Wildgoose Chase Moto Guzzi

General Category => Bike Builds, Rebuilds And Restorations Only => Topic started by: canuck750 on April 20, 2017, 11:36:43 AM

Title: 1977 Le Mans running and on the road
Post by: canuck750 on April 20, 2017, 11:36:43 AM
I have put the Le Mans on the bench and started the strip down, looked like this when I got it a couple years ago, fairing is off the bike but included, it runs ok just tired and tatty

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P6290050_zpsr95po7us.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P6290050_zpsr95po7us.jpg.html)

Stripping it down to the last nut and bolt has begun

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1128_zpsf5nspakf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1128_zpsf5nspakf.jpg.html)

I have had all the body work repainted and picked up the fresh painted parts the other day so I have no more excuses to get on with it.

I need to pull apart the drive line and see what it needs and then just clean, polish, plate, replace and put it back together. :grin:

Title: Re: 1977 Le Mans Rebuild getting started
Post by: Tom H on April 20, 2017, 11:40:16 AM
Have fun! Sounds like it should come out looking sweet!

Tom
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on April 20, 2017, 01:15:08 PM
Good one, definitely watching.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Northern Bill on April 20, 2017, 03:05:07 PM
I will be looking forward to seeing the finished product.  It looks good already!
Go Oilers Go!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: smdl on April 22, 2017, 01:50:28 PM
 :popcorn:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on April 22, 2017, 02:25:00 PM
Pulling bearings to prep some parts ready for powder coating, the swing arm pivot races were seized in place, took a lot of heat from the oxy/acet torch and blind bearing puller hammering away for minutes, the races are badly scored and the U joint carrier bearing is all rusted and notched, the U-joint itself is done, the needle bearings under one cap have migrated out of their proper place and where sitting in the bottom of the swing arm.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1131_zpsco0mllnm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1131_zpsco0mllnm.jpg.html)

I like to clean up the working surfaces before I send for powder coating, a fine grit sanding wheel and a wire brush head in a die grinder works fine

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1132_zps2wepb2yo.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1132_zps2wepb2yo.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1133_zpsr2kujgma.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1133_zpsr2kujgma.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1134_zpsq3hixyp2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1134_zpsq3hixyp2.jpg.html)

Rear wheel bearings where also very tight and cush drive plate was really wanting to stay in place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1137_zpsy9o670m2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1137_zpsy9o670m2.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1139_zps3qpecxgw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1139_zps3qpecxgw.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1140_zpsuq1hwhmk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1140_zpsuq1hwhmk.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1170_zps0b8txjnk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1170_zps0b8txjnk.jpg.html)

centre bearing carrier is pretty rusted

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1171_zpszg0yvak3.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1171_zpszg0yvak3.jpg.html)

but it cleaned up in the lathe with some emery paper

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1172_zpsmzdvtosv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1172_zpsmzdvtosv.jpg.html)

Wheel bearing surfaces need cleaning

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1174_zps4szclneh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1174_zps4szclneh.jpg.html)

Wire wheel makes short work of corrosion

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1175_zpsetqvru1k.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1175_zpsetqvru1k.jpg.html)

Next to strip the forks and send off the frame components for matt black and the wheels and fork lowers for wheel silver
Title: Re: 1977 Le Mans Rebuild getting started
Post by: pat80flh on April 22, 2017, 04:07:16 PM
Nice, good stuff.  Personally, the bike didn't look that bad...
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on April 22, 2017, 04:08:10 PM
Can you image the disaster it would have been if you'd just got it running and rode it?  :shocked:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on April 22, 2017, 04:21:34 PM
Definitely needed to be gone through, good call. Looked good to go in your first pic!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on April 22, 2017, 06:52:27 PM
Definitely needed to be gone through, good call. Looked good to go in your first pic!

The right hand side of the tank was dented, side cover tabs broken (used reproductions), seat base cracked, front fender cracked, both repaired by my expert painter. Rear brake caliper frozen bleeder broken off, rusted discs, front calipers leaking, master cylinders leaking, brake hoses brittle, etc.......

Just the way I like to get them, for me this was the perfect Le Mans to buy.

The black goo that came out of the rear drive with a fair amount of water and the condition of the engine oil was frightening. Next week I will pull apart the motor and measure up the crank,. looking forward to finding out what the condition is. I am replacing the valves, guides and springs as a matter of course, Guzzi valve are so cheap I don't think they its worth grinding old ones.

Everything is there on the bike so that's a bonus.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Northern Bill on April 22, 2017, 07:04:02 PM
It is amazing how good a bike can look on the surface.  Your bike should be like new when you finish!
I will probably start a complete reno on my T3 next winter.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on April 23, 2017, 12:51:56 AM
Looking forward in seeing the valve and valve guide steps. Are valve guides something you buy, or are the made/machined to fit the application? How many miles do you think this bike has?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on April 23, 2017, 11:37:18 AM
Looking forward in seeing the valve and valve guide steps. Are valve guides something you buy, or are the made/machined to fit the application? How many miles do you think this bike has?

Valve guides are press fit into the cylinder head casting

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/Valve%20Guide_zpsj3huvu24.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/Valve%20Guide_zpsj3huvu24.jpg.html)

A snap type ring retains the guide from being pushed out the top of the head. The guides are pressed out with a simple tool and then new guides pressed on. If the cylinder head has worn away around the guide an oversize O.D. guide is used, the proper size reamed from the head casting. I have only had a couple cylinders heads that required an oversize guide.
Guides are pretty cheap (I get them from MG Cycle), and I always replace them along with valves and springs. MG also sells a spring kit - 4 outer and 4 inner springs for a reasonable price.

These old Guzzi's are 40+ years now and the springs and guides are usually due for replacement. My local machine shop told me years ago that the Guzzi valve faces were quite thin and not worth machining since new ones are pretty cheap and there only 4 of them per motor. The savings on not facing old valves by purchasing new valves (minor facing of head) is a little more cost than keeping the old parts in place. Now if I were rebuilding a modern 4 cylinder bike with 4 valves per cylinder that would be another matter.

Cheers

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on April 23, 2017, 12:15:26 PM
Good info, thank you
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on April 26, 2017, 01:15:20 PM
Started to strip the motor down last night, haven't pulled the crank or cam, but so far thinks looks not too bad. Has the original timing chain rubber block tensioner, chain is loose, it will be replaced along with a new style tensioner. Cylinders are not scored, need to measure them and the pistons, rocker shafts are not scored, will replace guides, springs and valves.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1193_zpshatkvp46.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1193_zpshatkvp46.jpg.html)

I bit the bullet a couple weeks ago and ordered a Vapor Blast Cabinet from Vapour Honing Technologies, no more acid wash for me, just too dangerous and even with full protective gear I still get some residual ill feeling from using the stuff.  There is a lot of information on-line from Vapor Honing Technologies. plenty of demo You Tube videos that talk about use of the equipment, air compressors, blast media selection, applications etc...

http://vaporhoningtechnologies.com/vapour-blasting-motorcycle-engine-parts/

https://www.youtube.com/watch?v=uOJlrrLh7Ug

Vapor Honing Technologies makes a lower cost cabinet called the "weekend Warrior", it's not on their web site but I saw a link for it on a Laverda Forum and went from their.

Vapor Honing Technologies were very helpful, the Weekend Warrior is just like their heavy duty cabinet but less hp motor and does not come with all the options. The unit retails for $1999 + a little more for a foot pedal and inside wash nozzle. I had to get a bigger compressor, 5 hp single phase 220Volt, 80 gallon, I went for an Ingersol Rand unit.
The blast cabinet should arrive in a month or less then I am going to clean up all the castings on the Le Mans in the water blast unit.

I may have to into the part time cleaning business to offset the cost and justify the purchase but I am really looking forward to using it on this project and the other bikes I have in line to restore.



Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on April 26, 2017, 01:30:23 PM
Vapor blasting is the ultimate solution I think. Good investment in your case since you seem to restore lots of bikes, plus the health concern is enough to fully justify the expense.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on April 26, 2017, 02:46:10 PM
I can't believe you were using an acid wash.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on April 26, 2017, 07:22:14 PM
I can't believe you were using an acid wash.

Mark Ethridge at Moro Guzzi classics put me on to it, 100% safe for aluminum as it only removes oxidation and does not harm the casting. Many engine rebuild shops swear by it and I have had fantastic results for the past 6 years. But time has come to stop messing around with it as I really don't have the proper ventilation or make up air dystem to handle it properly. I will still use it for some delicate and or heavy oxidation clean up.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on April 26, 2017, 08:01:58 PM
They swear by it because they make the shop apprentice do the dirty work.


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Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on April 29, 2017, 02:15:38 PM
Finished the engine strip down and degreased and gave the parts a once over with acid wash, last time to finish of my Aluminum Brightener

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1215_zpsjlzfr4po.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1215_zpsjlzfr4po.jpg.html)

Bearing, crank and cam surfaces look very good

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1216_zpsjjz4hgcj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1216_zpsjjz4hgcj.jpg.html)

First engine I have stripped where the bearings do not have visible score marks

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1217_zpsstnwdg09.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1217_zpsstnwdg09.jpg.html)

Proof that filter motors last much longer than the early wire gauze set up

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1218_zps33a2qvsn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1218_zps33a2qvsn.jpg.html)

I need to mic the crank, clean the sludge trap etc.. but so far it looks good

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1219_zpstacxr4sz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1219_zpstacxr4sz.jpg.html)

Even the shells look good a micrometer will tell

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1221_zpsmonb54ub.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1221_zpsmonb54ub.jpg.html)

I may just get lucky for one on an engine rebuild, the cast iron cylinders have no scores or ridges, hopefully a light hone is all they need. I will send the rods out to be balanced and measured.


Title: Re: 1977 Le Mans Rebuild getting started
Post by: Matteo on May 06, 2017, 09:07:19 AM
 :popcorn: thanks for another bookmark!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: wirespokes on May 07, 2017, 12:53:42 AM
Besides being an engine with an oil filter, could the absence of damage be due to cast iron rather than chrome bores?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on May 07, 2017, 04:18:18 PM
Besides being an engine with an oil filter, could the absence of damage be due to cast iron rather than chrome bores?

Good point, the lack of chrome flakes + an oil filter = a much longer life expectancy for the motor.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: ailgev on May 08, 2017, 03:11:59 AM
Hi There

I Thought Lemans Bores Were Nikasilratherthan Cast Iron.

You May Want To Check Before You Start Honing. Dont Think The Nikasil Plating Likes Honing.

Paul
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on May 08, 2017, 03:34:56 PM
Hi There

I Thought Lemans Bores Were Nikasilratherthan Cast Iron.

You May Want To Check Before You Start Honing. Dont Think The Nikasil Plating Likes Honing.

Paul

I thought they were iron.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on May 08, 2017, 05:28:51 PM
I thought they were iron.

Yep as far as I know the original Le Mans 850cc engines use steel (iron) liners, they sure look like steel liners.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on May 08, 2017, 07:01:17 PM
Hi There

I Thought Lemans Bores Were Nikasilratherthan Cast Iron.

You May Want To Check Before You Start Honing. Dont Think The Nikasil Plating Likes Honing.

Paul

Nikasil/Nigusil bores weren't in use until late '79/early '80 AFAIK. I had a Euro '80 SP here once that was the earliest Guzzi I'd seen with Nikasil.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on May 09, 2017, 09:17:20 PM
I stripped the forks down this evening. Not many surprises, the dampers have absolutely no damping action left in them.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1225_zpsofiuhs6j.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1225_zpsofiuhs6j.jpg.html)

The tubes are pretty good, I polished up the bare alloy tops of the fork legs.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1226_zpsq3k3aomc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1226_zpsq3k3aomc.jpg.html)

I am going to fit progressive springs and FAC dampers. Fork dust boots, bolts, sealing washers and fork seals will be replaced, the lower fork legs are heading off to the powder coater along with the cast wheels, one coat of wheel silver and they should look like new.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on May 09, 2017, 10:49:11 PM
It's a marathon :grin: All the best :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on May 10, 2017, 02:18:52 AM
Vapor blasting is the ultimate solution I think. Good investment in your case since you seem to restore lots of bikes, plus the health concern is enough to fully justify the expense.
Does vapour blasting give the "factory" look or does it come out a bit flat and without a sheen that new engines have ? Some finishes look ok, but if you touch them once with a greasy hand, you can't get the smudge off. Is that an issue with vapour blasting ?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on May 10, 2017, 08:02:25 AM
Here is a good site that explains some vapor blasting steps and results.

http://www.arnoldsdesign.com/Vapor-Blasting.html (http://www.arnoldsdesign.com/Vapor-Blasting.html)

The part to the right on this image is vapor blasted as final stage.

Image courtesy of the Arnolddesign.com site linked above

(http://thumb.ibb.co/bGEuVk/100_5318.jpg) (http://ibb.co/bGEuVk)
 
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on May 10, 2017, 08:49:42 AM
Does vapour blasting give the "factory" look or does it come out a bit flat and without a sheen that new engines have ? Some finishes look ok, but if you touch them once with a greasy hand, you can't get the smudge off. Is that an issue with vapour blasting ?

I will let you know in a couple week's my machine should ne shipping by the end of the week. I coat all cleaned aluminum with ACF-50 which will be greasy until it dries, upon which dirt, smudge etc, just wipe off.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on May 10, 2017, 08:54:03 AM
ACF-50 is great stuff. I recommend it to anyone whom owns a chunk of aluminum  :azn:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on May 10, 2017, 08:54:11 AM
Here is a good site that explains some vapor blasting steps and results.

http://www.arnoldsdesign.com/Vapor-Blasting.html (http://www.arnoldsdesign.com/Vapor-Blasting.html)

The part to the right on this image is vapor blasted as final stage.

Image courtesy of the Arnolddesign.com site linked above

(http://thumb.ibb.co/bGEuVk/100_5318.jpg) (http://ibb.co/bGEuVk)



If you Google 'Vapor Honing Technologies' you will get to their site and it's full of You Tube videos that demonstrate all kinds of materials being vapor blasted, they explain the media selection, buying the right air compressor, charging the system and show you how the cleaning process works on various types of metals. I was really impressed with the carburetor cleaning. The finish is almost like a satin polish. I have seen examples of a 1960's Triumph 650 engine that had been vapor blasted and was very impressed with the finish.

I may be tempted to take apart some of the bikes I have finished and re-clean the alloy :wink:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on May 11, 2017, 02:19:28 AM
Thanks very much, I will watch this space.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 11, 2017, 09:44:14 AM
Progress is being made, albeit slowly, getting my Laverda SF1 on the road and running right, that sorted its back to the Le Mans.

The Vapour Blast cabinet has been working over time getting all the non painted or plated parts clean. I have vapor blasted with #7 glass bead followed by a hot soapy pressure wash and then into the ultrasonic cleaner and a clean hot water rinse, compressed air blast dry and then re blast again after a couple days. I have never before started an assembly with parts this clean.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1119_zpsmuwexmnt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1119_zpsmuwexmnt.jpg.html)

Most all looks good but the rear main has some corrosion that is not worth reusing

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1126_zps3c50sucv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1126_zps3c50sucv.jpg.html)

Pistons are good but a new set or stock rings and big end shells are coming from Harpers (along with a set of NOS lower fork legs).

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1125_zpsp228fa41.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1125_zpsp228fa41.jpg.html)

Bearings pulled out of the transmission case and cover, rear drive stripped, the pinion bearings need to be replace plus seals

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1117_zpsakm79psd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1117_zpsakm79psd.jpg.html)

Crank sludge trap was surprisingly clean, again I chalk that up to the Le Mans being a filter engine. I will replace the oil pump as new ones are now pretty cheap for oil filter engines

All the powder coating is done, flat black for frame components, wheel silver on the wheels.

Zinc plating and chrome plating is done and ready to start assembly.

Everything else in the motor looks good

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1120_zpsqd3slcko.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1120_zpsqd3slcko.jpg.html)

Heads look good but the guides will be replaced, valves are pitted and will also be replaced with a new spring kit.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1122_zpsklolqrju.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1122_zpsklolqrju.jpg.html)

Tomorrow I head down to Phoenix to ride my R1150RT up to Canada winding through central California, Oregon and Idaho, a week of mountain solitude riding, priceless.

Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on June 11, 2017, 12:41:12 PM
If you come through Portland let me know.


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Title: Re: 1977 Le Mans Rebuild getting started
Post by: twowings on June 11, 2017, 02:16:47 PM
Marvelous! Have a GREAT ride!!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 11, 2017, 03:11:03 PM
If you come through Portland let me know.


Sent from my iPhone using Tapatalk

Will do, I am thinking of heading from Palm Springs to Bishop and then cross one of the passes to the center of California, after that no plans.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on June 11, 2017, 08:49:47 PM
Hi Jim,

Fantastic stuff as always. I have long wanted one of those vapour blasting cabinets, yours are just making the itch worse. Looks fantastic.
Sounds good with your roadtrip! Have fun!

-Ulrik
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 19, 2017, 01:57:28 PM
A box of parts where on my desk after returning from a weeks vacation, thanks to Harpers I have a NOS set of Le Mans MK I fork lowers to compliment the rebuild, and a new set of stock piston rings and big end shells. Pretty cool to unwrap some original Mandelo wrapping and see the original (less than perfect) paint finish on the fork lowers, low gloss black paint to boot.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1130_zpsbywpvr6x.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1130_zpsbywpvr6x.jpg.html)

Thanks Curtis! :thumb:
 
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on June 19, 2017, 02:05:10 PM
Does that mean you need to lower the standards for the finishes of the other parts of the bike to match the NOS parts?  :violent1:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 19, 2017, 02:13:23 PM
Does that mean you need to lower the standards for the finishes of the other parts of the bike to match the NOS parts?  :violent1:

The thought has crossed my mind... how many times have you heard that the 'original finish' was never that good and that most restorations are 'over restorations'.

The Italians were not known for the quality of their paint or chrome and from what I have read Ducati was one of the very worst for finish.

Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on June 19, 2017, 07:31:48 PM
Hi Chuck

Glad you had a nice trip. Funny but not surprising that the NOS finish isn't as good as what you have finished yourself.

On the final drive, could you make a write-up on the fitment of new bearings, seals and the shimming of the bearings? I need to do my final drive too when I get home so it would be nice to have some expert knowledge to start out with :)

-Ulrik 
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 20, 2017, 11:50:37 AM
Hi Chuck

Glad you had a nice trip. Funny but not surprising that the NOS finish isn't as good as what you have finished yourself.

On the final drive, could you make a write-up on the fitment of new bearings, seals and the shimming of the bearings? I need to do my final drive too when I get home so it would be nice to have some expert knowledge to start out with :)

-Ulrik

I am not swapping the ring and pinion so I will be leaving the stock steel shim as is for the ring gear, and I plan on  only replacing the pinion bearings and hope to not have to replace the pinion shims. That said I am replacing all the seals and bearings and will run some engineers blue over the gear mesh and record the imprint and see if I can make sense of the pattern as compared to the service manual. The Guzzi service manual black and white pictures are in my opinion pretty hard to read for what the correct mesh pattern should look like.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on June 20, 2017, 10:40:27 PM
I am not swapping the ring and pinion so I will be leaving the stock steel shim as is for the ring gear, and I plan on  only replacing the pinion bearings and hope to not have to replace the pinion shims. That said I am replacing all the seals and bearings and will run some engineers blue over the gear mesh and record the imprint and see if I can make sense of the pattern as compared to the service manual. The Guzzi service manual black and white pictures are in my opinion pretty hard to read for what the correct mesh pattern should look like.

For now I'm not planning on changing the bearings, but all the seals should probably be changed while I'm at it. If you could take some pictures along the way like you usually do, that would be a big help :)

-Ulrik
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 25, 2017, 12:12:07 AM
I could not get the front engine / frame bolt to come free, I had to cut the bolt off with a Sawsall hack saw blade to remove the motor. I soaked the engine front cover in Evaporust for three weeks and still the remnants of the bolt would not come free. I tried heating the aluminum cover, penetrating fluid and a press, nothing. I set the cover in my milling voice on my tiny bench lathe and drilled the damn bolt out.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1154_zpsjch0brpa.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1154_zpsjch0brpa.jpg.html)

And this is what was left

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1155_zps9tk9tygp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1155_zps9tk9tygp.jpg.html)

I turned the FAC damper heads to look more like the stock Le Mans fork caps, the FAC dampers come like this

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1157_zps49a3kf5v.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1157_zps49a3kf5v.jpg.html)

A little machining they look more like stock parts

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1159_zpsswqxytsp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1159_zpsswqxytsp.jpg.html)

Assembled the forks, new progressive springs, I had the damper tubes zinc plated

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1166_zpsnvfk2et9.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1166_zpsnvfk2et9.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1167_zpshwqhpvq7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1167_zpshwqhpvq7.jpg.html)

Home made spring compressor to get to the snap ring

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1172_zpshm8toalv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1172_zpshm8toalv.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1174_zpsgs6wkz2r.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1174_zpsgs6wkz2r.jpg.html)

New fork bottom bolts and crush washers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1173_zpsybpfxdwq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1173_zpsybpfxdwq.jpg.html)

Fitted two new fork seals

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1171_zpskmzttrwp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1171_zpskmzttrwp.jpg.html)

I put 50 ml of fork oil into the fork tube to keep the springs lubricated

New dust boots and the forks are done

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1175_zps3mtlt92q.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1175_zps3mtlt92q.jpg.html)

I started on assembling the wheels, new bearings, zinc plated the spacer, I had the wheels powder coated with a clear top coat

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1176_zpsoux53hsa.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1176_zpsoux53hsa.jpg.html)


Title: Re: 1977 Le Mans Rebuild getting started
Post by: smdl on June 25, 2017, 06:18:02 AM
First rate work, Jim!  Thanks for sharing.

