all over the 900SS in the style department.

(https://i.postimg.cc/4xSsbJwp/IMG-7420.jpg) (https://postimg.cc/VJnxzPxN)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 26, 2020, 09:28:23 PM
Moving right along.   Wiring has officially started, which is always a pleasure with one of Greg Bender's harness sets.

(https://i.postimg.cc/q7BrHcHr/IMG-7456.jpg) (https://postimg.cc/LJWwz1sQ)
Title: Re: 77 Lemans - Extensive Fettle
Post by: moto-uno on September 27, 2020, 04:03:22 PM
  Lucky you to have a set of Lafraconi mufflers ( they should've been stock) .
  I'm curious about your tires , it appears the tread pattern is in opposite directions on them ?
  Man that is one sweet looking set of wheels  :thumb: .  Peter
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 27, 2020, 04:46:17 PM
  Lucky you to have a set of Lafraconi mufflers ( they should've been stock) .
  I'm curious about your tires , it appears the tread pattern is in opposite directions on them ?
  Man that is one sweet looking set of wheels  :thumb: .  Peter

The tires are Avon AM 26 Roadriders.  Opposite tread patterns depending on front or rear mounting. 

I agree, I am lucky to have those period LaFranconis.  They could almost pass for NOS. 
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on September 27, 2020, 05:39:03 PM
My Lemans had a bit of an oddity it seems. 

Every picture I have seen of an early Lemans has the canted rearward rear turn signal stems.   Like this.

(https://i.postimg.cc/HLYRnv7V/STEM.jpg) (https://postimages.org/)

(https://i.postimg.cc/NF3kXFJd/1978-Moto-Guzzi-Lemans-1-Exhaust.jpg) (https://postimages.org/)

My Lemans has the straight stems. 

(https://i.postimg.cc/WzF7tgnD/IMG-7459.jpg) (https://postimg.cc/XBW5zZt3)

The only pictorial I have found with the straight stems is the early Lemans parts book.

(https://i.postimg.cc/VspxgF2V/Screenshot-2020-09-27-121826.png) (https://postimg.cc/F1bCs0ry)

The finish of my stems matches the finish of the frame so I am not going to worry about changing them.  My theory is that the DOT required them to be within a certain distance from the brake light.  Just my house of defecation  theory.   :grin:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Antietam Classic Cycle on September 27, 2020, 06:44:20 PM
My '79 SP had the canted rearward stems, which broke not long after my purchase. Maybe the same thing happened to your Le Mans at some point and the owner just substituted the straight stems which were likely easier to get and cheaper.
Title: Re: 77 Lemans - Extensive Fettle
Post by: berniebee on September 28, 2020, 07:04:23 PM
Looking great! Those head guards are the nicest ones I've ever seen.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 12, 2020, 01:20:45 PM
My rehab is moving along well and feel good enough to spend a couple hours down in the shop.   

The throttle and choke cables and apparatus are back in place.

(https://i.postimg.cc/QM1GQwBg/IMG-7485.jpg) (https://postimg.cc/p9W6x0Jy)

(https://i.postimg.cc/gjcCP0g4/IMG-7488.jpg) (https://postimg.cc/HcKZwTD7)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 13, 2020, 02:21:56 PM
Before.   Both of the plastic housings were broken and unusable.   Instruments banged up. 

(https://i.postimg.cc/CMPQpFSY/IMG-5650-2.jpg) (https://postimg.cc/z3hjnYyP)

After Palo Alto refurb, and new plastic housings. 

(https://i.postimg.cc/8CwcvJMR/IMG-7492.jpg) (https://postimg.cc/zLbqZfdv)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Antietam Classic Cycle on October 13, 2020, 05:01:08 PM
 :thumb:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 14, 2020, 04:26:48 PM
Moving along

Before

(https://i.postimg.cc/h4YwxY1G/thumbnail-IMG-5067-2.jpg) (https://postimages.org/)

(https://i.postimg.cc/5Ny7j3Px/IMG-7496.jpg) (https://postimg.cc/VdyBVjQT)

(https://i.postimg.cc/v832Qjtq/IMG-E7498.jpg) (https://postimg.cc/s1G4mT87)
Title: Re: 77 Lemans - Extensive Fettle
Post by: s1120 on October 14, 2020, 04:40:21 PM
Looks amazing!!!!!!
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 19, 2020, 08:02:00 PM
The wiring is complete!  It is ready for a live fire exercise! 

https://youtu.be/D6-5CRHhWwU

(https://i.postimg.cc/K8NLJFHm/IMG-7524.jpg) (https://postimg.cc/755fLv4R)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Motorad64 on October 19, 2020, 09:41:36 PM
Looks great!  Where'd you source your plastic gauge housing?  Yours has the later ignition hole nicely blocked off like the originals.   Haven't been able to find one to replace my cracked original. 

Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 19, 2020, 10:28:45 PM
Looks great!  Where'd you source your plastic gauge housing?  Yours has the later ignition hole nicely blocked off like the originals.   Haven't been able to find one to replace my cracked original.