Shaun
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 25, 2017, 10:26:02 AM
Thanks Shaun, only 99 +/ - more components to build!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: guzzinka on June 25, 2017, 05:43:25 PM
Awestruck as usual with your work - what is the story behind this particular Lemans, as in - how did you come to get it and what do you know of its history?  Looks like it led a rough life for a while....
Title: Re: 1977 Le Mans Rebuild getting started
Post by: smdl on June 25, 2017, 06:17:12 PM
Thanks Shaun, only 99 +/ - more components to build!

Lol.  Almost there, then.

Cheers,
Shaun
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 25, 2017, 09:39:01 PM
Rear Wheel assembly, center hub replated and a new O ring

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1181_zpsogt2len2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1181_zpsogt2len2.jpg.html)

Tight fit it takes a big hammer to get it in

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1182_zpsgv4zducb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1182_zpsgv4zducb.jpg.html)

Snap ring

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1183_zpsgp7jqlmx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1183_zpsgp7jqlmx.jpg.html)

Brake disc bolts and cush rubbers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1189_zpscvhi0dih.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1189_zpscvhi0dih.jpg.html)

Drive plate

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1190_zpsw6goew7f.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1190_zpsw6goew7f.jpg.html)

Simple press to pull the drive plate down

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1192_zpscyqorze7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1192_zpscyqorze7.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1193_zpsdlvm7fa0.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1193_zpsdlvm7fa0.jpg.html)

Rubber ring

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1194_zpsd7h1eo2y.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1194_zpsd7h1eo2y.jpg.html)

Steel plate

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1195_zpswkybru98.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1195_zpswkybru98.jpg.html)

Bearings and distance spacer

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1196_zpsf9dgrvhk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1196_zpsf9dgrvhk.jpg.html)

Brake disc

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1199_zpsp9ruu9q6.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1199_zpsp9ruu9q6.jpg.html)

Rear wheel done

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1200_zpskbcurgox.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1200_zpskbcurgox.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1201_zps8nujffgz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1201_zps8nujffgz.jpg.html)

The front is a piece of cake, just bearings, distance spacer and two discs

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1202_zpsjj6hdyh9.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1202_zpsjj6hdyh9.jpg.html)

Now to get some rubber on these wheels



Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 25, 2017, 09:40:40 PM
Awestruck as usual with your work - what is the story behind this particular Lemans, as in - how did you come to get it and what do you know of its history?  Looks like it led a rough life for a while....

I bought this Le Mans off a long time WildGuzzi member, I don't know how long he owned it or where it came from, I have owned it for a couple years and finally got around to rebuilding it
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 25, 2017, 09:45:00 PM
Assembling the bearings into the swing arm

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1204_zpszxp2lfbc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1204_zpszxp2lfbc.jpg.html)

The big drive shaft bearing is a snug fit, big driver and a big hammer

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1205_zpshhqmlvw0.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1205_zpshhqmlvw0.jpg.html)

Snap ring to keep it there

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1206_zpsngmjw46o.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1206_zpsngmjw46o.jpg.html)

Pivot bearings greased

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1207_zpshrm5ob6b.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1207_zpshrm5ob6b.jpg.html)

New seals and test fit the spacers and pivot pin

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1208_zps3bb7iojt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1208_zps3bb7iojt.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1209_zpslavv5cd0.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1209_zpslavv5cd0.jpg.html)


Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on June 25, 2017, 09:53:58 PM
 :popcorn: :thumb:
Nice job Chuck, perfection as always :grin:

-Ulrik
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 25, 2017, 09:59:48 PM
I assembled the rear drive, new bearings, seals, O rings and gaskets

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1212_zpshyz58hmp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1212_zpshyz58hmp.jpg.html)

Getting the pinion nut off takes some real force

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1213_zpsqy7xrxni.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1213_zpsqy7xrxni.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1214_zpsxw4naalr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1214_zpsxw4naalr.jpg.html)

I pulled the bearings and put the shims back exactly as they where

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1216_zpsblpv0dgd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1216_zpsblpv0dgd.jpg.html)

Drove out the old races, pressed in new ones until they reach the stop

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1222_zpsuxlyi5hk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1222_zpsuxlyi5hk.jpg.html)

New O rings

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1224_zps7smesaaq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1224_zps7smesaaq.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1225_zpspntwrdau.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1225_zpspntwrdau.jpg.html)

Drive off the lower bearing

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1226_zpsalyedocj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1226_zpsalyedocj.jpg.html)

Note the shims

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1227_zpsq0xakecl.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1227_zpsq0xakecl.jpg.html)

Drive on the new bearing

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1229_zpsunxkbmwf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1229_zpsunxkbmwf.jpg.html)

Put the shims, spacer and upper baring on, torque the big nut back on and peen the nut

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1230_zpsxqxli1lz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1230_zpsxqxli1lz.jpg.html)

Fit the snap ring back on

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1231_zps316r7zyh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1231_zps316r7zyh.jpg.html)

New seal in the case, then the brass shim

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1233_zpsrpxbxlpp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1233_zpsrpxbxlpp.jpg.html)

New bearing set

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1234_zpsgybauacw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1234_zpsgybauacw.jpg.html)

Drop the pinion cluster back in

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1235_zpsmfvvcrzf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1235_zpsmfvvcrzf.jpg.html)

Drop in the crown wheel and the distance spacer

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1237_zps6lzyrdyr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1237_zps6lzyrdyr.jpg.html)

New paper gaskets sandwich the steel shim

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1238_zpsstnxpncr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1238_zpsstnxpncr.jpg.html)

I heated the cover in the oven to drop the bearing in

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1239_zpsyahlved3.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1239_zpsyahlved3.jpg.html)

Fitted the big seal and then new lock tabs and bolts

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1240_zps1kqx5p8o.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1240_zps1kqx5p8o.jpg.html)

Then when it was all done I realized one of the drain plug threads was shot so I ran compressed air into the case while I drilled for a helicoil, worked great the alloy shards blew out the hole as I drilled

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1244_zpsctyk67on.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1244_zpsctyk67on.jpg.html)


(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1251_zpss8yvdqxs.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1251_zpss8yvdqxs.jpg.html)

Rear drive done

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1254_zpsrvng0cez.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1254_zpsrvng0cez.jpg.html)



Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on June 26, 2017, 12:07:04 AM
You sure you want to use a Helicoil and not a Timesert?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on June 26, 2017, 09:14:59 AM
Looks good, you make it seem so simple :grin:

How do you check the preload of the pinion bearings and what should it be?

-Ulrik
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 26, 2017, 09:26:04 AM
You sure you want to use a Helicoil and not a Timesert?

I don't have Timeserts and a Helicoil has never let me down in twenty + years of using them, especially in something as non-stressed as a drain plug. There has been lots of debate on this site in the past on the pros and cons of both systems, good points for both.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 26, 2017, 09:35:04 AM
Looks good, you make it seem so simple :grin:

How do you check the preload of the pinion bearings and what should it be?

-Ulrik

Just take it all apart then put it all back together! I didn't replace the crown and pinion so I am hoping the shims / load does not change.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on June 26, 2017, 10:02:21 AM
Sounds resonable, I will try and do the same to mine when I get home then. I have a leaking drain plug, so I will do the change of seals, bearings and helicoil the drain and level plugs.

Thanks for sharing your rebuilds, they give a whole lot of excelent infomation, tips and tricks

-Ulrik

Sent from my SM-J105F using Tapatalk

Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 26, 2017, 10:34:29 PM
Transmission strip, clean up and inventory. This transmission is out of a 850T, I don't think it had many miles on it, the original Le Mans transmission went into Luca's 750S3. The S3 gears and dogs where just too worn out and I had to get a good transmission into the S3.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1258_zpso2bpl49t.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1258_zpso2bpl49t.jpg.html)

I heated the case and cover to 350 degrees in my shop oven to sweat the bearings out, the bearings are probably 'good enough' but I ordered a complete set from HMB Moto Guzzi so I am going to go ahead and replace all the case bearings

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1259_zpsrfc5mbbo.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1259_zpsrfc5mbbo.jpg.html)

The shift forks show very little sign of wear, that's a first!

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1260_zpscdhmik7o.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1260_zpscdhmik7o.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1261_zpstt9av6p1.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1261_zpstt9av6p1.jpg.html)

This gear dog and matching gear has some noticeable wear, I need to find a better set in my transmission spares box

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1262_zpsekouzy8s.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1262_zpsekouzy8s.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1264_zpsk4r8wfn7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1264_zpsk4r8wfn7.jpg.html)

Bearings, gaskets, O rings, seals, a new deep clutch spline drive and replacing the return spring should take care of parts.


Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on June 27, 2017, 01:05:11 AM
What's the difference between a T box and a LeMans?


Sent from my iPhone using Tapatalk
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 27, 2017, 09:43:59 AM
What's the difference between a T box and a LeMans?


Sent from my iPhone using Tapatalk



Nothing
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 28, 2017, 10:37:47 PM
Picked up my wheels today from the local bike shop, they could not get the front tire to sit properly, claimed the powder coat was too thick inside the rim???

So I fit an axle into a vice and quickly spun the wheel why I ran a 120 grit disc across the flange

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1267_zpsucvy4iqx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1267_zpsucvy4iqx.jpg.html)

And a drum on the flat

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1269_zps5libjd9f.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1269_zps5libjd9f.jpg.html)

And a micro band sander

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1270_zpsibgsendj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1270_zpsibgsendj.jpg.html)

Damn powder coat!

Back to the transmission, heated the case and cover up to 350F and then dropped the cold bearings into place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1276_zpsd7dww2iy.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1276_zpsd7dww2iy.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1279_zpshrtuxfsw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1279_zpshrtuxfsw.jpg.html)

Thanks to Joe W for sending me a tutorial on setting the shift drum and forks,

I swapped a better 5th gear and dog

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1281_zpsx06ck7eu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1281_zpsx06ck7eu.jpg.html)

New bearing pack

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1282_zpss6wkrswq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1282_zpss6wkrswq.jpg.html)

And O rings

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1283_zpsjltldubh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1283_zpsjltldubh.jpg.html)

mostly back together,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1284_zpspdpys80u.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1284_zpspdpys80u.jpg.html)

done for the night

Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on June 29, 2017, 08:00:20 AM
I've have come across posts mentioning the powdercoat thickness causing problems like this, but other say it's not a problem. I would blame the seal on the new TL tires as being too "good". When I had my Pirelli Sport Demons mounted on my G5 (same rims as yours), the installer almost gave up on the front as well; It finally then popped into place when the PSI went over 100psi - mine were not powder coated, and I didn't even paint the inside either. Just factory finish.

Nice work on this, I'm enjoying this thread a lot. Is the tutorial Joe W sent you a public document published somewhere? I've found a few other out there, some by Pete Roper and others from this board.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on June 29, 2017, 08:41:18 AM
I've have come across posts mentioning the powdercoat thickness causing problems like this, but other say it's not a problem. I would blame the seal on the new TL tires as being too "good". When I had my Pirelli Sport Demons mounted on my G5 (same rims as yours), the installer almost gave up on the front as well; It finally then popped into place when the PSI went over 100psi - mine were not powder coated, and I didn't even paint the inside either. Just factory finish.

I've experienced this issue when mounting almost any tire to the original Guzzi cast lead/butter rims. The only thing that seems to help is Windex - yes, the stuff used to clean glass. Other brands don't seem to work as well even.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 29, 2017, 09:39:19 AM
 Thanks for the info on mounting tires. I will drop the rim / tire off again and hope the shop is successful today
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 29, 2017, 12:38:42 PM
Is the tutorial Joe W sent you a public document published somewhere? I've found a few other out there, some by Pete Roper and others from this board.

Sorry but I can't find the email Joe sent me. Similar to what Pete Roper explains but Joe has cut open a transmission case to allow for a full view of the drum and forks in place. Installing the detent plunger along with the gear clusters, shift forks and shift drum made checking play and engagement so much easier. It never dawned on me in the past to fit the detent to assemble the forks and fork shaft was going to make the assembly easier. Also Joe has found that in most cases the drum shims are needed on the back side of the drum to center the shift forks.

I don't try to tighten up the shift drum too much from what it was originally shimmed at, this may be going against common wisdom but I have a suspicion that the Guzzi engineers may have intentionally designed in the slack in the shift drum to reduce wear on the shift forks and the dogs.

On this particular transmission the shift forks where in such nice shape that I just put it back together with adding one very thin shim to the back (rear cover side) of the drum. There is still some end play in the drum even with a paper gasket between the cover and case with the cover torqued down.

I found that using a very long set of bent end needle nose pliers worked great for pulling up the 1st gear shift fork to get it to pop into the shift drum, the 'bent' end of the needle nose fits clear of the case / forks and then could be twisted 90 degrees to pull up on the closed needle nose to lift the shift fork. The typical hook puller has never worked well for me in the past to lift the shift fork.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on June 29, 2017, 12:57:57 PM
Good info. I'm far from digging into the transmission, and at this point I'm just gathering info and working on building up my confidence level to jump in at some point, so build threads like this one, are greatly appreciated!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 29, 2017, 10:13:41 PM
Finished up the transmission this evening, new gasket for the neutral switch

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1285_zpsvmqp0ing.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1285_zpsvmqp0ing.jpg.html)

Checking contact to the shift drum bulb

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1286_zpsyrf4r74e.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1286_zpsyrf4r74e.jpg.html)

Replaced the shift return spring

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1287_zps1opi4twu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1287_zps1opi4twu.jpg.html)

Fitted the cam bolt that centers the return spring pawl

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1288_zps2pjv3ofn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1288_zps2pjv3ofn.jpg.html)

Rotating the cam bolt moves the return pawl mechanism up or down to meet the center of the shift drum

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1289_zpsyzcpyxlj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1289_zpsyzcpyxlj.jpg.html)

I 'glue' the gasket into position with wheel bearing grease and use long bolts to align the cover to the case and not fold the gasket while the cover drops down

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1294_zpsjswuhx2w.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1294_zpsjswuhx2w.jpg.html)

Then the shim that goes under the speedo drive gear

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1298_zpsncsqwcba.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1298_zpsncsqwcba.jpg.html)

And then the gear

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1299_zpsl4piqcky.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1299_zpsl4piqcky.jpg.html)

then the ball bearing that keeps the gear in place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1300_zpscsayo8aj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1300_zpscsayo8aj.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1301_zpsf1ayzox7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1301_zpsf1ayzox7.jpg.html)

the big nut torqued down

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1304_zpsykyu5zwa.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1304_zpsykyu5zwa.jpg.html)

lubed the seal and then set it onto place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1305_zpssduj5pkg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1305_zpssduj5pkg.jpg.html)

peen the nut

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1307_zpscvnaufea.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1307_zpscvnaufea.jpg.html)

new deep spline drive

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1309_zps5wrf7glt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1309_zps5wrf7glt.jpg.html)

lock washer and nut

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1310_zpssjcqsc44.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1310_zpssjcqsc44.jpg.html)

torque it down

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1313_zps7nmbcpmj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1313_zps7nmbcpmj.jpg.html)

O rings on the clutch rod

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1314_zpsweduzm2i.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1314_zpsweduzm2i.jpg.html)

lube and install the active end of the push rod

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1315_zpsbfof4rnn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1315_zpsbfof4rnn.jpg.html)

and fit the clutch arm

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1316_zps5ajkxb26.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1316_zps5ajkxb26.jpg.html)

done

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1317_zpsrtvgoav0.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1317_zpsrtvgoav0.jpg.html)




Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on June 30, 2017, 12:01:46 AM
 :popcorn: Top notch :)

How do you adjust the cam bolt to center the return yawl on the shiftdrum? I guess it will be done after the end cover has been mounted on the gearbox, if so, how do you know that it is adjusted correctly?

-Ulrik
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on June 30, 2017, 07:30:29 AM
Good stuff, nice job and thanks for taking the time to take the photos of the steps and parts!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 30, 2017, 09:21:59 AM
:popcorn: Top notch :)

How do you adjust the cam bolt to center the return yawl on the shiftdrum? I guess it will be done after the end cover has been mounted on the gearbox, if so, how do you know that it is adjusted correctly?

-Ulrik

The cam faced adjustment bolt has a range of about 3/4 a turn, I wind the bolt in hand tight, unwinding the bolt moves the shift pawl up and down, it needs to fall into alignment with the center of the shift drum, the hole in the transmission case cover for the shift drum is the center point. You don't need to be 100% accurate just get it as close as you can. if you keep unwinding the cam faced bolt it just  keeps moving the pawl the same amount, there is no additional adjustment possible beyond the original 3/4 turn.

Once the transmission and shift pedal is installed you can fine tune the adjustment bolt a wee bit to move the pedal / pawl to the centre between shift up / shift down.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 30, 2017, 10:32:46 PM
Replaced the block to transmission studs with replated ones, the old studs will get replated for the next build

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1318_zps6mzyewup.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1318_zps6mzyewup.jpg.html)

Locktight to keep them in place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1319_zpsfcpmcf5z.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1319_zpsfcpmcf5z.jpg.html)

Painted the underside of the block with engineers blue and then flat sanded the base of the block with a 400 grit sheet of sanding paper glues to a 18" square granite tile

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1321_zpsm0km1fug.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1321_zpsm0km1fug.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1323_zpsyeeaznwp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1323_zpsyeeaznwp.jpg.html)

Fitted the front bearing with new lock tabs and locktight

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1324_zpsasexii4w.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1324_zpsasexii4w.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1325_zps4tqasuod.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1325_zps4tqasuod.jpg.html)

Refitted the sludge trap cap

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1326_zpsytp56y2c.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1326_zpsytp56y2c.jpg.html)

New rear bearing, replaced the oil feed tube

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1327_zpsokag5a2b.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1327_zpsokag5a2b.jpg.html)

I heat the case to 200 degrees in the oven, drop on a new flange gasket and place a couple studs into the case bolt holes to guide the bearing in, the hot case expands and the bearing just falls into place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1330_zpsnn4nyziq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1330_zpsnn4nyziq.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1331_zpsmz1quiwh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1331_zpsmz1quiwh.jpg.html)

I used schnor washer to fix the rear bearing flange to the block and dab of locktight

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1332_zpsz3myzgd4.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1332_zpsz3myzgd4.jpg.html)

Thread sealant on the bottom two bolts that penetrate the case

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1333_zpsxqsdq0ub.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1333_zpsxqsdq0ub.jpg.html)

JB weld mixed to fill the cam plug

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1334_zps01w7vdvk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1334_zps01w7vdvk.jpg.html)

New gasket on the big breather tube

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1335_zps8lbu7ywj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1335_zps8lbu7ywj.jpg.html)

New rear main seal lubed and ready to press in

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1336_zps0lmoq6ev.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1336_zps0lmoq6ev.jpg.html)

The press tool works great setting the seal to just the right depth and square

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1338_zpsnyfc9cuj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1338_zpsnyfc9cuj.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1340_zpskwfplb0q.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1340_zpskwfplb0q.jpg.html)

Heads came back from the machine shop today with new guides, springs and valves

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1341_zps5ulmiht7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1341_zps5ulmiht7.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1342_zpsdlulonv8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1342_zpsdlulonv8.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on June 30, 2017, 10:47:02 PM
What is the JB Weld for?


Sent from my iPhone using Tapatalk
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on June 30, 2017, 11:30:27 PM
What is the JB Weld for?


Sent from my iPhone using Tapatalk

Sealing over the rear cam plug is a long standing recommended mod for all big blocks. I have never had one leak but its cheap insurance when you have the engine out of the bike. There is a lip in the block casting that the cap pops into, a smear of JB Weld in the recess lapping over the cap should keep it sealed for life.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on July 01, 2017, 04:13:28 AM
Very good :thumb: and now I know what I need to install a new rear main seal in my bike.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 01, 2017, 02:25:29 PM
Very good :thumb: and now I know what I need to install a new rear main seal in my bike.

The rear main seal installation tool is worth buying if you need to replace a rear main seal, the seal is very hard to get in square without the tool. Nothing fancy to it and one could make a seal driver with a proper bolt that matches the crank center thread and big thick plate or washer.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on July 01, 2017, 04:05:40 PM
The rear main seal installation tool is worth buying if you need to replace a rear main seal, the seal is very hard to get in square without the tool. Nothing fancy to it and one could make a seal driver with a proper bolt that matches the crank center thread and big thick plate or washer.

If I have the rear main bearing/flange out, I always install the seal into it before installing the bearing/flange into the engine case. Just easier for me.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 01, 2017, 10:01:18 PM
If I have the rear main bearing/flange out, I always install the seal into it before installing the bearing/flange into the engine case. Just easier for me.

Good call, that would be easier!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 01, 2017, 10:07:01 PM
I got an hour in today and fitted new big end shells and con rod cap nuts, coated the shells faces with assembly lube

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1356_zpsjkmxdjcm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1356_zpsjkmxdjcm.jpg.html)

Torqued in t 24 foot lbs.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1357_zpsyxxwo0gi.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1357_zpsyxxwo0gi.jpg.html)

The piston pins where a real tight fit, even with the pistons heated to 350 degrees it took the pin press to get them in

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1360_zpsdczvrrgr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1360_zpsdczvrrgr.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1361_zps0grc27yh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1361_zps0grc27yh.jpg.html)

Lubed the cam

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1362_zpsd6yaxgle.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1362_zpsd6yaxgle.jpg.html)

The flange was in spec co I just milled three oil feed reliefs like the new flanged have

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1363_zps3h6g22gx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1363_zps3h6g22gx.jpg.html)

New oil pump, they are pretty reasonably priced these days

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1364_zpsiqaj4kpb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1364_zpsiqaj4kpb.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1365_zpshzs3xchd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1365_zpshzs3xchd.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on July 01, 2017, 10:17:57 PM
This is great :grin: :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 02, 2017, 10:37:11 AM
Thanks Balvenie, I hope it is of some use to anyone interested in rebuilding a Tonti frame bike and in particular a Le Mans MK I.

I make no claims to being a mechanic or an expert, if anyone spots something I have done incorrectly, and that happens!, please post the error or send me a pm.


Cheers

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: twowings on July 02, 2017, 12:41:05 PM
This thread is a joy to watch...so envious of your skills!  :bow:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: toolittletime on July 02, 2017, 06:09:51 PM
Very nice job Jim....love to watch these threads, especially with all of the detailed pictures you post.
Tim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on July 02, 2017, 07:51:26 PM
Very nice job Jim....love to watch these threads, especially with all of the detailed pictures you post.
Tim

 :1: It is like a very detailed instruction in how to build a Moto Guzzi. It is great! :grin:

-Ulrik
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 02, 2017, 10:15:12 PM
Speaking of errors, here's one, the cam chain tensioner should be installed with the front bearing flange, so I pulled two bolts and the lock tab and fitted the tensioner. I then remove the wear bar and spring until the chain is installed

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1368_zpsxyx7wgfr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1368_zpsxyx7wgfr.jpg.html)

New endless chain and the gears cleaned up

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1369_zpsgvf1lee9.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1369_zpsgvf1lee9.jpg.html)

The marks on the cam and crank sprocket need to align and the chain and all three gears need to be installed as a unit. 1st I fit the gears without the chain and line up the marks then carefully remove the gears and then fit the chain to them and press all three gears onto their shafts at once

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1370_zps7svqcoyo.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1370_zps7svqcoyo.jpg.html)

Then the crank gear lock tab can be fitted

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1372_zpsjfzmaxlg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1372_zpsjfzmaxlg.jpg.html)

And the lock nut, round face to the engine, flat side out

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1373_zpsdjavbgul.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1373_zpsdjavbgul.jpg.html)

Tightening both the cam and crank nuts at once work against one another and can be torqued tight, real tight!

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1374_zpslrjoursg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1374_zpslrjoursg.jpg.html)

One of the crank lock nut slots will have a star tab that can be bent over to lock the nut

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1375_zpso1vcwgai.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1375_zpso1vcwgai.jpg.html)

The oil pump nut and lock washer with a dab of locktight

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1376_zpsqjzqhiqk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1376_zpsqjzqhiqk.jpg.html)

cam followers cleaned up

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1378_zpsumga49l1.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1378_zpsumga49l1.jpg.html)

Lubed

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1379_zpsj8zzsjtd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1379_zpsj8zzsjtd.jpg.html)

Installed and then the cylinder base gasket and the 6 o'clock and 12 o'clock O rings can be installed

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1380_zpsm0u455pz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1380_zpsm0u455pz.jpg.html)

Make sure the gasket does not block the oil passage hole

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1381_zpsvcopoif8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1381_zpsvcopoif8.jpg.html)

Oil the piston grooves and fit the new rings

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1382_zpsde33ipxt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1382_zpsde33ipxt.jpg.html)

I lightly honed the cylinders with WD-40 and a fine hone

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1383_zps75yezkma.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1383_zps75yezkma.jpg.html)

Ring compressor

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1384_zpszf3tp7q8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1384_zpszf3tp7q8.jpg.html)

Carefully tap the cylinder down over the ring compressor

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1385_zpsnzcgf7a4.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1385_zpsnzcgf7a4.jpg.html)

Then remove the ring compressor and finish pushing the cylinder down

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1386_zpsdsjutrcm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1386_zpsdsjutrcm.jpg.html)

Fit the head gasket and make sure the oil hole is lined up

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1388_zpsyswiigye.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1388_zpsyswiigye.jpg.html)

Drop the head on and fit four O rings over the block studs

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1389_zpsxadobv5k.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1389_zpsxadobv5k.jpg.html)

Then fit the rocker frame and the wave washers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1391_zpspcdelnys.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1391_zpspcdelnys.jpg.html)

Special nut for the 6 o'clock stud

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1392_zpsymvrd3ui.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1392_zpsymvrd3ui.jpg.html)

Then the other cylinder, now it looks like a Ducati!

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1393_zps9pauwr0u.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1393_zps9pauwr0u.jpg.html)

Viton O rings on the 6 o'clock head plugs

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1394_zps24dwugab.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1394_zps24dwugab.jpg.html)

head torqued down

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1395_zps7qgvveuk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1395_zps7qgvveuk.jpg.html)

Oil pressure sensor

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1396_zpshog4zjym.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1396_zpshog4zjym.jpg.html)

Head oil feed pipe

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1397_zpsmllolrwy.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1397_zpsmllolrwy.jpg.html)

The rocker parts

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1404_zpsshwzi7y8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1404_zpsshwzi7y8.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1405_zpsy6ssvqm6.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1405_zpsy6ssvqm6.jpg.html)

Distributor lock ring

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1406_zpsarfjltqr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1406_zpsarfjltqr.jpg.html)

crankcase oil breather one way valve

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1407_zpsasdhyz4o.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1407_zpsasdhyz4o.jpg.html)

Made a pair of gaskets for the intake manifolds

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1401_zpsen7p471n.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1401_zpsen7p471n.jpg.html)

The 6mm manifold bolts unique to the Le Mans

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1402_zpsvopbdbda.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1402_zpsvopbdbda.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1403_zpsikezzzqd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1403_zpsikezzzqd.jpg.html)

New rubber carb boots

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1409_zps2fhwkzed.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1409_zps2fhwkzed.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1410_zpsgpicmqlm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1410_zpsgpicmqlm.jpg.html)

Almost a motor now


Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on July 02, 2017, 10:29:42 PM
Looks beautiful Jim. I can just imagine myself  having a severe case of the crazies, trying to install the three cogs fitted to their chain :grin:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 02, 2017, 10:44:42 PM
Looks beautiful Jim. I can just imagine myself  having a severe case of the crazies, trying to install the three cogs fitted to their chain :grin:

I should have explained how to do it a little better, to begin I install only the cam and crank sprockets and line up the timing marks.

Next fit the chain around the two gears it will fit easily without the oil pump gear.

Now pull the chain and two gears off the shafts but not off the front of the engine and drop the oil pump gear into the bottom loop of the chain

Next push the whole thing back as a unit onto the shaft, wiggle it around until the cam pin and crank slot align and your home free,

Spin the crank and makes sure the cam and crank timing marks align

sounds a lot harder than it is

Cheers

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 02, 2017, 11:39:31 PM
It wasn't all bike building, I got the Laverda SF1 out on the road along with my buddy on his beautiful and all original Pantah

(http://i249.photobucket.com/albums/gg217/canuck750/1973%20Laverda%20SF1/IMG_14131_zpsmvpkwarr.jpg) (http://s249.photobucket.com/user/canuck750/media/1973%20Laverda%20SF1/IMG_14131_zpsmvpkwarr.jpg.html)

The Laverda runs like a top and pulls like a tractor and makes a pretty nice sound too

(http://i249.photobucket.com/albums/gg217/canuck750/1973%20Laverda%20SF1/IMG_1366_zps1nowmojr.jpg) (http://s249.photobucket.com/user/canuck750/media/1973%20Laverda%20SF1/IMG_1366_zps1nowmojr.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on July 03, 2017, 04:14:16 AM
Thanks Jim. I think I get it :grin: :thumb: Nice Laverda too :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 03, 2017, 09:47:57 PM
Fitting the sump, flip the engine upside down and place a gasket down

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1414_zpslyyhwds7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1414_zpslyyhwds7.jpg.html)

I am installing a deep sump outside filter unit, new stainless fasteners and all torqued down

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1415_zpscpqgbfjx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1415_zpscpqgbfjx.jpg.html)

Check the gear timing marks and then I attached a dial gauge to the back of the crank, inserted a piston stop into the left spark plug hole and confirmed TFC on compression on the left 'S' cylinder

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1416_zpstk6iocri.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1416_zpstk6iocri.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1417_zpsbsvjx7kg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1417_zpsbsvjx7kg.jpg.html)

Pulled the engine off the build stand and onto the engine holder

Grease the tach drive gear face on the cam

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1424_zpsamelvgep.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1424_zpsamelvgep.jpg.html)

Install a front cover gasket

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1425_zpslqc1xluw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1425_zpslqc1xluw.jpg.html)

Pop the cover on with a new seal for the alternator

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1426_zps3m09jvty.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1426_zps3m09jvty.jpg.html)

Use the correct hardened steel bolt for the alternator and a schnor washer

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1428_zpsezvounyn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1428_zpsezvounyn.jpg.html)

Install the rocker gaskets and rocker covers, new fasteners, torque the covers down

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1423_zpsutijmgi4.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1423_zpsutijmgi4.jpg.html)

With the engine sealed up I pressurized the case to 60 psi and checked for leaks, soapy water on the back of the breather tubes, no bubbles

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1429_zpso7uklado.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1429_zpso7uklado.jpg.html)

The paint mark on the back of the crank should line up with the cast pointer in the back of the crankcase,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1419_zpsvtzjsi3z.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1419_zpsvtzjsi3z.jpg.html)

I made a mark on the flywheel before I removed it to know where the flywheel should bolt on and marked it with a new paint dab

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1420_zpsjqnioot1.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1420_zpsjqnioot1.jpg.html)

The 'S' mark should be in position to be viewed through the transmission inception plug

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1421_zpst2h4sqy3.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1421_zpst2h4sqy3.jpg.html)

This mark should align with the pointer on the crank case

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1431_zpslxj3kr6f.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1431_zpslxj3kr6f.jpg.html)

Torque down the flywheel with schnor washers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1433_zpsx40rfwfy.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1433_zpsx40rfwfy.jpg.html)

I put a dab of glue from a hot glue gun onto the back of the clutch springs to hold them in position until the pressure plate is in place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1448_zps80urgwyy.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1448_zps80urgwyy.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1449_zpshszbjsu4.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1449_zpshszbjsu4.jpg.html)

Check the pressure plate recesses on the back are aligned to the springs, the mark in the pressure plate matches a mark on the flywheel, I repainted the marks

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1452_zpsdjd7nrcw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1452_zpsdjd7nrcw.jpg.html)

Then tighten down the clutch plate alignment tool

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1453_zpsabejkiin.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1453_zpsabejkiin.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1454_zpsukujhiwd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1454_zpsukujhiwd.jpg.html)

new clutch plates and an intermediate plate

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1455_zpstgd1pjna.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1455_zpstgd1pjna.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1456_zpsozafdawx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1456_zpsozafdawx.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1457_zps2amzc7fb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1457_zps2amzc7fb.jpg.html)

Then the ring gear can be attached, schnor washers again

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1458_zpsepz9vahk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1458_zpsepz9vahk.jpg.html)

And the clutch rod mushroom pops in to place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1459_zpsbuqtga43.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1459_zpsbuqtga43.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1460_zpszzisyfge.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1460_zpszzisyfge.jpg.html)

Stator fitted

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1461_zpsb93omwzm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1461_zpsb93omwzm.jpg.html)

And the air spacer and cover, haven't decided if I will polish the cover, I think the original Le Mans where not polished??

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1462_zpspnq1lb3w.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1462_zpspnq1lb3w.jpg.html)

OK that's one motor built

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1463_zpsd6ueg7d8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1463_zpsd6ueg7d8.jpg.html)








Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on July 04, 2017, 08:28:54 AM
Looks like the flywheel bolts are 8.8? You really need higher strength 10.9 bolts in that application. 8.8 are fine for the ring gear though.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 04, 2017, 08:38:11 AM
Thanks Charlie! I will check the bolt grade.

Jim
Title: 1977 Le Mans Rebuild getting started
Post by: swooshdave on July 04, 2017, 10:00:39 AM
(https://uploads.tapatalk-cdn.com/20170704/9e161ae70330bf9649f7f85ce158ae3f.jpg)

Mk1 Series 2 at Barber. Note the black alternator cover and unpolished timing cover.


Sent from my iPhone using Tapatalk
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 04, 2017, 11:02:44 AM
Thanks Dave, great picture, lots of good detail information there.

If you have any more detail pictures of the Barber bike please share them.

I am going to fit the Euro version headlight, I don't care for that big black bezel sticking out of the fairing.

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on July 04, 2017, 11:14:11 AM
Yes, I took a bunch of detail shots. I'll post them in a bit.


Sent from my iPhone using Tapatalk
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on July 04, 2017, 11:41:06 AM
(https://uploads.tapatalk-cdn.com/20170704/376ccc53170994820c7d39d0db9e7b16.jpg)
(https://uploads.tapatalk-cdn.com/20170704/4cdae652128b67913cb842ad7b57f965.jpg)
(https://uploads.tapatalk-cdn.com/20170704/adaedfe671cd0d7e164857223ac44add.jpg)
(https://uploads.tapatalk-cdn.com/20170704/b70581111220d4f134a70fbfa405da63.jpg)
(https://uploads.tapatalk-cdn.com/20170704/f00e85e1fcaac59dc36fe9de3c1fda37.jpg)
(https://uploads.tapatalk-cdn.com/20170704/a0eabc56f29dd63434ec53a436f77ab3.jpg)
(https://uploads.tapatalk-cdn.com/20170704/90f12f60d005e2e04ee18ba7b2c0f9a1.jpg)
(https://uploads.tapatalk-cdn.com/20170704/e4569df27870365bc215c9588309fe2c.jpg)(https://uploads.tapatalk-cdn.com/20170704/1a807169eef7d67ef7f33119b0f67df8.jpg)
(https://uploads.tapatalk-cdn.com/20170704/ce6f1e203341926dd63e163c638e6069.jpg)
(https://uploads.tapatalk-cdn.com/20170704/32e45b0ba2010f5f5b7712f54a931e81.jpg)
(https://uploads.tapatalk-cdn.com/20170704/48114104db5939d71d14dad84caecdc7.jpg)
(https://uploads.tapatalk-cdn.com/20170704/915af2224f0a63bcf22a4137772f73e3.jpg)
(https://uploads.tapatalk-cdn.com/20170704/feeff7f9cb3cb333ac9a3527ce2432c2.jpg)
(https://uploads.tapatalk-cdn.com/20170704/658f35069d280ee314dd50172b9624bf.jpg)(https://uploads.tapatalk-cdn.com/20170704/eca21fd4c8fed8a273843fdd989f0c0a.jpg)
(https://uploads.tapatalk-cdn.com/20170704/f40eda34079d3e9ec62c53ae00c5c2bc.jpg)
(https://uploads.tapatalk-cdn.com/20170704/58c60169b3a00c543b745a2af8facfea.jpg)
(https://uploads.tapatalk-cdn.com/20170704/44567eb9088a448615f54fe7413e6e32.jpg)
(https://uploads.tapatalk-cdn.com/20170704/d32b555238e057a1e182b3925b592444.jpg)(https://uploads.tapatalk-cdn.com/20170704/a2471b32c2ca7cee5a814f654379d3cb.jpg)
(https://uploads.tapatalk-cdn.com/20170704/f6455bc3637483ceba66c4f7831f5281.jpg)
(https://uploads.tapatalk-cdn.com/20170704/d5ea0451c3624198d5f6bbcc365628cf.jpg)(https://uploads.tapatalk-cdn.com/20170704/55142abe4fed09807f050e581c91fc01.jpg)
(https://uploads.tapatalk-cdn.com/20170704/786b6a492f3c9c8fb7c9bd776734c44f.jpg)(https://uploads.tapatalk-cdn.com/20170704/24ececbf9676fbc3624a228428527f5d.jpg)

I'll reiterate that Barber is the finest motorcycle museum in the world. If you have not been put it on your list as the next thing to do.


Sent from my iPhone using Tapatalk
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 04, 2017, 01:52:21 PM
Thanks Dave!!!

These pictures will be of a great help to me reassembling my Le Mans.

I have Barbers on my bucket list, I have to get there in the next year or two, I have heard so many great things about it.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 04, 2017, 02:00:03 PM
Looks like the flywheel bolts are 8.8? You really need higher strength 10.9 bolts in that application. 8.8 are fine for the ring gear though.

Great eye Charlie, like you thought the bag of bolts I was using are all 8.8, I bought a box each of 50 - 25mm and 20mm  - 10.9 high strength bolts from my local bolt supply shop.

Tossing out the old 8.8's this evening!

Thanks again for letting me know, shearing flywheel bolts would not have made for a good day.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on July 04, 2017, 04:04:22 PM
Great eye Charlie, like you thought the bag of bolts I was using are all 8.8, I bought a box each of 50 - 25mm and 20mm  - 10.9 high strength bolts from my local bolt supply shop.

Tossing out the old 8.8's this evening!

Thanks again for letting me know, shearing flywheel bolts would not have made for a good day.

Looks like you have 4 of each - 8.8 and 10.9 on the ring gear. Or maybe four are zinc-plated and four are black oxide.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 05, 2017, 10:25:20 PM
10.9 bolts installed on the flywheel and ring gear,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1465_zps46rmoqcb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1465_zps46rmoqcb.jpg.html)

Mated the transmission to the engine

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1466_zpsfxn4cb42.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1466_zpsfxn4cb42.jpg.html)

And this time I stamped a rebuild date onto a non-descript location on the engine block

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1468_zpsrhakwiyr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1468_zpsrhakwiyr.jpg.html)

and the back of the transmission

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1467_zpsctkyqaua.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1467_zpsctkyqaua.jpg.html)

Chances are this Le Mans will not need to be rebuilt again and 40 years from now when this bike is 80 years old some future owner may want to know when it was rebuilt
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on July 06, 2017, 09:14:59 AM
Except they won't know what that date means.


Sent from my iPhone using Tapatalk
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 06, 2017, 09:18:53 AM
Except they won't know what that date means.


Sent from my iPhone using Tapatalk

I have to leave some mystery behind the marks :grin:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on July 06, 2017, 09:44:11 AM
Did you paint the tools used in this project all blue, or are they purchased somewhere all like that? Some (most) seem specifically to Moto Guzzi, is that the case?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 06, 2017, 10:02:20 AM
Did you paint the tools used in this project all blue, or are they purchased somewhere all like that? Some (most) seem specifically to Moto Guzzi, is that the case?

 :embarassed: I powder coat all my specialty tools blue,  it started one day years ago while powder coating some blue parts and rather than dump the powder I started to paint tools, one thing leads to another ... OCD, and I know their mine if I lend them out, not that there is a big call for Guzzi tools around here. :smiley:

I found some used on Ebay, some where bought new, they sure come in handy though a lot of them are not absolutely necessary and other tools could be improvised. The crank nut tool, the starter ring gear holder, rear transmission nut holder, swing arm spindle tool are essential and the other make the work easier.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 07, 2017, 11:40:49 PM
The Le Mans build goes on the backburner for a while. My Laverda decided to start making an ugly grinding noise so I dropped the motor, pulled it apart and split the cases. Now to get an expert to take a look at the crank and see if its good, I think the cam chain was the culprit.

This is one serious heavy lump, a real challenge to get it out of the frame.