I used the commonly available housing,  filed the 2 notches for the ignition switch off to make the hole round, and used a piece of the cracked housing as a donor to make the round filler. 
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 20, 2020, 11:16:34 AM
So close!    I wont be able to ride it until Spring due to being only 2 weeks since my hip surgery.  I do want to at least start it though.

(https://i.postimg.cc/xCnffxD5/IMG-7529.jpg) (https://postimg.cc/5HKdpmtQ)

(https://i.postimg.cc/SRtkGmX1/IMG-7532.jpg) (https://postimg.cc/hQxkDW1V)

(https://i.postimg.cc/3rL8hFLj/IMG-E7533.jpg) (https://postimg.cc/mhHfNCWh)

(https://i.postimg.cc/m2tbg1qv/IMG-7534.jpg) (https://postimg.cc/1f1xWXyB)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Antietam Classic Cycle on October 20, 2020, 11:47:08 AM
 :thumb: :thumb:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 20, 2020, 12:38:06 PM
Here's a summary of work done.


ENGINE

The engine was partially disassembled for inspection and found to be in very good condition.

Rear main seal replaced, and gave the exterior a detail. 

CLUTCH

Replaced clutch and upgraded to the deep spline.

TRANSMISSION

Disassembled for inspection and found to be in good condition.

Rear and front main seals replaced.   Front seal had been leaking.

DRIVELINE

U-Joint replaced and all spline drive shaft and couplings.

U-joint carrier bearing replaced.  The bearing felt rough and upon removal found the inner race had 3 cracks.

Rear drive spline and mating drive spline on rear wheel replaced, along with new cush rubbers.

BRAKES

All 3 brake rotors were refinished by TrueDisk.

All brake pads replaced with "best" Brembo carbon ceramic pads.

New front master cylinder rebuild kit. 

Brake lines replaced with black steel braided lines.

MISCELLANEOUS

Damaged instruments repaired by Palo Alto Speedometer Service

Damaged instrument cluster housings replaced

New wiring harness from Greg Bender.  A thing of beauty!

Fresh paint by PaintWorks.  Craig did his usual amazing work including the satin black finish on the fuel tank.

New exact reproduction seat from Guzzibits.

All rusty hardware was zinc plated at Manner Plating (local).

Fresh Avon AM 26 RoadRiders and converted to tubeless.

Fork seals and many other rubber bits replaced. 
Title: Re: 77 Lemans - Extensive Fettle
Post by: jwinwi on October 20, 2020, 01:10:16 PM
Nice work Dave! Looks *almost* too nice to ride...
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 21, 2020, 05:08:26 PM
(https://i.postimg.cc/8cpKgdqJ/IMG-7552.jpg) (https://postimg.cc/7GRMgzPw)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Canuck750 on October 21, 2020, 06:27:24 PM
Nice job Dave! Looks fantastic  :thumb:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Turin on October 21, 2020, 10:54:33 PM
Wow that is pretty. I can't have my stuff that nice !
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 26, 2020, 07:29:00 AM
Playing around with Iphone camera. 

(https://i.postimg.cc/SKk6Gbf0/IMG-E7570.jpg) (https://postimg.cc/mPp1bqnV)

(https://i.postimg.cc/jjczg3MD/IMG-E7571.jpg) (https://postimg.cc/VSSr5gQw)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 27, 2020, 07:39:38 AM
I made a big assumption that the Dyna III was in running condition when I tore the bike down.  I did not start the bike before teardown.    I have now found that the ignition module has a bad right channel.   I spent some time eliminating other components such as the pick ups or coils before I called Dynatek and ordered a new module.  I did notice that mount position of the module was fouling against the tank.  I am not sure if that helped the failure along, but it wasn't good. 
(https://i.postimg.cc/tCmsCHV9/IMG-5648edit.jpg) (https://postimg.cc/LnL9NwTW)

I am mounting the module on one of the tubes in the battery compartment.  It is hidden behind the side cover.

I have also decided to add one of Greg Bender's relay solutions to this bike to protect the un-obtanium switchgear.   
Title: Re: 77 Lemans - Extensive Fettle
Post by: Antietam Classic Cycle on October 27, 2020, 08:30:48 AM

I am mounting the module on one of the tubes in the battery compartment.  It is hidden behind the side cover.

I have also decided to add one of Greg Bender's relay solutions to this bike to protect the un-obtanium switchgear.

As long as the Dyna module has good air flow and a good ground, that location will work.

The relay solution is definitely a good idea, especially for the ignition circuit.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on October 31, 2020, 08:25:35 AM
New Dyna III module installed last night.   Now sparking on both!   I should be able to start it this weekend. 

Also I installed Greg Bender's Relay Solution this week.  It works perfectly.  No surprise there. 
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on November 02, 2020, 02:55:58 PM
Running very nicely!  I decided to replace the old throttle cables.  Road test should happen later this week.

https://youtu.be/oeQyb_YnRGs
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on November 07, 2020, 07:30:37 AM
The Lemans is 100% ready for a road test, and we have a spurt of almost summer like weather to get it done.   There are 2 things holding me back.

First is my hip.  I am sure I could probably pull off a short road test without harming anything, but there is a small voice in my head saying that 5 weeks from my hip surgery is too soon.