(http://i249.photobucket.com/albums/gg217/canuck750/1973%20Laverda%20SF1/IMG_1475_zpszglo5gfu.jpg) (http://s249.photobucket.com/user/canuck750/media/1973%20Laverda%20SF1/IMG_1475_zpszglo5gfu.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1973%20Laverda%20SF1/IMG_1487_zpsun7kdvvc.jpg) (http://s249.photobucket.com/user/canuck750/media/1973%20Laverda%20SF1/IMG_1487_zpsun7kdvvc.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1973%20Laverda%20SF1/IMG_1476_zpstwk42rnt.jpg) (http://s249.photobucket.com/user/canuck750/media/1973%20Laverda%20SF1/IMG_1476_zpstwk42rnt.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on July 08, 2017, 12:21:36 AM
Do you sleep?


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Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 08, 2017, 01:22:18 PM
Do you sleep?


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Not much and I get bored easily :laugh:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Chuck in Indiana on July 08, 2017, 05:00:03 PM
I'm seeing some seriously hot stuff here..
(http://i249.photobucket.com/albums/gg217/canuck750/1973%20Laverda%20SF1/IMG_1487_zpsun7kdvvc.jpg)
What I wanted to post about though.. is that some people gripe about museums and machines that are not ridden. Those pix Swooshdave took are invaluable to a restorer to see what an original *really* looked like. Attaboy.  :smiley:
Museums certainly have their place and this is one of the things I like about them.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 08, 2017, 09:13:36 PM
I have received conflicting opinions on the Laverda forum on the heat mark, some guys say its normal from the assembly process, others say not, I am going to dry reassemble the engine, build a crate and ship it off to the Guru Wolfgang Haerter in B.C.

I got everything vapour blasted today and ready for inspection,

(http://i249.photobucket.com/albums/gg217/canuck750/1973%20Laverda%20SF1/IMG_1509_zpsiztg81ur.jpg) (http://s249.photobucket.com/user/canuck750/media/1973%20Laverda%20SF1/IMG_1509_zpsiztg81ur.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1973%20Laverda%20SF1/IMG_1511_zpsww7kq1xi.jpg) (http://s249.photobucket.com/user/canuck750/media/1973%20Laverda%20SF1/IMG_1511_zpsww7kq1xi.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1973%20Laverda%20SF1/IMG_1537_zpshmmwukig.jpg) (http://s249.photobucket.com/user/canuck750/media/1973%20Laverda%20SF1/IMG_1537_zpshmmwukig.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 14, 2017, 10:29:33 AM
My Laverda motor has been crated and shipped to Wolfgang Haerter at Columbia Car & Cycle for an examination so my bike lift is blocked with a partially disassembled Laverda SF1 preventing a Le Mans assembly to continue. Shifting over to another project I removed the heads from the Benelli 650 Tornado, there was a good 1/2 inch of dirt and rust in each cylinder congealed to a thick pudding of rust from filling the chambers with penetrating fluid. Washed out the mess and it looks like this, firmly seized

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1111_zpsny2dzxzd.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1111_zpsny2dzxzd.jpg.html)

And the flip side of improper storage looks like this

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1112_zpsf6mg20ne.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1112_zpsf6mg20ne.jpg.html)

I have filled the cylinders to the brim with Evaporust to let the chemical do its work for a month hopefully the pistons will free up

Looks like its going to take a bit more than a light hone and some valve lapping paste to get it back in shape :violent1:



Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on July 14, 2017, 11:10:24 AM
Just push the Laverda onto the floor and get on with the LeMans. Priorities man!


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Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 14, 2017, 01:58:11 PM
Just push the Laverda onto the floor and get on with the LeMans. Priorities man!


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Your right, I should have stripped the Laverda motor out at my office warehouse and got the frame  assembly going on the Le Mans at home. Having bikes and tools split between two locations is a drag. My space at home is about 14 feet x 6 feet to work on a motorcycle but 90% of my tools are there. My storage space at the office is about 1000 square feet but I have a few tools and its a ways from home.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 20, 2017, 02:25:29 PM
Meanwhile still sidelined from the Le Mans Build, Laverda on the lift and back to the Benelli..... Soaking the cylinders with Evaporust has so far not resulted in freeing the pistons but it did remove a lot of rust from the cylinder walls.

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1181_zpsn7esqmgt.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1181_zpsn7esqmgt.jpg.html)

I placed the whole engine in my vapor blast cabinet and cleaned the cylinders, piston crowns and cases as much as possible prior to cleaning each part individually.

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1185_zpsydjceswr.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1185_zpsydjceswr.jpg.html)

The crank will rotate and raise the pair of cylinders off the case, enough to fit some square 11/2" bar spacers between the underside of the cylinders and the engine case. I am planning on making a steel plate with 8 holes drilled to match the head stud pattern and then between the underside of the plate and the top of the piston fit a small hydraulic ram attached to my 5 ton porta-power. My plan is the hydraulic force of the ram will force the piston / crank down and crack the rings free of the block.

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1182_zpsrcx8ihlk.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1182_zpsrcx8ihlk.jpg.html)

I have about a 3/4" lift on the current locked position, I only need a tiny bit of drop to break the bond. Any thoughts if this idea is going to work, not damage the crank....?

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1186_zpsxkfiffnv.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1186_zpsxkfiffnv.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Don G on July 20, 2017, 04:14:10 PM
Jim: make sure that what ever you put on the piston crown is near the same diameter as the piston, if not you could push what ever through the crown, also be sure that the piston can travel, this way you are not bending a con rod. also warm the jug with a soft heat a couple of times before attempting. I have used this method on a number or Brit bikes to good effect. DonG
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 20, 2017, 04:49:42 PM
Jim: make sure that what ever you put on the piston crown is near the same diameter as the piston, if not you could push what ever through the crown, also be sure that the piston can travel, this way you are not bending a con rod. also warm the jug with a soft heat a couple of times before attempting. I have used this method on a number or Brit bikes to good effect. DonG

Thanks Don, A little heat can go a long way.

I am going to make an aluminum 'plug' to sit on top of the piston crown and take the brunt of the hydraulic ram's contact. I think I only need to move the piston the thickness of a piston ring, a mm should do. Once the bond is broken I should be able to rotate the crank and reveal the piston pin and clips, .... at least that is the plan.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on July 22, 2017, 09:09:08 PM
Evaporust? Is that similar to Kroil? How long have you been letting it soak? Sometimes you do have to resort to brute force.


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Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 22, 2017, 09:12:16 PM
Cases split, crank hanging by the rods, steel plate attached and 5 tons pressure on the piston .... nothin :thewife:

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1203_zpshqwalkr4.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1203_zpshqwalkr4.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1214_zpsadncxd4a.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1214_zpsadncxd4a.jpg.html)

I filled the cylinders with fresh Evaporust and will keep soaking the cylinder / piston. 

Damn theses rings are rusted to the iron liner.

Good news is the crank is not rusted and the bearings turn

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1215_zpsygwgffee.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1215_zpsygwgffee.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on July 22, 2017, 09:20:54 PM
What is the way to go for maximum originality on the paint for the frame swing arm etc. mine's a Mk 2 but is it the same brew ?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 22, 2017, 10:06:55 PM
What is the way to go for maximum originality on the paint for the frame swing arm etc. mine's a Mk 2 but is it the same brew ?

The best match the local powder coater could come up with was flat black, the finish looks like a very low gloss, not actually flat and |I am very happy with the results.

I had the exhaust header, clamps,  and cross over ceramic coated matte black, matches the new repro muffler I bought.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on July 22, 2017, 10:07:41 PM
This is a bit of a heart stopper mate :shocked: :cry:
Better luck next time :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 22, 2017, 11:30:28 PM
Evaporust? Is that similar to Kroil? How long have you been letting it soak? Sometimes you do have to resort to brute force.


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Evaporust is non toxic, non flammable, basically vinegar I bet. The cylinders have been soaking for a week, just won't budge. I may add aquarium heaters to the bores to heat the Evaporust, heat will make the reaction speed up. There is so little space between the cylinder wall and the piston for the rust remover to work its way into the ring. I may just grind out the pistons with a dire grinder, I have another pair of decent used pistons to use. I will give it another week.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on July 23, 2017, 12:55:27 AM
I assume you've heard of acetone and ATF?


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Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on July 23, 2017, 01:27:06 AM
The best match the local powder coater could come up with was flat black, the finish looks like a very low gloss, not actually flat and |I am very happy with the results.

I had the exhaust header, clamps,  and cross over ceramic coated matte black, matches the new repro muffler I bought.
Thank you, that'll be my aim then.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on July 23, 2017, 08:48:29 AM
The best match the local powder coater could come up with was flat black, the finish looks like a very low gloss, not actually flat and |I am very happy with the results.

I had the exhaust header, clamps,  and cross over ceramic coated matte black, matches the new repro muffler I bought.

The powdercoater I use calls it "Jet Black".
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 23, 2017, 04:23:54 PM
I assume you've heard of acetone and ATF?


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Yep just never had much luck with it, I tried a lot of brute force, got one cylinder 'almost' off.

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1245_zpsiidpdr1e.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1245_zpsiidpdr1e.jpg.html)

Heat, heat and more heat,

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1246_zps5tnyhdli.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1246_zps5tnyhdli.jpg.html)

then filled the cylinders with Evaporust, let it boil for a good 30 minutes,

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1249_zpsw6gzxzrv.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1249_zpsw6gzxzrv.jpg.html)

still stuck, so the whole top of the crankcase is inverted with the cylinders submerged in Evaporust.

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1259_zps1qndzjdo.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1259_zps1qndzjdo.jpg.html)

I hate rust
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on July 24, 2017, 04:01:24 AM
 :shocked:
Looks pretty stuck I must say! But I'm sure you'll get it out at some point :grin:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on July 24, 2017, 09:19:56 AM
Electricity?


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Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on July 24, 2017, 09:44:01 AM
Do you have a giant ultrasonic cleaner? I've broken loose hobby sized engines that were seized up that way by sitting in ultrasonic cleaner for 30+ minutes. May or may not work in this case, but worth a shot if you have or have access to one. Good luck.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Don G on July 24, 2017, 10:11:04 AM
A little rust goes a long way! Patience, heat and a bit of lube will over come eventually. Get rammy and things get broken.  DonG
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 26, 2017, 09:23:39 PM
A little rust goes a long way! Patience, heat and a bit of lube will over come eventually. Get rammy and things get broken.  DonG

Almost got the pistons out, taking your advice, soaking in Evaporust and applying heat, got them both so the rings where starting to be exposed in the crescent cut outs of the cylinder liner bases. Back to soak for a couple more days and then hopefully the pistons will drop out. Never have I had something as stuck as this, over a month of various chemicals soaking into the rings.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Psychopasta on July 26, 2017, 09:42:07 PM
Kudos on the patience Canuck! This makes my V50 look like a walk in the park  :bow:

- P
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 27, 2017, 11:01:02 PM
Finally

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1270_zpseenpbqoq.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1270_zpseenpbqoq.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1271_zpsjr5dnpn8.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1271_zpsjr5dnpn8.jpg.html)

The pistons are toast, the cylinders are junk, both cylinders have cracked skirts, I found a good used set of pistons and cylinders, the crank bearings don't feel very good ......

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1274_zpskf1jqjjt.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1274_zpskf1jqjjt.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: smdl on July 27, 2017, 11:28:41 PM
 :thumb: :thumb: :thumb:

Way to go, Jim!

Shaun
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on July 28, 2017, 04:49:36 AM
Yeay! You got them apart! Knew you would, this looks like it must be one of the worst starting points you have had so far 🤤

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Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on July 28, 2017, 08:25:38 AM
Congrats on the removal of the piston/cylinders! Patience is a virtue, and you have it. I would have not only destroyed those parts, but probably would have also bulldozed down my shop with everything in it!

In regards to the powdercoat color, I went with what my powdercoater called "matte black" finish. Though, if I were to do it again I think I would opt to add the matte clearcoat option he offered as I think it would have given it a little more depth. The "gloss black" version he had I thought it was too shiny and showed too many of the imperfections, but probably closer to the factory frame paint in reality I think. I do think the less glossy looks better on these bikes since they don't have a lot of chrome on them

Vinegar... I soaked one of my tanks in a blend of white wine and apple cider vinegar for about 2-weeks; It ate through the alloy of the factory petcocks, and actually damaged the factory tank lining. The taps actually popped out out and the tank full of vinegar just drained out. Luckily, I had the tank sitting over a bin. So short term, vinegar is OK. Long term (more than say a few days), it will cause damage to certain materials. I thought I had pics of my deteriorated fuel taps on my phone, but can't find them. If I still have the taps, I'll post a pic later. They look like something that washed ashore out of the ocean.

Some pics the matte black powdercoat on my G5:


(http://thumb.ibb.co/hxVdN5/1.jpg) (http://ibb.co/hxVdN5)

(http://thumb.ibb.co/ehHgaQ/2.jpg) (http://ibb.co/ehHgaQ)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on July 28, 2017, 09:01:45 AM
Finally

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1270_zpseenpbqoq.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1270_zpseenpbqoq.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1271_zpsjr5dnpn8.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1271_zpsjr5dnpn8.jpg.html)

The pistons are toast, the cylinders are junk, both cylinders have cracked skirts, I found a good used set of pistons and cylinders, the crank bearings don't feel very good ......

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1274_zpskf1jqjjt.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1274_zpskf1jqjjt.jpg.html)

From the photos, I'm wondering if they weren't gummed into place instead of rusted into place. A few years ago I rebuilt the top-end on a customer's R75/5 BMW that had been left sitting petcocks open for several years. The gas drained through the carbs, flooded the cylinders and evaporated. When he bought it to me, he forgot to tell me that backstory, so I proceeded to remove the stuck pistons from the cylinders assuming they were rusted into place. Tried all sorts of penetrants, heat and non-damaging force. Once I switched to serious gum-cutting solvents, the pistons started to move and I eventually got them out undamaged.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on July 28, 2017, 09:12:36 AM
From the photos, I'm wondering if they weren't gummed into place instead of rusted into place. A few years ago I rebuilt the top-end on a customer's R75/5 BMW that had been left sitting petcocks open for several years. The gas drained through the carbs, flooded the cylinders and evaporated. When he bought it to me, he forgot to tell me that backstory, so I proceeded to remove the stuck pistons from the cylinders assuming they were rusted into place. Tried all sorts of penetrants, heat and non-damaging force. Once I switched to serious gum-cutting solvents, the pistons started to move and I eventually got them out undamaged.

That's also why I had suggested ultrasonic cleaner. Heat makes gummed up things worst in my experience, whereas ultrasonic cleaners with just a tad of dish soap zap varnish.

I used to work in the service department for O.S. & SuperTigre model engines for the R/C industry and we'd service hundreds of small engines per week. Those glow engines for fuel use a blend of Nitromethane, Methanol, and Oil in different percentages depending on application (Marine, Aero, Dirt). When left untreated with after run engine oils for years, they would severely gum/rust up and were impossible to take apart. Running them in an ultrasonic cleaner however would break them loose in most cases.

Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 28, 2017, 10:01:52 AM
The cylinder walls have deep grooves created by the oxidation of the pistons rings, the pitting is from the rust that occurred above the piston crown from the dirt that accumulated from the open intake ports and / or exhaust valves. When I got the heads off there was at least a 1/2" deep layer of crud in the cylinders. The petcocks and gas tank was full of a similar layer of dirt, rust, feathers, seeds and what appeared to be a bird or mouse skeleton. The pistons may have originally become stuck from residue fuel but after that rust took over. The crack in the cylinder base is evident in this picture. May have been caused by the hydraulic pressure of the porta-power forcing the piston down into the bore. In any event the cylinders are crap, but I got a good used set of cylinders, pistons and rings from Dieter Burian in Germany.

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1278_zps6rnywvpe.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1278_zps6rnywvpe.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on July 28, 2017, 12:26:26 PM
Just to follow up on the fuel taps vinegar thing:


(http://thumb.ibb.co/j4a4ek/IMG_5760.jpg) (http://ibb.co/j4a4ek)

(http://thumb.ibb.co/fJGXX5/IMG_5761.jpg) (http://ibb.co/fJGXX5)

(http://thumb.ibb.co/ckKms5/IMG_5762.jpg) (http://ibb.co/ckKms5)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on July 28, 2017, 01:35:27 PM
WOW , I have never seen anything like that before.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on August 06, 2017, 09:50:10 PM
I have been distracted from the Le Mans build for lack of an open lift at my garage so I have continued to strip the Benelli 650 Tornado down, cataloguing what is missing or damaged or beyond spec. After a couple weeks of stripping parts off the bike, cleaning the pieces as they come off I am left with this pile

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1410_zpsdnhncyy5.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1410_zpsdnhncyy5.jpg.html)

All the rest is in plastic boxes awaiting reassembly, sheet metal off to the painter.

Hopefully the Laverda motor bottom end rebuild will be done this month and I can get the Laverda back together and off the lift.

If anyone is hesitant to tackle a Benelli for parts availability I am happy to report that most of the parts are available in Germany from Mr. Detlef Burian. He is very prompt with answering questions and shipping is quick, he takes PayPal. His on line catalogue is great, prices and availability are displayed online.

http://www.benelliparts.de/

Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on September 06, 2017, 10:15:35 AM
I picked up my Benelli parts from the painter yesterday, I think he did a great job.

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1651_zpsuuf4hyhb.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1651_zpsuuf4hyhb.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: smdl on September 06, 2017, 10:23:15 AM
I picked up my Benelli parts from the painter yesterday, I think he did a great job.

(http://i249.photobucket.com/albums/gg217/canuck750/1974%20Benelli%20650S%20Tornado/IMG_1651_zpsuuf4hyhb.jpg) (http://s249.photobucket.com/user/canuck750/media/1974%20Benelli%20650S%20Tornado/IMG_1651_zpsuuf4hyhb.jpg.html)

Beautiful!  :drool:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on September 06, 2017, 12:34:42 PM
That looks tasty! Did you use a certain color code, or was it a paint match type of thing? Looks really good. Also, how are the decals applied (over or under clear coat)? Maybe it's paint, not decals...

That is going to look very nice, looking forward to seeing it finished.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on September 06, 2017, 02:03:02 PM
That looks tasty! Did you use a certain color code, or was it a paint match type of thing? Looks really good. Also, how are the decals applied (over or under clear coat)? Maybe it's paint, not decals...

That is going to look very nice, looking forward to seeing it finished.

My painter was given pictures of a green / black Benelli 650 and he used a late model Guzzi paint from a V7. The green and black are paint, the white strip is a tape pin stripe with a clear coat over top. The painter rounded off the end of the white stripe just like the original paint work.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Psychopasta on September 06, 2017, 08:58:17 PM
A good painter is a wonderful thing. I love the green color!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on September 07, 2017, 05:06:31 AM
Looks great!!!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 11, 2017, 09:27:59 PM
The Laverda engine is rebuilt and back in the bike, Laverda off the lift and an open space for the Le Mans.

1st thing, reattach the VIN tag

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1724_zps27tddo3y.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1724_zps27tddo3y.jpg.html)

Tap in a new set of tapered steering bearings

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1725_zpstzflxbel.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1725_zpstzflxbel.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1726_zpszjsraobu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1726_zpszjsraobu.jpg.html)

Drop a greased bearing over the stem, bas washer and rubber in place.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1727_zpsbjyccezn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1727_zpsbjyccezn.jpg.html)

The bearing seated tight against the base washer

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1728_zpsrvdt65xr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1728_zpsrvdt65xr.jpg.html)

Push the lower clamp and stem through the frame, place the upper bearing and cap and nut

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1730_zps0zo6gi4v.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1730_zps0zo6gi4v.jpg.html)

I think this washer belongs here but I can't recall for certain, seems to belong though

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1732_zpsqmjn72bh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1732_zpsqmjn72bh.jpg.html)

Drop the top clamp on, center nut and steering damper

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1736_zpsa4hyi9sk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1736_zpsa4hyi9sk.jpg.html)

New rubber tank dampers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1734_zpstf5wzrqs.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1734_zpstf5wzrqs.jpg.html)

And tank mount bushings

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1735_zpswj9qcvhz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1735_zpswj9qcvhz.jpg.html)

Not much so far but the 'big' pieces are done and ready to drop into place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1738_zpsyzl1o2wx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1738_zpsyzl1o2wx.jpg.html)

Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on October 11, 2017, 10:48:49 PM
You make it look easy, Jim :wink: :grin: :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on October 12, 2017, 02:57:04 AM
The satin finish on the frame looks great. Better than the gloss treatment some do.
What us the actual colour ?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on October 12, 2017, 05:35:18 AM
Very nice!  I was wondering when you would get back to the Le Mans.  Good to see it coming together and looking forward to the updates.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on October 12, 2017, 07:51:31 AM
Just checked the T3 manual (same triple nut system) and you have the washer in the correct place. All looks great!

Edit: Also confirmed using the LM1 manual. Which brings me to this question... what does that knob on top of the upper lock nut do? Manual says "Shock absorber Rod" - don't quite understand how that works,
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 12, 2017, 12:19:19 PM
Just checked the T3 manual (same triple nut system) and you have the washer in the correct place. All looks great!

Edit: Also confirmed using the LM1 manual. Which brings me to this question... what does that knob on top of the upper lock nut do? Manual says "Shock absorber Rod" - don't quite understand how that works,

Thanks for confirming the washer, my parts manual was left at my office last night.

The LMI has the same steering damper as the V7 Sport / 750S / 750S3. The knob rotates a steel plate 45 degrees (+/-) that lengthens the arm of the hydraulic steering damper connected to the lower triple and the frame. Period test reports of the V7 Sport often reported the steering friction damper was not working, ... because its not a friction damper and the knob is not turned to increase friction!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 12, 2017, 12:20:15 PM
The satin finish on the frame looks great. Better than the gloss treatment some do.
What us the actual colour ?

The finish is matte black powder with a clear matt powder over top. Its as close as I could get in a powder coat to match the near flat black of the original.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on October 12, 2017, 02:04:29 PM
Thanks for explain that part! I see that link now in the parts manual.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 12, 2017, 10:15:05 PM
The engine and transmission were finished months ago, I bought this handy hydraulic dirt bike lift (300 lbs. capacity) to transfer heavy things like an engine from a bench up to the bike

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1739_zpsxi0kduue.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1739_zpsxi0kduue.jpg.html)

Frame rails and hardware

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1740_zps8dbogi89.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1740_zps8dbogi89.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1749_zpssmqyrdii.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1749_zpssmqyrdii.jpg.html)

Captive nuts on the frame tabs for the transmission plate

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1741_zpssspveacb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1741_zpssspveacb.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1748_zpsin2rzgsp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1748_zpsin2rzgsp.jpg.html)

Center stand parts

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1743_zpsbeso65vk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1743_zpsbeso65vk.jpg.html)

And it all goes into place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1742_zpsad1lnpmb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1742_zpsad1lnpmb.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1752_zpsxdmrchjz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1752_zpsxdmrchjz.jpg.html)

Foot rest guards

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1745_zpszcqidns4.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1745_zpszcqidns4.jpg.html)

Foot rest bits

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1746_zpsc5acqq1q.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1746_zpsc5acqq1q.jpg.html)

And one box is emptied and back on the frame

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1747_zps65gdydpr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1747_zps65gdydpr.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1750_zpsjl1kd1f5.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1750_zpsjl1kd1f5.jpg.html)

Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on October 12, 2017, 10:32:56 PM
Looks really good Jim.
I'm really enjoying this thread. Nice work as always :grin:

-Ulrik

Sent from my SM-A520F using Tapatalk

Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on October 12, 2017, 10:41:00 PM
What fun :grin: :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on October 12, 2017, 11:55:56 PM
The finish is matte black powder with a clear matt powder over top. Its as close as I could get in a powder coat to match the near flat black of the original.
[/quoteThank you.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Psychopasta on October 13, 2017, 08:53:44 AM
It does feel good when things start going back on, doesn't it?  :thumb:

- M
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 13, 2017, 09:38:31 AM
It does feel good when things start going back on, doesn't it?  :thumb:

- M

Reassembly is definitely the best part of a rebuild, the cleaning , stripping, repairing is just the drudgery before the 'clean' work.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on October 13, 2017, 10:36:05 AM
Looking good! Three things: the "captive nuts": 1) interesting application, but I've never felt the need for anything other than the original hex nuts. 2) I think you'll find that the nylock nuts on the right side, holding the footrests/lower frame rails to the main frame, will interfere with the swingarm. There's not much clearance there, that's why Guzzi originally used a half-height nut. Don't want to gouge the freshly powdercoated swingarm... 3) How far recessed into the transmission rear cover is the throw-out bearing outer body? Looks like a few mm? In my experience, if it's recessed that far, the clutch may not release completely/drag. Have you checked to see if the clutch works properly? Easy to do by hooking up the cable and lever. 
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 13, 2017, 06:52:03 PM
Looking good! Three things: the "captive nuts": 1) interesting application, but I've never felt the need for anything other than the original hex nuts. 2) I think you'll find that the nylock nuts on the right side, holding the footrests/lower frame rails to the main frame, will interfere with the swingarm. There's not much clearance there, that's why Guzzi originally used a half-height nut. Don't want to gouge the freshly powder coated swingarm... 3) How far recessed into the transmission rear cover is the throw-out bearing outer body? Looks like a few mm? In my experience, if it's recessed that far, the clutch may not release completely/drag. Have you checked to see if the clutch works properly? Easy to do by hooking up the cable and lever.

I find it hard to get my fat fingers under the side frame tabs to hold a nut in place, not stock but easier to assemble.

I have a big stock of the fat nylocks and stainless bolts, yes they are definitely too long to wiggle the swing arm into place, on my previous builds I have to back off the nuts to get the swing arm in place and then retighten it all. I should bite the bullet and get some proper length bolts and thin nuts to make life easier :thewife:

Good advice on the clutch, I will assemble the front end next with handlebars and levers and check the clutch operation.

Cheers

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 13, 2017, 10:15:58 PM
Back to opening up the forks and moving the snap ring to beneath the lower cap

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1756_zpsvtxodvr9.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1756_zpsvtxodvr9.jpg.html)

replated and powder coated bits

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1758_zps41fnx2rg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1758_zps41fnx2rg.jpg.html)

forks, headlight brackets, instrument tabs and handlebars all clamp together

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1759_zpsgwe94xoz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1759_zpsgwe94xoz.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1760_zpsgizysz7g.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1760_zpsgizysz7g.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1763_zpsqgvm0mff.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1763_zpsqgvm0mff.jpg.html)

I think the LMI had the calipers mounted to the front but this is how I am going to assemble them because that's the way they were when I got the bike

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1761_zpsxix0cniw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1761_zpsxix0cniw.jpg.html)

I found some shallow nuts for the lower frame rail bolts, may solve the fitting the swing arm issue,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1753_zpstpvhzxjq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1753_zpstpvhzxjq.jpg.html)

close up of the clutch rod end, does it look correct Charlie?

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1754_zpsvt7zgpfx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1754_zpsvt7zgpfx.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on October 14, 2017, 11:28:17 AM
A little recessed, but not too much. I would definitely recommend making sure the clutch releases completely before continuing assembly though.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 14, 2017, 12:21:24 PM
Thanks Charlie!

I wil fit the clutch lever and cable and test the operation

I now realize I need to swap the fork lowers as I have a stock set of new brake hoses and a new fender with the hose guide holes drilled for calipers facing forward, some things are just meant to be as Mandelo planned

Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on October 14, 2017, 06:24:06 PM
I now realize I need to swap the fork lowers as I have a stock set of new brake hoses and a new fender with the hose guide holes drilled for calipers facing forward, some things are just meant to be as Mandelo planned

Good, because that was bothering me, but I wasn’t going to say anything  :azn:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 14, 2017, 08:09:51 PM
I followed your advice Charlie and fitted the clutch lever, cable and shift pedal

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1770_zpshxqngorm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1770_zpshxqngorm.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1769_zpstsvzvql7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1769_zpstsvzvql7.jpg.html)

Shifts up and down smoothly, hoorah!

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1771_zpskje2aeca.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1771_zpskje2aeca.jpg.html)

Fitted the brake pedal while I was at it

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1766_zps4aewyxki.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1766_zps4aewyxki.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1768_zpsmatar2a4.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1768_zpsmatar2a4.jpg.html)

Steering damper installed

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1764_zpstbkupmdk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1764_zpstbkupmdk.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1765_zps1s4bzva5.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1765_zps1s4bzva5.jpg.html)

Been struggling with the $#!!%$ swing arm, I hate installing swing arms, need to leave it for a day, just can't get the damn U joint to mesh with the outputs shaft, if slides on freely on its own but just keeps fighting me as a complete assembly, I always struggle with these :thewife:

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1772_zpsxqyclbdz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1772_zpsxqyclbdz.jpg.html)

all the splines are grease, it 'should' slide on

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1773_zpstreg8yie.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1773_zpstreg8yie.jpg.html)


Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on October 14, 2017, 08:53:51 PM
 :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on October 15, 2017, 12:15:03 AM
Good, because that was bothering me, but I wasn’t going to say anything  :azn:

I was going to say something.


Sent from my iPad using Tapatalk
Title: Re: 1977 Le Mans Rebuild getting started
Post by: thomas on October 15, 2017, 07:52:54 AM
HI
WRT the swingarm and the UJ, I find it helps to fit the rear axle into the one arm of the s-w and to pinch it with the pinch bolt. You can then rest the axle on your fore arm (sitting on your arse behind the bike) and use that hand to help fit the s-a into position.
Also I have shaped a long flat plate to just fit into the splined connector at the rear end of the drive shaft. This can then be used to rotate the U-J and coerce the U-J splines to engage with the gearbox output shaft.

And regarding the captive nuts: I actually tack-weld captive nuts in place before sending the frame for paintwork.

cheers
Thomas
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 15, 2017, 10:10:29 AM
HI
WRT the swingarm and the UJ, I find it helps to fit the rear axle into the one arm of the s-w and to pinch it with the pinch bolt. You can then rest the axle on your fore arm (sitting on your arse behind the bike) and use that hand to help fit the s-a into position.
Also I have shaped a long flat plate to just fit into the splined connector at the rear end of the drive shaft. This can then be used to rotate the U-J and coerce the U-J splines to engage with the gearbox output shaft.

And regarding the captive nuts: I actually tack-weld captive nuts in place before sending the frame for paintwork.

cheers
Thomas

Great tip!  Thanks I will give that a try.

Cheers

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 15, 2017, 06:16:46 PM
I got the swing arm in this afternoon, good tip using the axle as a brace to support the weight.

I swapped out the old swing arm pins for these new ones with a hex head, much easier to adjust than the slot head stock ones

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1778_zpslyjdffkb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1778_zpslyjdffkb.jpg.html)

And replaced the rusted swing arm pivot caps with reproduction units and new rubber insert caps

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1779_zpsiac5rxxd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1779_zpsiac5rxxd.jpg.html)

Several years ago I found a NOS pair of Le Mans MKI shock absorbers on German Bay thinking one day I may find a Le Mans to rebuild,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1781_zpsn3zrfcpq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1781_zpsn3zrfcpq.jpg.html)

washers and fasteners, the inner one is essential to keep the shock from rubbing against the frame or bevel drive

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1782_zpsd0q57dwg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1782_zpsd0q57dwg.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1784_zps2dokz2zf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1784_zps2dokz2zf.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1785_zpsrq90psxf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1785_zpsrq90psxf.jpg.html)

Left shock upper mount secure the top of the lift handle

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1793_zps7gy8lq97.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1793_zps7gy8lq97.jpg.html)

Which is secured through the rear brake line splitter

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1791_zpsznh1qie8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1791_zpsznh1qie8.jpg.html)

Temporarily fitted the front calipers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1794_zpsbcj5izop.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1794_zpsbcj5izop.jpg.html)

And some of the miscellaneous brackets, this one for the harness cable connectors

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1790_zpsdbqe9jvo.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1790_zpsdbqe9jvo.jpg.html)

Relay and the brake line carrier

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1789_zpsr9bmyhhr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1789_zpsr9bmyhhr.jpg.html)

Starter relay and side cover pin

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1795_zpszqkvixhu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1795_zpszqkvixhu.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1797_zpsze2rsfqh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1797_zpsze2rsfqh.jpg.html)

Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on October 15, 2017, 10:09:26 PM
Your work is uncompromising and an inspiration to anyone doing the same.
I have a Mk2 about to start and can only hope to do half as well. No excuses for me though, mine's just like yours was condition wise.
May I ask, what is the distance "eye to eye" of the shocks you fitted ?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on October 15, 2017, 10:50:26 PM
Like the matt finished frame  :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 16, 2017, 09:33:21 AM
May I ask, what is the distance "eye to eye" of the shocks you fitted ?

The shocks are 12 5/8" center to center

Cheers

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on October 16, 2017, 10:10:29 PM
The shocks are 12 5/8" center to center

Cheers

Jim
Thank you Jim.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 16, 2017, 10:40:14 PM
More small bits and pieces coming out of boxes and back onto the bike,

Front fender, I cut the heads off some black bolts I had bought for the ring gear but where not high strength and fitted the studs into the fork legs with lock tight

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1826_zpsoco1juvh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1826_zpsoco1juvh.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1824_zps7ytmfaak.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1824_zps7ytmfaak.jpg.html)

and the front brake cable guides with new rubber grommets

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1825_zps8gk6jwg0.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1825_zps8gk6jwg0.jpg.html)

front signal light bracket attaches to the lower triple clamp  using the pinch bolts and spacers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1807_zpsumnj32u7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1807_zpsumnj32u7.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1809_zpszrlhbgt2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1809_zpszrlhbgt2.jpg.html)

Regulator and coil brackets

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1810_zpsl4fm1pdb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1810_zpsl4fm1pdb.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1811_zps6fkrmd9h.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1811_zps6fkrmd9h.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1812_zps9oskpt2j.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1812_zps9oskpt2j.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1813_zpsttqcevok.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1813_zpsttqcevok.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1814_zpsqu0vrugu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1814_zpsqu0vrugu.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1816_zpsvtniir9s.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1816_zpsvtniir9s.jpg.html)

And the rectifier bracket and fuse box

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1817_zpsjkka6hbl.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1817_zpsjkka6hbl.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1818_zpsrl8rv31h.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1818_zpsrl8rv31h.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1819_zps5a4d5a9e.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1819_zps5a4d5a9e.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1820_zpslrqovyo7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1820_zpslrqovyo7.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1822_zpsyaluxonm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1822_zpsyaluxonm.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1821_zps7qx7ruzc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1821_zps7qx7ruzc.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on October 17, 2017, 02:12:52 AM
Honestly mate, I'm not trying to crawl up your bum, but this is an inspirational Alladin's cave of information to me as someone hoping to emulate your work.
There should be no reason with the guidance you gave given, why my Mk 2 isn't a set successful a job.
I can only try my best and follow your steps. Thank you for sharing so unselfishly.
Would you mind telling me what that Red is please ?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on October 17, 2017, 02:17:54 AM
Agree with Huzo here, you set the standards so high that us other guys can just take it as a example and try to make it just as good!

Sent from my SM-A520F using Tapatalk

Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 17, 2017, 09:19:01 AM
Would you mind telling me what that Red is please ?

I will get the paint code from my painter and post it,

Looking forward to seeing your MKII resurrection, I always liked the body work on the MKII and think its a shame when people turn them into the MKI.

cheers

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on October 17, 2017, 09:35:15 AM
I like that you are going with the original style relays, rectifier & regulator stuff.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 17, 2017, 09:56:48 AM
I like that you are going with the original style relays, rectifier & regulator stuff.

They work OK on my other bikes, I swapped an electronic regulator on my V7 Sport and it turned out to be faulty, same as the second electronic one I installed, finally installed the old one and its worked fine ever since! That took a couple of weeks chasing my tail trying to figure out why the charging circuit wasn't working.

I really think its important to keep these old beasts as original as possible, some other person is eventually going to take over care of this bike and will be relying on its current condition as 'correct'. I would hope that it stays stock for ever. There are some fasteners that I need to change out after looking at SwooshDaves' excellent pictures from the Barber Museum but I need to find a source for 'parkerized' finish on the hex head bolts supporting the top of the shock absorbers and a couple other locations.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on October 17, 2017, 10:06:08 AM
I couldn't agree more for these types of restorations. Plus, make trouble-shooting much easier than if you have odd ball stuff in there.

I think the red-top Magneti Marelli oil-filled coils may be the actual correct ones (no longer available new) used in Guzzi bikes from that era up to '80-'81. Just mentioning in case you wanted to go that far with it.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 17, 2017, 10:16:33 AM
I couldn't agree more for these types of restorations. Plus, make trouble-shooting much easier than if you have odd ball stuff in there.

I think the red-top Magneti Marelli oil-filled coils may be the actual correct ones (no longer available new) used in Guzzi bikes from that era up to '80-'81. Just mentioning in case you wanted to go that far with it.

Thanks!  I will check with Harper's if they have some NOS ones
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on October 17, 2017, 10:36:41 AM
Don't get the knockoff red tops; Those are wax-filled and some leak. The original ones have the word Magneti Marelli in relief type on the Bakelite top. I'm sure you've seen them.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: thomas on October 17, 2017, 03:15:31 PM
Hi
It could just be the camera angle but it looks to me as if your front mudguard is fitted back to front?   The short bit should be forward and the long bit between the wheel and the motor.

regards
Thomas

More small bits and pieces coming out of boxes and back onto the bike,

Front fender, I cut the heads off some black bolts I had bought for the ring gear but where not high strength and fitted the studs into the fork legs with lock tight


(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1824_zps7ytmfaak.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1824_zps7ytmfaak.jpg.html)



Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 17, 2017, 04:33:31 PM
Hi
It could just be the camera angle but it looks to me as if your front mudguard is fitted back to front?   The short bit should be forward and the long bit between the wheel and the motor.

regards
Thomas

Your correct, I had it the other way around but it looked wrong to my eye, checked some images on the web and sure enough I have it backwards. :thewife:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 17, 2017, 05:28:04 PM
Would you mind telling me what that Red is please ?

Painter confirmed this is the colour he used, this was provide by a WildGuzzi member and I am very happy with the results.

Mahindra tractor colour. Omni paint by PPG. brand code 926406 an OEM 4478522.


Black on underside and top of gas tank is Satin Black.

Cheers

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 17, 2017, 05:36:38 PM
There should be no reason with the guidance you gave given, why my Mk 2 isn't a set successful a job.

A couple pictures of the MK II from inside the Moto Guzzi museum three summers past, the paint was faded and the bike was not cleaned up much for display, still a great example of a MK II.

(http://i249.photobucket.com/albums/gg217/canuck750/Moto%20Guzzi%20Museum/P7200249_zps1240cba6.jpg) (http://s249.photobucket.com/user/canuck750/media/Moto%20Guzzi%20Museum/P7200249_zps1240cba6.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/Moto%20Guzzi%20Museum/P7200250_zpsaab59385.jpg) (http://s249.photobucket.com/user/canuck750/media/Moto%20Guzzi%20Museum/P7200250_zpsaab59385.jpg.html)

Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on October 18, 2017, 03:18:24 AM
A couple pictures of the MK II from inside the Moto Guzzi museum three summers past, the paint was faded and the bike was not cleaned up much for display, still a great example of a MK II.

(http://i249.photobucket.com/albums/gg217/canuck750/Moto%20Guzzi%20Museum/P7200249_zps1240cba6.jpg) (http://s249.photobucket.com/user/canuck750/media/Moto%20Guzzi%20Museum/P7200249_zps1240cba6.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/Moto%20Guzzi%20Museum/P7200250_zpsaab59385.jpg) (http://s249.photobucket.com/user/canuck750/media/Moto%20Guzzi%20Museum/P7200250_zpsaab59385.jpg.html)
Yeah, I had a look at when I was there and I recall our Mk2's in Oz, being a orange tinged red, more than the cherry tinge of that one.
Granted it was faded over the years. Do you reckon it has original paint ?
Also is the mirror placement stock ?
Thanks very much indeed for your care and effort in helping.
Huzo.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 18, 2017, 01:11:28 PM
Hi Huzo,

I don't the mirrors on the LM MKII are stock, any pictures I have seen of a MK II had no mirrors at all.

Maybe mirrors where dealer added?

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on October 18, 2017, 08:40:37 PM
That mirror looks to be the same type that was installed on early SPs from the factory.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 18, 2017, 09:01:28 PM
SP 1000 in the museum in the same line up as the Le Mans MKII

(http://i249.photobucket.com/albums/gg217/canuck750/Moto%20Guzzi%20Museum/P7200251_zpsa32c15a8.jpg) (http://s249.photobucket.com/user/canuck750/media/Moto%20Guzzi%20Museum/P7200251_zpsa32c15a8.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on October 18, 2017, 10:21:36 PM
Oh, ok then.
Thanks again for your post.
It has become my "go to" page for inspiration and guidance.
No BS...
BTW, where the hell do you get stuff like a brand new rubber base for the battery tray and other items of that ilk ? It just separates the beautiful resto's from the "almost made it" type of look that I hope to avoid.
And without cringing, I'm gunna be a bit reluctant to show you my Mk2 job having seen yours, but I will use your methods and progression as something to aspire to and do the best I can.
I suppose you just treat every stage as the most important thing at the time and not be afraid to ask questions, but you've demonstrated what can be done !
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on October 19, 2017, 09:08:49 AM
BTW, where the hell do you get stuff like a brand new rubber base for the battery tray and other items of that ilk ? It just separates the beautiful resto's from the "almost made it" type of look that I hope to avoid.