Then the weather will be changing soon.  At this point the bike is ready for the winter.  The gas tank hasn't had fuel as I have been using a fuel bottle for tuning, and I have already drained and dried the float bowls and fuel lines. If I was to gas it up I would have to go through the fuel emptying process again.

The Lemans will have to wait until Spring for its road test. 
Title: Re: 77 Lemans - Extensive Fettle
Post by: Canuck750 on November 07, 2020, 03:03:55 PM
The Lemans will have to wait until Spring for its road test.

Wise decision!

The bike looks and sounds great, another great restoration!  :bow:

What is next in the pipe line for winter?

 :popcorn:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on November 07, 2020, 03:55:41 PM
Wise decision!

The bike looks and sounds great, another great restoration!  :bow:

What is next in the pipe line for winter?

 :popcorn:

The T3 California is next up.    Then I will get to 55 Triumph T110 that has been waiting patiently.  Then the 64 XLCH, 65 BSA, 73 CL350, couple of chopper projects....
Title: Re: 77 Lemans - Extensive Fettle
Post by: Canuck750 on November 07, 2020, 06:07:13 PM
The T3 California is next up.    Then I will get to 55 Triumph T110 that has been waiting patiently.  Then the 64 XLCH, 65 BSA, 73 CL350, couple of chopper projects....

Wow, you got a long list, excellent!

 :popcorn:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Turin on November 07, 2020, 07:48:12 PM
Yikes! I'd go nuts with a back bench of projects like that.
Title: Re: 77 Lemans - Extensive Fettle
Post by: s1120 on November 09, 2020, 07:39:39 AM
The Lemans is 100% ready for a road test, and we have a spurt of almost summer like weather to get it done.   There are 2 things holding me back.

First is my hip.  I am sure I could probably pull off a short road test without harming anything, but there is a small voice in my head saying that 5 weeks from my hip surgery is too soon.

Then the weather will be changing soon.  At this point the bike is ready for the winter.  The gas tank hasn't had fuel as I have been using a fuel bottle for tuning, and I have already drained and dried the float bowls and fuel lines. If I was to gas it up I would have to go through the fuel emptying process again.

The Lemans will have to wait until Spring for its road test.

Even though thats a tough decision, its a good one..  Spring will come, and you can enjoy it then. She looks amazing, and sounds great! 
Title: Re: 77 Lemans - Extensive Fettle
Post by: leroy_can on January 19, 2021, 07:22:42 PM
 HI Dave, I figured out who the Les P. you mentioned is, major compliment thank-you. Every time I see one of your threads it is yet another awesome restoration of some very desirable Guzzi and although you only list Guzzis on your bikes owned list  I think you have a much more extensive collection. When I pulled my LMIV down last week I found the same 6 cracks in the inner race as you and that is the second time for me. I have never had a tight to install u-joint and they were always quite loose on disassembly. I came up with a mod to the swing arm so I can assemble the bearing to the joint and then install it all in the swingarm. I will do a story on it once I take some photos.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Scout63 on February 13, 2021, 10:27:03 PM
I’ve been remiss in looking at build threads.  Great freshening up on the LM. I can’t wait to read about and hear it run this Spring.
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on April 03, 2021, 11:58:47 PM
I had my first opportunity to give the Lemans its road test.  I am happy to report that the bike functions flawlessly. 

I was wondering if it would live up to the hype.  It does!  I am amazed how powerful this 850 cc is in Lemans spec.  I wonder how it would do against the new V7-850?   It easily has the best sound of any bike I have ever ridden. 

(https://static.imgzeit.com/reduced/4c3c4f1996e38ce4/IMG_8509.JPG)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Antietam Classic Cycle on April 04, 2021, 08:59:26 AM
 :thumb:
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on April 04, 2021, 09:34:08 AM
:thumb:

Not quite Charlie!  The left petcock is leaking.  I think I will put new ones in. 
Title: Re: 77 Lemans - Extensive Fettle
Post by: Canuck750 on April 04, 2021, 07:15:57 PM
A 45 year old design that still looks great today!
Title: Re: 77 Lemans - Extensive Fettle
Post by: Antietam Classic Cycle on April 05, 2021, 07:04:45 PM
This one is back for further sorting - 30 (illegal) miles back in January weren't enough to work out all of the bugs. Engine built by Manfred Hecht (992 cc, unknown cam, ported and dual-plugged heads, lightened flywheel, Carillo rods, titanium valve spring retainers, PHM 40s), Charley Cole did the transmission and rear drive. Staintune exhaust. Ohlins shocks. It isn't pretty, but it runs super strong.


(https://i.ibb.co/VjHmM0x/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/VjHmM0x)
Title: Re: 77 Lemans - Extensive Fettle
Post by: Dave Swanson on April 10, 2021, 10:22:07 AM
Here is a post carb balance rev up video.

https://youtu.be/eFpi__xGu_U

The Harmonizer is hands down the sllickest and easiest balance tool I have ever used.

(https://i.postimg.cc/FHBrKr05/IMG-8519.jpg) (https://postimg.cc/mP7fXGd8)