Here in the US, it's all available from MG Cycle, Harper's and Moto International.

http://www.mgcycle.com/index.php?main_page=product_info&cPath=37_209&products_id=597
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 19, 2017, 10:41:45 AM
I see a lot of restorations where the rubber parts, fasteners, hoses etc, have not been replaced. These are relatively cheap to replace and I think when these items look great the rest of the bike looks that much better.

I get most of my rubber bits from HMB in Germany and MG Cycle.

This is a list of the items I usually replace

(http://i249.photobucket.com/albums/gg217/canuck750/Moto%20Guzzi%20Rubber%20Parts/Rubber%20Parts_zpsfzjtuazx.jpg) (http://s249.photobucket.com/user/canuck750/media/Moto%20Guzzi%20Rubber%20Parts/Rubber%20Parts_zpsfzjtuazx.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on October 19, 2017, 08:34:21 PM
Here in the US, it's all available from MG Cycle, Harper's and Moto International.

http://www.mgcycle.com/index.php?main_page=product_info&cPath=37_209&products_id=597
Thank you very much A.C.C.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 19, 2017, 10:01:08 PM
One last assembly to rebuild, the original starter, stripped down for powder coating and to replace the brush pack, check the solenoid and it looks like I should find a better set of outer core windings

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1836_zpsnmjixa5w.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1836_zpsnmjixa5w.jpg.html)

One last box of misc. bits to powder coat, small diameter headlight shell I got from Stien Dinse, seat bracket, signal stems etc..

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1837_zpsdctb8syr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1837_zpsdctb8syr.jpg.html)

I hadn't noticed the instrument bezel was damaged, MG Cycle sells a similar one but its not the same as the repro has the ignition switch cut out, may have to do in a pinch,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1833_zpsskuvfsop.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1833_zpsskuvfsop.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on October 19, 2017, 10:05:04 PM
Is that the same instrument bezel as the T3?


Sent from my iPhone using Tapatalk
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 19, 2017, 10:10:27 PM
Is that the same instrument bezel as the T3?


Sent from my iPhone using Tapatalk

Don't know, does the T3 have its ignition switch in the bezel or on the top of the frame like the Le Mans?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on October 19, 2017, 10:10:58 PM
Don't know, does the T3 have its ignition switch in the bezel or on the top of the frame like the Le Mans?

Frame.


Sent from my iPhone using Tapatalk
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 19, 2017, 10:15:03 PM
Frame.


Sent from my iPhone using Tapatalk

Thanks Dave,

the T3 should be a match, anyone have a nice used one they can part with?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: swooshdave on October 19, 2017, 10:18:22 PM
Thanks Dave,

the T3 should be a match, anyone have a nice used one they can part with?

With all the cafe builds I’m sure they aren’t rare. I bet if you posted in the General area asking if they are the same bezel and if anyone has one you’ll get some good responses.


Sent from my iPhone using Tapatalk
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 20, 2017, 11:13:33 PM
I do my own powder coating on small pieces, mostly because my local coating shop would rather not deal with all the tiny pieces I want coated. An old Westinghouse wall oven tucked under my bench (free on my local small adds paper), and an Eastwood Auto powder gun and powder, very cheap and easy to do.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1839_zpsydzivbye.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1839_zpsydzivbye.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1840_zpsg0hsrljm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1840_zpsg0hsrljm.jpg.html)

I wash everything down with acetone prior to spraying on the powder

Turns out pretty good and it will stand up to abuse

low gloss black and stamped metal for the fairing brackets

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1842_zpsadrqkbqr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1842_zpsadrqkbqr.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1843_zps3umz1dv0.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1843_zps3umz1dv0.jpg.html)

Probably spent less than $10 on powder to get these pieces done
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on October 21, 2017, 09:35:48 AM
Do you do anything different to powder coat chrome pieces, like the headlight trim?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 21, 2017, 03:11:41 PM
Do you do anything different to powder coat chrome pieces, like the headlight trim?

I just run the chrome plated parts over a fine brass wheel in my bench grinder to knock off any flaking chrome.

I got the wheels on this morning

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1864_zpsyhdhydp2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1864_zpsyhdhydp2.jpg.html)

Shimmed the front calipers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1845_zps3q45hv3q.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1845_zps3q45hv3q.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1846_zpsbebeilq2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1846_zpsbebeilq2.jpg.html)

To get the rear brake caliper on I had to back off the left rear shock stud

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1867_zpsvlut1yje.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1867_zpsvlut1yje.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1868_zpsyie3g8pk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1868_zpsyie3g8pk.jpg.html)

Then I lowered the bike onto the lift and dropped the suspension tie downs

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1870_zpsv8mr0slq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1870_zpsv8mr0slq.jpg.html)

Looking like a motorcycle again

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1871_zpsaouphxp8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1871_zpsaouphxp8.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on October 21, 2017, 03:38:36 PM
Looking good!  :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on October 21, 2017, 04:24:58 PM
Bloody genius !
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Psychopasta on October 21, 2017, 09:34:41 PM
Great work!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on October 22, 2017, 06:17:14 AM
Looks great Jim!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 22, 2017, 06:56:52 PM
Thanks for the kind words fellas.

Stripped the carbs down, not too bad inside.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1872_zpsnmjznf7u.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1872_zpsnmjznf7u.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1883_zps1elhtvvy.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1883_zps1elhtvvy.jpg.html)

Suspended across the basket in my ultrasonic cleaner

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1884_zpsj3rup7fn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1884_zpsj3rup7fn.jpg.html)

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.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1885_zpswxrwpj2d.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1885_zpswxrwpj2d.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1886_zpsmcvkwqw0.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1886_zpsmcvkwqw0.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1887_zpsbof3cxqh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1887_zpsbof3cxqh.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1890_zpslhtgk9qw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1890_zpslhtgk9qw.jpg.html)

Then the harness through the cover and steel plate

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1891_zpso3vb40p6.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1891_zpso3vb40p6.jpg.html)

Plug the harness three wires in to the lamp assembly

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1892_zpsa40uckhf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1892_zpsa40uckhf.jpg.html)

Fit the rubber washers onto the studs

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1894_zps9jxgi7qj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1894_zps9jxgi7qj.jpg.html)

And rubber washers on the inside of the fender as well

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1895_zpsckicxzfw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1895_zpsckicxzfw.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1897_zpsrdux1ld5.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1897_zpsrdux1ld5.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1898_zpssn0wvkxo.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1898_zpssn0wvkxo.jpg.html)

Bulbs, gasket and lens and the tail light is done

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1899_zpsski003qd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1899_zpsski003qd.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1900_zpsia0fwpfr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1900_zpsia0fwpfr.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1901_zpsqopfxk4g.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1901_zpsqopfxk4g.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1944_zpsblj7wkye.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1944_zpsblj7wkye.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1945_zpsgobgkyfk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1945_zpsgobgkyfk.jpg.html)

set the fender assembly onto the bike

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1948_zpsxqbwqqpv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1948_zpsxqbwqqpv.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1949_zpszyounies.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1949_zpszyounies.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1950_zpskpwjtg4u.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1950_zpskpwjtg4u.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1947_zpsba5wxtzg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1947_zpsba5wxtzg.jpg.html)

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?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 23, 2017, 10:22:57 PM
Carb parts cleaned and dried

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1956_zpsjozby56a.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1956_zpsjozby56a.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1955_zpstwfihbno.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1955_zpstwfihbno.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo 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.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 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.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: mgmark 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.

(http://thumb.ibb.co/nQFcD6/IMG_0009.jpg) (http://ibb.co/nQFcD6)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on October 24, 2017, 02:57:19 PM
Mine might be a replica reproduction. It's as hard as a bull's arse!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 24, 2017, 10:08:45 PM
assembled the rear caliper

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1957_zpsde2kmoxc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1957_zpsde2kmoxc.jpg.html)

new rigid rear brake line

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1959_zpsgq7t9hpj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1959_zpsgq7t9hpj.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1960_zpscra9khvf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1960_zpscra9khvf.jpg.html)

attached the zinc plated cable guide

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1961_zpsobjmbk56.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1961_zpsobjmbk56.jpg.html)

assembled the clutch perch / lever

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1962_zpsvf9rstlf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1962_zpsvf9rstlf.jpg.html)

grease the spring and ball

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1963_zps2xlonp68.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1963_zps2xlonp68.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1965_zpsmvxncftb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1965_zpsmvxncftb.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1966_zpsy9tczx77.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1966_zpsy9tczx77.jpg.html)

handlebar lock screw

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1967_zpsjfr6whqu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1967_zpsjfr6whqu.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1971_zps5swko6b8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1971_zps5swko6b8.jpg.html)

switches cleaned up

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1972_zps2sm2of3x.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1972_zps2sm2of3x.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1974_zpsq1zovrnk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1974_zpsq1zovrnk.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1985_zpsytonskjj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1985_zpsytonskjj.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1986_zpstbheln56.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1986_zpstbheln56.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1989_zpsgydefzmk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1989_zpsgydefzmk.jpg.html)

Assembled the front master cylinder

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1979_zpszcfe0hgq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1979_zpszcfe0hgq.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1982_zpsm81muhu6.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1982_zpsm81muhu6.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1987_zpspgcpy7nt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1987_zpspgcpy7nt.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1988_zpsyabjpmmm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1988_zpsyabjpmmm.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1990_zpssb8y1oqk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1990_zpssb8y1oqk.jpg.html)



Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on October 25, 2017, 05:31:01 AM
Beautiful work.  Thanks for all of the pictures!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo 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:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Psychopasta 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
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo 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:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 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.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1992_zpsykmpfwud.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1992_zpsykmpfwud.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1993_zpsx7see3mk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1993_zpsx7see3mk.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1994_zpsjhht2vs4.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1994_zpsjhht2vs4.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1997_zpsxv3xefln.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1997_zpsxv3xefln.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1999_zpsr4trgpgb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1999_zpsr4trgpgb.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2001_zpsq0xwjqng.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2001_zpsq0xwjqng.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1995_zpsdcihkuda.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1995_zpsdcihkuda.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2003_zpskbyd9v1v.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2003_zpskbyd9v1v.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2008_zpsfuyxriyb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2008_zpsfuyxriyb.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2002_zpsxaxz8i8q.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2002_zpsxaxz8i8q.jpg.html)

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.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 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/

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2010_zpsazmbltyo.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2010_zpsazmbltyo.jpg.html)

Kit comes with new bushings for the cap and nose piece

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2011_zpsi2kpipwz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2011_zpsi2kpipwz.jpg.html)

Press in easily in a bench vice

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2012_zps6wjxm51s.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2012_zps6wjxm51s.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2013_zps5qo8f4tt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2013_zps5qo8f4tt.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2017_zpsjh1qsoqc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2017_zpsjh1qsoqc.jpg.html)

soldered on the new brushes

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2020_zps2swhgml2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2020_zps2swhgml2.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2021_zpsrdk0pjrj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2021_zpsrdk0pjrj.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2022_zpsghkogmkc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2022_zpsghkogmkc.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2023_zpskbyblkci.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2023_zpskbyblkci.jpg.html)

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$$

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2024_zpsrepd20yf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2024_zpsrepd20yf.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2025_zpsfgkiwnpp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2025_zpsfgkiwnpp.jpg.html)

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.



Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 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,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2032_zpsngn5coql.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2032_zpsngn5coql.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2047_zpsceepfkjx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2047_zpsceepfkjx.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2052_zpsdwinxr1f.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2052_zpsdwinxr1f.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2055_zpsclts7wup.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2055_zpsclts7wup.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/IMG_2053_zps06tbfqzg.jpg) (http://s249.photobucket.com/user/canuck750/media/IMG_2053_zps06tbfqzg.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2060_zps3oihnrpc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2060_zps3oihnrpc.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2062_zpss1mtbyxn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2062_zpss1mtbyxn.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2036_zpsni7docsg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2036_zpsni7docsg.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2065_zpsyw1h3liw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2065_zpsyw1h3liw.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2066_zpspiksmmdr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2066_zpspiksmmdr.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2044_zpsdapo0sjv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2044_zpsdapo0sjv.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2051_zpsbpcium89.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2051_zpsbpcium89.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2064_zps3meo1fjy.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2064_zps3meo1fjy.jpg.html)

And I got the plate holder powder coated and mounted

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2040_zps7lizf8nq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2040_zps7lizf8nq.jpg.html)

Signal flasher holder bracket and rubber

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2048_zps4b5j8id6.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2048_zps4b5j8id6.jpg.html)

and the breather hose

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2058_zpse1mqetly.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2058_zpse1mqetly.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on October 29, 2017, 06:46:25 PM
Lovely :grin: I can almost smell the newness :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Chuck in Indiana on October 30, 2017, 07:36:46 AM
Most excellent as usual, Jim.  :bow:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover 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!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 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.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 30, 2017, 09:27:24 PM
Fairing and headlight fitted

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2074_zpsmtut2bg1.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2074_zpsmtut2bg1.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2075_zpsstnraqbc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2075_zpsstnraqbc.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2076_zpsvx2wcjzq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2076_zpsvx2wcjzq.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2077_zpsbp1fffri.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2077_zpsbp1fffri.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2078_zps0abr6s94.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2078_zps0abr6s94.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2079_zpsbttc4vwt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2079_zpsbttc4vwt.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2080_zpsoejdn0sw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2080_zpsoejdn0sw.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2082_zpsuyj3wel6.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2082_zpsuyj3wel6.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2085_zpsju6cwlve.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2085_zpsju6cwlve.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: smdl on October 30, 2017, 10:27:30 PM
Beautiful!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on October 30, 2017, 11:47:54 PM
Thanks Shaun, what you been building these days?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: smdl 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
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on October 31, 2017, 06:39:20 AM
Jim,

Looking good!  It's getting there.

Ted
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2089_zpsbndtngyx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2089_zpsbndtngyx.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2090_zpsabvtqgis.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2090_zpsabvtqgis.jpg.html)

Same on the opposite side

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2091_zpsc3efsy3i.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2091_zpsc3efsy3i.jpg.html)

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

Rubber washers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2093_zpssiukyya5.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2093_zpssiukyya5.jpg.html)

and the wire retainer on the wheel side

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2094_zpswof5mbm6.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2094_zpswof5mbm6.jpg.html)

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

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2096_zpstvowzb6w.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2096_zpstvowzb6w.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2097_zpsltgjowpi.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2097_zpsltgjowpi.jpg.html)

and fitted the transmission breather hose

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2100_zps3q4zfllv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2100_zps3q4zfllv.jpg.html)

Now to finish the carbs and fit the distributor / electronic ignition, install the dash and instruments, wire harness,........
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on October 31, 2017, 10:00:26 PM
Love your "show", thanks Jim :grin:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo 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.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 02, 2017, 10:11:15 PM
Fitted a pair of new repro rubber hand grips, the original type that have almost no padding and leave your hands numb

And I had a set of repro decals for the original switches, some of the original decals were missing or faded out, these are a decent match and cheap

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2114_zpstfpctuot.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2114_zpstfpctuot.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2115_zpskzwwlxto.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2115_zpskzwwlxto.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2113_zpsnbxfws1m.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2113_zpsnbxfws1m.jpg.html)

Gregory Bender made me a complete new wire harness and all of the sub harness kits, Greg makes perfect copies, if you are rebuilding a Guzzi Greg can make a harness for you, all models.

http://www.thisoldtractor.com/for_sale_wiring_harness.html

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2116_zpss0qaueiv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2116_zpss0qaueiv.jpg.html)

I fitted the main harness, the sub harness kits yet to go in

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2117_zpsbhao9o13.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2117_zpsbhao9o13.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2118_zps5lrwmetb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2118_zps5lrwmetb.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2119_zpsu6zrryvm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2119_zpsu6zrryvm.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2120_zps80llbp8t.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2120_zps80llbp8t.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2121_zpsb3t9gg2w.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2121_zpsb3t9gg2w.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2122_zps4cwy7anf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2122_zps4cwy7anf.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2123_zpshue8s2jw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2123_zpshue8s2jw.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2125_zpsjgxeizu1.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2125_zpsjgxeizu1.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on November 03, 2017, 07:15:48 AM
Looking great!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 06, 2017, 10:50:48 AM
I continue to install the sub harness kits, checking continuity on the RH switch I have a dead line, so I did what I should have done before fitting the switch, pulled it apart to find a lot of corrosion,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2126_zpsgdtv7yyc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2126_zpsgdtv7yyc.jpg.html)

A fine wire brush cleaned up the contacts and I spliced in Greg Benders sub harness to send new wires back to the multi pin plug, fitted a new ground lug contact to the bars and it seems to be solved

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2127_zpsfc688j4f.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2127_zpsfc688j4f.jpg.html)

Lesson learned again, 40 year old bike and everything and I do mean everything needs to be disassembled, checked, cleaned, replaced etc.....
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on November 06, 2017, 11:15:31 AM
Lesson learned again, 40 year old bike and everything and I do mean everything needs to be disassembled, checked, cleaned, replaced etc.....

Looking great Jim, it will be one fine machine when you're done. And I could not agree more with your statement above. All the issues I had with my bike were almost exclusively connected to parts which I thought were good enough and then didn't take apart. So yeah lesson learned EVERYTHING needs to be taken apart and checked. Even the much newer parts on mine like the clutch mastercylinder and so on.

Looking forward to see the next installment of your build. I'm following along with interest even if I don't post everytime. And I'm sure I'm not the only one to do so.

-Ulrik
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 08, 2017, 10:27:03 PM
I received some new Dellorto carb parts today from the world wide Laverda Guru and all around great guy Wolfgang Haerter - Columbia Car and Cycle in Nakusp British Columbia, Canada. Wolfgang stocks an amazing inventory of NOS Laverda parts and a very big stock of Dellorto, CEV, Tomaselli, IKON shocks and other lines of Italian motorcycle parts.

http://www.laverda.ca/

Wolfgang ships world wide and he can find obscure parts for many Italian bikes.

My Laverda 750 SF1 uses Dellorto PHF 36 carbs similar to those on the Le Mans and I had a hard time getting the Laverda to idle and take off smoothly, Wolfgang replaced the atomizers and slides along with O rings, gaskets and fuel valves, needles and jets. Wolfgang tells me that on the non-filter bikes the Dellorto atomizers are due for replacement after 30,000 miles and in most cases the slides are badly worn. Wolfgang sent me new 60/3 slides but the new ones need some machining, the castings on the underside of the slide are too wide for he old carbs, simple machining required

old slide on top, new on the bottom

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2129_zps3erry6pu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2129_zps3erry6pu.jpg.html)

middle slide after machining

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2130_zps0vsl0fuk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2130_zps0vsl0fuk.jpg.html)

The original slides on this LeMans are pretty scored and the new ones fit much tighter. Hopefully these rebuilt Dellortos will provide smooth idle and crisp running.

Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on November 09, 2017, 08:23:22 AM
Crazy to see the many subtle variations of the same part. Did you have to build-up somehow the slide/wall you machined out?

What do those slide walls go over? I don't have a carb in front of me, and my brain isn't pulling up any recent memories of what that carb body looks like in those spots.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 09, 2017, 09:47:08 AM
Crazy to see the many subtle variations of the same part. Did you have to build-up somehow the slide/wall you machined out?

What do those slide walls go over? I don't have a carb in front of me, and my brain isn't pulling up any recent memories of what that carb body looks like in those spots.

Nothing has to be built up, only machined away. The slide base is flat on one side and 'cut away' on the opposite. The cast carburetor body is machined to accept the diameter of the slide + clearance, in the base of the carb along the receiving 'flat' side there is a recess machined into the carb body that the 'wall' of the slide (visible form the underside of the slide) will nest into. If the tabs on the new slide are not machined off the slide can not fully nest into the carb body and the slide will not fully close.

This is the closed side (non cutaway side) of the slide in the fully closed (off) position

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1874_zpssjqjutbd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1874_zpssjqjutbd.jpg.html)

Opposite (cut away) side

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_1876_zpsg8525rlv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_1876_zpsg8525rlv.jpg.html)

When the slide of fully closed the flat base of the slide makes contact with bottom of the cast carb body ' shutting the door'

The idle speed screw fits into one of the cut out ramps that is next to the tab to be machined back.

I don't know why Dellorto cut a ramp on each side of the slide.

s for why these new slides don't fit out of the box, well Dellorto must have changed the carb body casting to accept the tab mass.

Scored and sloppy slides leak air, as air gets by the slide the engine speed picks up.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on November 09, 2017, 01:12:30 PM

The idle speed screw fits into one of the cut out ramps that is next to the tab to be machined back.

I don't know why Dellorto cut a ramp on each side of the slide.


Ah, that's it. The ramp for the needle, makes sense. Having it on each side is likely to accommodate the same barrel/part for both D or S (right or left) carb bodies. Will the steep ramp like that be a problem? Will you need to have a fatter, more rounded (blunt) adjustment needle tip?

I think they exist, probably because of these variations...
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 09, 2017, 02:45:51 PM
Ah, that's it. The ramp for the needle, makes sense. Having it on each side is likely to accommodate the same barrel/part for both D or S (right or left) carb bodies. Will the steep ramp like that be a problem? Will you need to have a fatter, more rounded (blunt) adjustment needle tip?

I think they exist, probably because of these variations...

I will let you know once the new atomizers arrive and I can get the carbs back together

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 10, 2017, 10:04:07 PM
I removed the terminal connectors from the alternator wire harness to slide the reproduction rubber boot over the loom,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2132_zpst77chojx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2132_zpst77chojx.jpg.html)

Refitted connectors

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2133_zpsvqg7vyqj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2133_zpsvqg7vyqj.jpg.html)

Connected the alternator wires to the terminals

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2134_zps3adn1nac.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2134_zps3adn1nac.jpg.html)

And then installed the cover, rubber boot fits into the groove in the alternator cover

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2135_zpsqafcdkug.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2135_zpsqafcdkug.jpg.html)

New ignition switch

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2136_zps5ms74xkz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2136_zps5ms74xkz.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2137_zps1qjv1whn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2137_zps1qjv1whn.jpg.html)

Installed the switch into the steel holder and fitted a repro rubber cover

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2139_zpsaw1rhpeq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2139_zpsaw1rhpeq.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2140_zpswbd0q2d6.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2140_zpswbd0q2d6.jpg.html)

Starter wiring and neutral indicator

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2150_zpszo1excyb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2150_zpszo1excyb.jpg.html)

The bike was missing the brake reservoir level indicator cap, found a good used one, cleaned the terminals up

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2151_zpscboquwit.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2151_zpscboquwit.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2152_zpsiqqzrpvh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2152_zpsiqqzrpvh.jpg.html)

Waiting on parts to finish a lot of jobs off, hopefully they arrive next week.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on November 11, 2017, 03:04:55 AM
Lovely :grin: :thumb: Thanks Jim.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on November 11, 2017, 05:02:46 AM
Great stuff!!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on November 11, 2017, 09:08:16 AM
This thread is like a Bible for me, as a guide for my Mk 2.
Utterly  invaluable...
Title: Re: 1977 Le Mans Rebuild getting started
Post by: thomas on November 11, 2017, 12:16:03 PM
Hi
Popular wisdom reckons it's a good idea to rotate the alternator stator by 120° such that the brush holder moves from the 12 o'clock position to the 8 o'clock position.
When it is in the 12 o'clock position riding over a bump can cause the brushes to momentarily break contact with the sliprings and this is not a good thing. I think this is also mentioned in Guzziology?
Doing this will also give the extra length of the wiring somewhere to go.

regards
Thomas
 

I removed the terminal connectors from the alternator wire harness to slide the reproduction rubber boot over the loom,
SNIP
Connected the alternator wires to the terminals

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2134_zps3adn1nac.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2134_zps3adn1nac.jpg.html)

SNIP

Waiting on parts to finish a lot of jobs off, hopefully they arrive next week.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 11, 2017, 06:23:06 PM
Hi
Popular wisdom reckons it's a good idea to rotate the alternator stator by 120° such that the brush holder moves from the 12 o'clock position to the 8 o'clock position.
When it is in the 12 o'clock position riding over a bump can cause the brushes to momentarily break contact with the sliprings and this is not a good thing. I think this is also mentioned in Guzziology?
Doing this will also give the extra length of the wiring somewhere to go.

regards
Thomas

Great tip, thanks Thomas,

time to rotate the stator!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 12, 2017, 05:02:53 PM
I got a new choke lever from Columbia Car and Cycle, had to scratch my head for a while to figure out how it comes apart to get new cables onto the fitting, flip the lever into full open and then unspin the lever part form the body and pull he lever end free of the cylinder

Powder coated the two bracket parts

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2157_zpstzf1zkcp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2157_zpstzf1zkcp.jpg.html)

Bolt the cylinder head bracket to the cylinder clamp

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2158_zpskroganb5.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2158_zpskroganb5.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2159_zpsp1lctq2x.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2159_zpsp1lctq2x.jpg.html)

And attach the assembly to the left hand cylinder head

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2160_zpsdfwsqfme.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2160_zpsdfwsqfme.jpg.html)

I dug the original seat out of storage, cleaned it as best I could then applied three coats of liquid black shoe polish and shoe protectant clear coat, looks much better, still worn but it has no rips and its original, I am still going to try and repair the new reproduction but not holding my breath

Attached the signal light extensions Greg Bender made up for me, zip tied the separate wires together, fitted new rubber seat bumpers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2162_zpsn9bk7mtp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2162_zpsn9bk7mtp.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2163_zpsssufghil.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2163_zpsssufghil.jpg.html)

And its on the bike

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2164_zps3cjctjo7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2164_zps3cjctjo7.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2167_zpsxlsnlvbb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2167_zpsxlsnlvbb.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2168_zps5wwzsfje.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2168_zps5wwzsfje.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: twowings on November 12, 2017, 07:08:36 PM
This thread is like Zen Meditation for a Guzzi owner!
Seeing your attention to detail and the  fantastic results calms my soul...thanks for sharing it!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on November 12, 2017, 11:16:42 PM
I would not presume to pick anything you have done.
Is the turn indicator lens upside down for a reason ? This is the best thread I've ever seen on this topic, and thank you for your guidance.
Huzo.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on November 13, 2017, 09:33:01 AM
I would not presume to pick anything you have done.
Is the turn indicator lens upside down for a reason.

I have a feeling Canuck750 makes these "mistakes" to see if we are actually paying attention.  :grin:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 13, 2017, 10:36:58 AM
I would not presume to pick anything you have done.
Is the turn indicator lens upside down for a reason ? This is the best thread I've ever seen on this topic, and thank you for your guidance.
Huzo.

Good eye, hadn't noticed that until now, need to check the other 3 :wink:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 14, 2017, 05:34:30 PM
I got this reproduction instrument bezel in today's mail, unfortunately like all the other ones listed online this one has the extra hole cut out for the center mount ignition key, post Le Mans MKI.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2169_zpsklryxdky.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2169_zpsklryxdky.jpg.html)

So I need to come up with a plan to seamlessly cover the key opening

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2170_zpsuktht8ki.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2170_zpsuktht8ki.jpg.html)

So that it looks like this

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P6290095_zpsd3wopogj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P6290095_zpsd3wopogj.jpg.html)

Both the original and the repro have the cast vertical ridge centred on the bezel (painted white on the repro).

I am considering cutting out a flat section of the old bezel, shaping it and gluing it over the opening on the reproduction part.

Any other ideas to make a hole go away that I have not thought of?

On another front the Electronic Ignition also came in from HMB in Germany,

I have never trued the Newtronic ignition but have fitted the Dyna to at least four Guzzi Tonti bikes with dual point distributors. This one is a little different, but it has good simple instructions, anyone have any real world experience with these and have any tips on use?

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2171_zpsw7ub4yhh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2171_zpsw7ub4yhh.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on November 14, 2017, 09:31:08 PM
As for attaching/gluing a flat part over the hole, I can think of two options. 1) Use a circular piece which just covers the hole. 2) make a bigger, six sided piece to correspond with the whole flat area around the hole and glue that.                                                                                       
               Good luck Jim :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: jvb on November 14, 2017, 11:50:21 PM
Or you can cover with Falcon logo MG part number 17517700 as used as the steering stem bung (30mm)
(http://thumb.ibb.co/eEjcoR/17517700.jpg) (http://ibb.co/eEjcoR)

upload multiple pictures (http://imgbb.com/)
. Ignition hole 22mm.

Nice build.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on November 15, 2017, 05:42:43 AM
I was thinking a tight fitting rubber bung may work well
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 15, 2017, 09:33:16 AM
Good ideas, I think I will see if I can find a plug of some sort, the MG cap is nice but I don't want to draw attention to the fix
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on November 15, 2017, 02:55:19 PM
You could turn up a plug in your lathe out of black delrin or something similar and vapourblast it to get the same finish as the original dash has.

-Ulrik
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 15, 2017, 11:05:50 PM
Parking the instrument bezel while I mull over what to do, I may cut out the whole solid piece off the old one and then mate it to the new one, its an all or nothing approach...

So lets build some carbs, I apologize in advance, this is going to take a while .......

the new atomizers and needles showed up today, lots and lots of small parts

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2178_zpsgxcsmlod.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2178_zpsgxcsmlod.jpg.html)

These are the old ones being replaced, most of them look not bad but the minute wear won't be visible to the eye and if the bike doesn't run right then what's the point of rebuilding everything else

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2180_zpsbtlafpxw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2180_zpsbtlafpxw.jpg.html)

Float valve seat gasket

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2181_zpspnxockeh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2181_zpspnxockeh.jpg.html)

Screw in the brass seat and then thread in the new atomizer

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2182_zpsew8w0u92.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2182_zpsew8w0u92.jpg.html)

Main jet holder

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2183_zpsddlswudg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2183_zpsddlswudg.jpg.html)

New main jet - 145

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2202_zpsxmiavaxn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2202_zpsxmiavaxn.jpg.html)

This part, don't know what its called

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2185_zpsvzyzlzql.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2185_zpsvzyzlzql.jpg.html)

low speed jet

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2186_zps6djn5dnt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2186_zps6djn5dnt.jpg.html)

new fuel filter

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2187_zps2h2zzwqw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2187_zps2h2zzwqw.jpg.html)

new gasket on the fuel fitting bolt

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2188_zpsnetaixr2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2188_zpsnetaixr2.jpg.html)

New mixture screw, spring, washer and O ring

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2189_zpskafgrfbx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2189_zpskafgrfbx.jpg.html)

Choke jet with a new O ring

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2190_zpsscgu1vtu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2190_zpsscgu1vtu.jpg.html)

This jet that fits into the top of the accelerator pump body

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2192_zpsgks40bza.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2192_zpsgks40bza.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2193_zps9ge8zp4o.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2193_zps9ge8zp4o.jpg.html)

idle speed screw and spring

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2197_zpsyxttf77z.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2197_zpsyxttf77z.jpg.html)

And this two piece brass part with two O rings

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2198_zpsdmcv1s1d.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2198_zpsdmcv1s1d.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2199_zps8z8d1gnd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2199_zps8z8d1gnd.jpg.html)

New fuel valve clipped t the float

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2200_zpspglefoyq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2200_zpspglefoyq.jpg.html)

Setting the float height

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2209_zps8bmqbaqg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2209_zps8bmqbaqg.jpg.html)

Temporary set the new choke plungers and springs

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2208_zpsvydgeccq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2208_zpsvydgeccq.jpg.html)

New tiny O ring on the choke cable guide body

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2203_zps8uzhwclu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2203_zps8uzhwclu.jpg.html)

New needles, clip on 2nd position

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2206_zpsx2rzwq2r.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2206_zpsx2rzwq2r.jpg.html)

New O ring on the cap

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2211_zpsy11kzmy9.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2211_zpsy11kzmy9.jpg.html)

Secondary throttle cables fitted through the slide, then the needle and clip

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2213_zpslgbg0trh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2213_zpslgbg0trh.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2214_zpsh75qctbs.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2214_zpsh75qctbs.jpg.html)

New diaphragm and gasket

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2218_zpsyjiuzchw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2218_zpsyjiuzchw.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2196_zpssyivsfff.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2196_zpssyivsfff.jpg.html)

Remove the lever set screw

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2219_zpsdv1jpd5z.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2219_zpsdv1jpd5z.jpg.html)

Pull out the shaft

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2220_zpsxvju2wkl.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2220_zpsxvju2wkl.jpg.html)

Then remove the felt seal

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2222_zpsdagu6rp6.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2222_zpsdagu6rp6.jpg.html)

Grease the seal and then fit it back into the cap

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2223_zpsjdtvhfm9.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2223_zpsjdtvhfm9.jpg.html)

Fitted the new Teflon washers either side of the shaft,, tighten the set screw and replaced the top cap.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2216_zpsmn0irdc7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2216_zpsmn0irdc7.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2215_zps1xwhrgtt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2215_zps1xwhrgtt.jpg.html)

The final touch new screended intakes

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2224_zpsdeniaoqr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2224_zpsdeniaoqr.jpg.html)

Hopefully they function as good as they look

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2225_zpshkfn4cy1.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2225_zpshkfn4cy1.jpg.html)

That's a serious looking carburetor

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2226_zps2dk6dwh3.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2226_zps2dk6dwh3.jpg.html)




Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on November 15, 2017, 11:35:31 PM
Bugger it!
It's official, you are in a different league. The fact remains that if your tutorial is followed, similar results should be achievable, but I don't think I'm that good.
(By a fair margin)...
I've posted a few things that have grown some legs, and there's been other beauties, but this is the best thread I've seen, bar none...
As motivation....?
Un paralleled. :bow:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on November 16, 2017, 06:04:44 AM
It's been a long time since I touched carbs....brought back a lot of memories looking at the build up.

Those carbs do look the business!!!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 16, 2017, 02:42:05 PM
The fact remains that if your tutorial is followed, similar results should be achievable,

You can and will produce a great restoration, tackle the work in segments, completing one assembly at a time to keep interest and momentum going.

Looking forward to seeing your LM II, they are rare beasts, I have seen a few CX100's but real LM II's are very rare over here having never been officially imported to North America. I had a chance to buy one two years ago close to me in Canada and passed, I think I made a mistake and should have bought it. I have seen pictures of an original white LM II and I think they look fantastic.

Cheers

Jim
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 16, 2017, 10:19:32 PM
fitting new throttle cables

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2228_zpspprcfukh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2228_zpspprcfukh.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2229_zpsexxqdcdc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2229_zpsexxqdcdc.jpg.html)

grease the throttle body, fit the cables onto the guides

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2231_zpsoqwskogf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2231_zpsoqwskogf.jpg.html)

looks odd but this is the position of the throttle and cables I see on pictures I googled

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2232_zps9hckj78q.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2232_zps9hckj78q.jpg.html)

I routed the fuel lines using Siamese banjo fittings,  on Google the fuel line to the tank routes different from this, probably need to rotate the banjo counter clockwise 90 degrees, the 6 o'clock fitting would then loop a fuel line up to the petcock.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2236_zpsiomgdfgu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2236_zpsiomgdfgu.jpg.html)

replaced the cap screws and the cable guide screws with new cad plated fasteners, I get picky about not leaving any fastener on a bike that is going to quickly corrode when exposed to moisture. I see a lot of nice builds only to be let down by corrode fasteners, new bolts, screws and nuts are cheap and re-plating existing ones is cost effective

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2237_zpsqpozf2dr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2237_zpsqpozf2dr.jpg.html)

this is the first time I worked on PHF36 carbs with the top cap linkage (Laverda do not use the same top lever assembly on their PHF36 units), impressed with how the throttle cables attaches to the carb, so simple to install or replace the cables without having to pull the slides as on the VHB series or the Laverda equipped PHF units.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Sporteous on November 16, 2017, 11:40:53 PM
I'm about to fit these same carb tops onto my Mock 1 (SP1000 pretending to be a Mk1 or 2), my question is are the carbs on the wrong sides? Shouldn't the cable holders be facing inwards?
Beautiful work, I believe I have admired your SF750 on the Laverda forum also, I used to have a 3CL 1000 until recently.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 17, 2017, 10:17:57 AM
I'm about to fit these same carb tops onto my Mock 1 (SP1000 pretending to be a Mk1 or 2), my question is are the carbs on the wrong sides? Shouldn't the cable holders be facing inwards?
Beautiful work, I believe I have admired your SF750 on the Laverda forum also, I used to have a 3CL 1000 until recently.

Well I will be damned if they the carb tops are not reversed!! :embarrassed:

Thanks for correcting that for me, should have taken a better look at my record pictures

Not like I don't have at least 200 pictures of the 'old' bike'

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P6290060_zpsbv40igvb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P6290060_zpsbv40igvb.jpg.html)

I am getting to step aside from bike building (and that work thing) for a short get away to go ride in Arizona with my two sons for four days starting Sunday, can barley wait to get out of the snow and cold!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: balvenie on November 17, 2017, 05:20:17 PM
have a good ride, Jim :thumb:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on November 17, 2017, 11:42:46 PM
Why has the left carb got a "filter" and the right one a bell mouth ?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on November 18, 2017, 09:09:53 AM
Why has the left carb got a "filter" and the right one a bell mouth ?

The photo with the bellmouth is "after", the photo with filter was taken "before".
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 18, 2017, 11:44:08 AM
I swapped the carb tops side to side, and rotated the fuel hose banjo, now this looks correct

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2241_zpshweat187.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2241_zpshweat187.jpg.html)

Got into the distributor as well, replaced the advance springs, the shaft does not sound great, need to tear it down and see what's up

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2239_zps8ce7tomt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2239_zps8ce7tomt.jpg.html)

All for now, I step on plane heading south to sunny Arizona this afternoon to ride around Phoenix and Tuscon for four days. My yearly long weekend get away ride wit my two sons.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: SED on November 19, 2017, 08:55:11 PM
Beautiful work.  Your skill and patience I aspire to.
Thank you.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 23, 2017, 09:52:29 PM
Got the header and crossover back from the ceramic coater, Charlie pointed me in the direction of a seller with the stock header and cross over, thanks Charlie!

Ceramic coated the flange and fitted new two piece compression clamps

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2244_zpsay8wd2ek.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2244_zpsay8wd2ek.jpg.html)

The ceramic coating is tough but it does mark quite easily

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2247_zpsvhz06awb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2247_zpsvhz06awb.jpg.html)

I fitted a new pair of LaFranconi reproduction mufflers, the reproduction is so close to original right down to the shamefully terrible paint job

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2248_zpslc9pnkmz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2248_zpslc9pnkmz.jpg.html)

Left Side too shiny, right side dull and patchy

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2250_zpsycdjo0n7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2250_zpsycdjo0n7.jpg.html)

The paint on the mufflers is so lousy it starts to wipe off with wax remover!!

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2254_zpstbqni0to.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2254_zpstbqni0to.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2256_zpswqxwapte.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2256_zpswqxwapte.jpg.html)

I will take them off and get them ceramic coated, really disappointed in how LaFranconi can sell a new pair of mufflers so poorly finished!

Back to the distributor, I have another one in my stash that turns very smoothly and the points plate is not corroded, the numbers stamped on the distributors is not the same and the spare one I have has an O ring fitted into the body, the one that came on the bike does not have an O ring

Le Mans stock distributor

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2258_zpsuxyc3pmp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2258_zpsuxyc3pmp.jpg.html)

My spare with an O ring

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2259_zpswquxdzya.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2259_zpswquxdzya.jpg.html)

Anyone know if I can fit the O ring style distributor?

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2260_zps69vad17k.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2260_zps69vad17k.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2261_zpsmwk4tlwf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2261_zpsmwk4tlwf.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2262_zps83poe5le.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2262_zps83poe5le.jpg.html)

Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on November 24, 2017, 08:46:35 AM
Not a terribly difficult job to rebuild the original distributor. Bearings are 6001-RS1, the o-rings are the same as the ones for the cylinder studs. The hardest part is removing the pin securing the drive gear to the shaft.
http://thisoldtractor.com/moto_guzzi_tonti_distributor_disassembly-_bearings-_and_.html
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 24, 2017, 11:41:21 AM
Not a terribly difficult job to rebuild the original distributor. Bearings are 6001-RS1, the o-rings are the same as the ones for the cylinder studs. The hardest part is removing the pin securing the drive gear to the shaft.
http://thisoldtractor.com/moto_guzzi_tonti_distributor_disassembly-_bearings-_and_.html

Thanks Charlie!

Do you know if the distributors are interchangeable?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on November 24, 2017, 12:18:03 PM
Thanks Charlie!

Do you know if the distributors are interchangeable?

Sorry, I don't.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 25, 2017, 01:01:06 PM
Thanks Charlie for passing me on to the distributor rebuild info, picked up a pair of bearings today, one of them was shot

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2272_zps0o0voy8k.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2272_zps0o0voy8k.jpg.html)

Getting the pin out of the gear was a treat, now I need to find a similar pin to press back in and peen over

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2271_zpsas9jmxxh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2271_zpsas9jmxxh.jpg.html)

The roll pin for the shaft retainer came out easily enough

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2269_zps1rogonwn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2269_zps1rogonwn.jpg.html)

O rings are rock hard
Title: Re: 1977 Le Mans Rebuild getting started
Post by: pushrodtwin on November 25, 2017, 01:21:00 PM
You are doing a wonderful job on both of these bikes, & someone needs to restore the occasional Benelli. I owned a 650 Tornado once, it was in better condition than yours, I did ride a little & it had some endearing attributes. Cant remember what they were!  However, for one as bad as yours I would have considered using it as donor for more worthy projects.  :grin: The headlight bucket, for example is the same as a V7 Sport, the wheels & forks are great for specials, I used the 38 Marzzochis in my Egli Vincent after I cut 40mm off the stanchions & sliders.  :grin:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Antietam Classic Cycle on November 25, 2017, 03:11:34 PM
Getting the pin out of the gear was a treat, now I need to find a similar pin to press back in and peen over

I use a roll pin there also, IMO it's more than adequate for the job. I have a whole baggie of them sent to me by Greg Bender, but that doesn't help you any.  :wink:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 25, 2017, 08:57:28 PM
I fitted a new roll pin into the retainer ring and a section of hard steel rod through the gear and then heated the ends of the rod and peened them flat,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2294_zpsgwlkzz7v.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2294_zpsgwlkzz7v.jpg.html)

powder coated the points plate, the electronic ignition uses optical scanners so I don't think a lack of a ground to the distributor body is an issue but I could be wrong,...

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2295_zpsmbtv5enc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2295_zpsmbtv5enc.jpg.html)

Newtronics 'cameras' replace the points

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2296_zpse7tmr2g5.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2296_zpse7tmr2g5.jpg.html)

I fitted a new O ring, this one was way too thin and the clamp would not tighten enough to hold the distributor, out it came a much thicker O ring fitted, seems to be correct

and smoothed out the lower body of the distributor casting so it would not bind with the block

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2301_zps5ihrkiiy.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2301_zps5ihrkiiy.jpg.html)

I needed to file off the rectangular tab on the underside of the distributor cap, a thick rubber spacer is used between the distributor and the cap

I cracked the plastic rotor fitting it over the cam, new one on order, thank goodness HMB sells individual replacement rotors, need to be 'very gentle' fitting the plastic rotor on.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2302_zpstb2phuxi.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2302_zpstb2phuxi.jpg.html)

Wires exit the front of the distributor

Those Guzzi engineers sure didn't leave any wasted space around the distributor, small fingers and a crow foot wrench needed to tighten the clamp bolts

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2303_zpsu8mlqete.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2303_zpsu8mlqete.jpg.html)

Next to connect the ignition module and high tensions coil leads
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on November 26, 2017, 08:32:06 AM
 :popcorn:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: SED on November 26, 2017, 09:03:40 PM
Looking great!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on November 26, 2017, 09:08:48 PM
Your skill is so far above mine it's laughable and I can accept that.
But where the bloody hell do you get so much patience !!!?
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 27, 2017, 10:34:45 AM
Your skill is so far above mine it's laughable and I can accept that.
But where the bloody hell do you get so much patience !!!?

I never show pictures of the north wall of my garage where I often fling a tool in anger against the wall :embarassed:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on November 27, 2017, 10:50:22 AM
What is the process for ceramic coating? Is it just ceramic based enamel then baked at a certain temp? Why do you think it marks/scuffs easily? Is it the nature of the beast, or did the tech doing the work mess-up somehow? (that's 4 questions in 1-2 lines  :azn:)

Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 27, 2017, 04:48:57 PM
What is the process for ceramic coating? Is it just ceramic based enamel then baked at a certain temp? Why do you think it marks/scuffs easily? Is it the nature of the beast, or did the tech doing the work mess-up somehow? (that's 4 questions in 1-2 lines  :azn:)

I don't know much about the ceramic process other than the metal is prepped the same as for powder coating and the coating is sprayed on and is quite thin, it does not fill in like powder. If the base part has nicks or pits on the surface the ceramic coating will not hide the imperfections.  The header that came with the bike was full of rust pits and after blasting and coating it looked pretty poor, I was lucky to find a very good used one to have coated.

The matte black scuffs about the same as it would if the part was painted, doesn't scuff through to the base metal but it marks if rubbed by a tool or for instance the exhaust collars slide down the header when installing the headers (ask how I know). Powder coat is much more durable for abrasion and you can polish up powder coat. The up side is that the ceramic finish does not wear off from heat / cool cycles and washing like a typical dirt bike header does. The header / muffler will also be much cooler to the touch when running.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 27, 2017, 09:55:49 PM
I fitted the Newtronic black box to the inside of the rear splash guard, similar location to the fuse box location on a V7 Sport so it shouldn't interfere with the battery.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2316_zpsicuzfeql.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2316_zpsicuzfeql.jpg.html)

The Newtronic kit comes with a set of green and red leads that plug into the wire harness leads of the original distributor points connectors, the length of wires just needs to be trimmed and a pvc sheath added to make it look stock

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2315_zpslthwadgj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2315_zpslthwadgj.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2314_zpsvp70a8eb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2314_zpsvp70a8eb.jpg.html)

The white wire coming out of the multi pin plug goes down to the coil 12v + tab on the coli

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2317_zpsml3msjxs.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2317_zpsml3msjxs.jpg.html)

And that's about it for the electronic ignition, just need to fit a new rotor on the distributor cam and then check the timing

New high tensions leads

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2318_zpsthkcl4r7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2318_zpsthkcl4r7.jpg.html)

I set the high tension wire in a vice to drive the brass connector over the end of the wire

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2319_zpsyckovwcq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2319_zpsyckovwcq.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2320_zpsina8flmx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2320_zpsina8flmx.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2321_zpsn82u6ezu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2321_zpsn82u6ezu.jpg.html)

Two coil connections finished

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2322_zpsylon68ju.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2322_zpsylon68ju.jpg.html)

And the plug ends terminated

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2323_zpsf6tk2b6m.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2323_zpsf6tk2b6m.jpg.html)

Back to the instruments, I cut the blank cap piece off the damaged bezel

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2324_zps0p8sdcob.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2324_zps0p8sdcob.jpg.html)

And I glued it over the new bezel with abs cement

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2325_zpsv0a3ttyz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2325_zpsv0a3ttyz.jpg.html)

fitted the gauges

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2326_zpsbgvs3vsx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2326_zpsbgvs3vsx.jpg.html)

and then the sub wire harness

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2327_zpsfaqzrjuw.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2327_zpsfaqzrjuw.jpg.html)

and the rubber isolators

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2328_zpsdowtgtub.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2328_zpsdowtgtub.jpg.html)

tach and speedo cables fitted before I secure the bezel

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2329_zpsf6llelfi.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2329_zpsf6llelfi.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2330_zpslk0jhzrl.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2330_zpslk0jhzrl.jpg.html)

I had to carefully bend the steel ends of the tach and speedo cables to turn 90 degrees and clear the headlight bucket

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2331_zpshh9uqpkr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2331_zpshh9uqpkr.jpg.html)

while the fairing was off I fitted the rubber trim around the headlight opening, that was a royal pain to get on!

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2333_zpsnttx2iyb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2333_zpsnttx2iyb.jpg.html)

the windscreen goes on after the fairing is attached, getting the nuts on to the inside of the fairing to secure the screen took me the better part of an hour, no room to get fingers in, just a very long needle nose plier and a screwdriver to turn the screw, it helped to loosen the handlebars and fold them in to get more room to the back of the fairing

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2335_zpsykmkndx1.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2335_zpsykmkndx1.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2334_zpsgmnio5lk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2334_zpsgmnio5lk.jpg.html)

just a few more wires to connect and the electronics is hopefully done

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2336_zpsx6k57zz7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2336_zpsx6k57zz7.jpg.html)

riders view

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2337_zpsw0rqmuca.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2337_zpsw0rqmuca.jpg.html)
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on November 28, 2017, 04:59:53 AM
Jim,

Looks like some great dremel work on the bezel!

As always, great patience and outcome.

Ted
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Rick4003 on November 28, 2017, 06:39:34 AM
Looks the business!

Sent from my SM-A520F using Tapatalk

Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 28, 2017, 09:39:38 PM
Finished a few small details, fitted a pair of 8mm bolts with aluminum sealing washers to the top of the FAC dampers

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2338_zps7g7n2l6j.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2338_zps7g7n2l6j.jpg.html)

The swing arm cap nuts are stainless steel reproductions and the cap is much thicker than the old steel ones so the plastic plug does not seat into the cap and they keep trying to free themselves from the cap so I spun the cap off and took my soldering gun, melted the inside of the plastic cap and peened the plastic over with the blunt end of a punch.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2339_zpswicisy7r.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2339_zpswicisy7r.jpg.html)

Installed the battery ground wire and the speedometer cable

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2340_zpsiogwg6of.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2340_zpsiogwg6of.jpg.html)

Replaced the old suspect relay with a new one Greg Bender supplied with his wire harness kit

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2341_zps5rqwuf9m.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2341_zps5rqwuf9m.jpg.html)

Installed the tachometer cable

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2342_zpsyon5btfk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2342_zpsyon5btfk.jpg.html)

Terminated the front signal light leads and placed the signal light ground wires on a frame lug

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2343_zpskoq3f1g7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2343_zpskoq3f1g7.jpg.html)

And fitted a round female plug end onto the oil pressure sender wire

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2344_zpsmrhdvghp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2344_zpsmrhdvghp.jpg.html)

MG Cycle has the choke cables back in stock so once they arrive that should be the last new parts I need to fit.

Then to fit a battery and start checking all the electrical is working.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Huzo on November 29, 2017, 12:16:18 AM
Beyond description...
And I don't believe the tool throwing thing...
You're above that.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on November 29, 2017, 01:29:31 AM
You are really doing a great job on this bike, it's getting a lot of love! As far the caps go, the OEM plugs for the swing arm caps were rubber originally and would actually work at snapping in. The new repro ones out there are hard plastic and don't really work (as you found out too). I don't think they snap in on the steel oem caps either, do they?

With the plugs being pre-snapped in like that, how are you going to fine tune the swing arm bolt adjustment? Sometimes tightening the cap will also spin the swingarm bolt making it too tight, so you might need to hold it with and Allen wrench and use a wrench (not socket) to tighten the cap, which brings me to another point... if I remember correctly, those tighten at a pretty high ft/lbs rate, and in my experience SS doesn't do too well in those cases. Might be ok in your case being those are large diameter bolts. I just question reproduction SS hardware out there on the market a lot after learning their properties (pros and cons), and I just wonder if they actually test their applications properly, or do they just make SS 'stuff'.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on November 29, 2017, 01:47:46 AM
Ok, just looked up the torque specs, and it looks like the caps tighten at 57 ft/lbs. I thought they were ones with crazy high 120 or so values.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 29, 2017, 09:44:54 AM
The stainless steel cap nuts have a thicker body to the top, the depth of the hole is deeper so neither the original rubber plug or the new plastic ones will properly fit. The design is a carry over from the Loop Frame bikes that used a pivot pin that has two holes drilled into the face to accept a 2 pin wrench that can only be fit with the cap off. I don't believe that Guzzi intended to use the cap plug as means of adjusting the pivot pin. I think the purpose of the cap is to lock the position of the pivot pin. I replace the 2 pin type pivot bolt with the newer socket head design, much better than the original 2 pin or the later flat blade type adjuster pin. When I install the pins I oil them and tighten them right up then back them of just a smidge, fit the cap finger tight then give it a twist with a great big open end wrench. I agree that stainless steel is the not the right product for a stressed fastener but the large diameter of the cap probably equates to significant strength for the specified torque, and it looks pretty :wink:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 29, 2017, 09:36:43 PM
A finishing touch, fitting the reproduction side covers

new badge crimp clips

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2345_zpsb4dlz0xb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2345_zpsb4dlz0xb.jpg.html)

gently push them flush to the outside of the cover

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2346_zpsofohxxhh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2346_zpsofohxxhh.jpg.html)

start the emblem, flip the cover over with the emblem on a flat bench and push the cover over the emblem pins, slowly!

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2347_zpswwkrsry5.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2347_zpswwkrsry5.jpg.html)

Nice original emblems cleaned up nice

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2348_zps7foeqqh2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2348_zps7foeqqh2.jpg.html)

Now to fit the rubber grommets, problem is the fiberglass is formed 3 x as thick as it should be to allow the grommet to snap into place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2349_zpslityzgro.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2349_zpslityzgro.jpg.html)

out comes the dremel again, this is nerve racking, cutting enough of the fiberglass down and hoping not to hit an air bubble in the gel or crack the tab

1st to ream out the holes so to the right size

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2350_zpsutdkrsus.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2350_zpsutdkrsus.jpg.html)

and very slowly get down to this

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2351_zpsqzpikkqb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2351_zpsqzpikkqb.jpg.html)

Only punched two holes in my thumb pressing the grommets into position with a fine flat blade screw driver

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2352_zps2lossq4b.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2352_zps2lossq4b.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2353_zpsqdyiz25i.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2353_zpsqdyiz25i.jpg.html)

And then it binds on the brake arm

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2354_zpsmjzwi0bo.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2354_zpsmjzwi0bo.jpg.html)

more trimming and a black sharpie to touch up the ground edge

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2356_zpsdcjfprbf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2356_zpsdcjfprbf.jpg.html)

left side went on without issues

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2359_zpsmtxsj2sh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2359_zpsmtxsj2sh.jpg.html)

tight carb clearance on the left

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2360_zpscj4myw6p.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2360_zpscj4myw6p.jpg.html)

lots of room on the right

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2361_zpsx4ofk7eo.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2361_zpsx4ofk7eo.jpg.html)

a 10 minute job that only took 2 hours :thewife:
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on November 30, 2017, 06:08:01 AM
Jim,

Great detail work and patience as always!

What's the deal with the reproduction cover?  Is the quality so poor that it is not manufactured to the same dimensions as the original ones were?  Is that typical of reproduction parts for the older bikes?

Ted
Title: Re: 1977 Le Mans Rebuild getting started
Post by: Groover on November 30, 2017, 08:42:32 AM
Loving that deep red color. Everything is looking great!
Title: Re: 1977 Le Mans Rebuild getting started
Post by: canuck750 on November 30, 2017, 09:37:02 AM
Jim,

Great detail work and patience as always!

What's the deal with the reproduction cover?  Is the quality so poor that it is not manufactured to the same dimensions as the original ones were?  Is that typical of reproduction parts for the older bikes?

Ted

I bet the mold was taken off an original side cover and then fiberglass laid up without regard for the thickness, the top edge is thin like the original but the face and flange is very thick, typical of fiberglass reproductions, originals are plastic and on this bike (and most others probably) the tabs that hold the grommets are broken. To remove the side cover care must be taken to grasp the back side of the grommet and fiberglass and gently pull the grommet free of the steel pin attached to the frame. I have had reproduction parts for other  bikes and at best the fit is adequate, similar to the fairing one has to drill all new mounting holes and transferring the original hole locations with a paper pattern can be tough, especially on compound curves like the fairing. It would be great if the folks that made the reproductions drilled all the holes.
Title: Re: 1977 Le Mans Rebuild getting started
Post by: TRw1 on November 30, 2017, 03:19:45 PM
Interesting stuff.  Thanks for the education.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 02, 2017, 09:37:21 PM
Fitting a pair of new petcocks, I hate risking a fire on old leaky petcocks,

I punch a mark at the OFF position and wipe a dab of red paint into the recess so there is no confusion on when the petcocks are turned off

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2373_zpsctduhacn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2373_zpsctduhacn.jpg.html)

Flip the gas tank over, wind some Teflon tape on the fuel lugs

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2374_zpsdn1h9mrs.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2374_zpsdn1h9mrs.jpg.html)

Then with a 19mm and 22m open wrench turn the petcock nuts onto the lugs and tighten the petcock body down

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2375_zpsg5rcvwrf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2375_zpsg5rcvwrf.jpg.html)

A new rubber fuel tank back retaining strap

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2369_zpsd1ge6ufc.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2369_zpsd1ge6ufc.jpg.html)

Fit the strap metal loop under the frame tab and then pinch the frame tab to close around the strap so it does not fall off when the tank is lifted off

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2370_zpsxg7gtyx7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2370_zpsxg7gtyx7.jpg.html)

Carefully tilt the gas tank forward and up over the front frame rubbers and tilt the tank down until it rests on the frame rubbers, pull the rubber strap up and over the gas tank tab

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2405_zpsvhbqr9mf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2405_zpsvhbqr9mf.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2382_zpsndmj0eeb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2382_zpsndmj0eeb.jpg.html)

Repro gas tank emblem pins are too long and need a couple mm ground off,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2376_zpsn4qjfosq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2376_zpsn4qjfosq.jpg.html)

I then add mounting tape to the back side of the emblems, I don't trust the crimp clips to hold the emblem tight

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2378_zps5cns8h6n.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2378_zps5cns8h6n.jpg.html)

Fit the pins into the crimp clips, press firmly, you get one chance to get it right with the tape

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2379_zpsv5o1u99p.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2379_zpsv5o1u99p.jpg.html)

and the other side

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2380_zpsawioajuf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2380_zpsawioajuf.jpg.html)

Polish up the gas cap

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2381_zpstmrdvabi.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2381_zpstmrdvabi.jpg.html)

Looks the business if I do day so myself

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2383_zpswthnrdgm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2383_zpswthnrdgm.jpg.html)

Fitted the seat strap, right side has the removable clip

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2388_zpsbdc6xzvs.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2388_zpsbdc6xzvs.jpg.html)

through bolt on the left

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2389_zps73waxa5f.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2389_zps73waxa5f.jpg.html)

clutch perch mirror threads where stripped, drilled the hole out for a 10mm helicoil

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2390_zps4oryvrms.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2390_zps4oryvrms.jpg.html)

Tap

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2391_zps28ufimg1.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2391_zps28ufimg1.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2392_zpsha1qdhuq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2392_zpsha1qdhuq.jpg.html)

10mm helicoil with red locktight

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2393_zpsvtordnuo.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2393_zpsvtordnuo.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2394_zpslreshfya.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2394_zpslreshfya.jpg.html)

Helicoil seated

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2395_zpsxxfrolcy.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2395_zpsxxfrolcy.jpg.html)

I had a pair of these chrome mirrors kicking around, I think chrome mirrors belong on 70's bikes

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2398_zpstlfzxerz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2398_zpstlfzxerz.jpg.html)

I am sure others would prefer bar end mirrors but not me

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2399_zpsjzh3idft.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2399_zpsjzh3idft.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2400_zpsrfh3bpci.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2400_zpsrfh3bpci.jpg.html)

Fuel line fitted to the new tap

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2404_zpspkwdcg3f.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2404_zpspkwdcg3f.jpg.html)

Now the trouble shooting, getting it running and sorted out

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2387_zps7crvs47l.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2387_zps7crvs47l.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2386_zpsxgrymodv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2386_zpsxgrymodv.jpg.html)
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Rick4003 on December 02, 2017, 11:40:36 PM
Hi Jim

I have to agree with you, it really does look the business!  :drool: It is most certainly better than when it left the factory  :bow:


Fuel line fitted to the new tap

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2404_zpspkwdcg3f.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2404_zpspkwdcg3f.jpg.html)




Are you going to fit some sort of clamp or retainer ring on the fuel lines or will you just keep it like that? I always put hoseclamps on, although I'm not really sure if they are necessary. I just like the extra security from it.

-Ulrik
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Huzo on December 03, 2017, 12:10:39 AM
It would be an insult to ask and I would not expect an answer.
Put as tactfully as I can...
To produce a result as mouth wateringly beautiful as you have, do you have to spend more than the bike will be "worth" to the fortunate new owner, or is the money spent, reflected in the enhanced value of the finished machine ?
I know that a work of art like yours is worth more than the sum of it's parts and as a step by step guide to a fabulous re birth of an acclaimed classic, your generosity in allowing us into your Alladin's cave of wisdom, patience and skil has a value for me that can't be quantified.
As I said once before, I'm about to embark on the same journey with a Mk 2, and if I fall short, (as I certainly will), of your standards, I can blame no one but myself.
Nothing you have done is "hard" if looked at in isolation, but the wholistic nature of your approach to this work is inspirational and as a guide to success is invaluable.
I will copy and print it into a manual for my journey.
Thank you very much for your willingness to share..
Huzo.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Huzo on December 03, 2017, 12:12:49 AM
Do you mind telling me what the dayglo orange colour is on the fairing ?
Title: Re: 1977 Le Mans Rebuild almost done
Post by: TRw1 on December 03, 2017, 06:57:58 AM
Jim - it is looking fantastic!  Hopefully, the troubleshooting will go well.  Those following this thread are anxiously awaiting next steps!

Ted
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Groover on December 03, 2017, 07:16:33 AM
looking very very nice  :bow:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 03, 2017, 10:28:28 AM
Are you going to fit some sort of clamp or retainer ring on the fuel lines or will you just keep it like that?
-Ulrik

The lines are just temporary for now, I will hang a gasoline bottle connected to the carbs to fire up the bike and tune it. Fuel lines will definitely go on once the tuning is done.

I still need to install the choke cables so the tank will probably come off a couple times before I am really done.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: swooshdave on December 03, 2017, 11:42:08 AM
Sorry to have to say this but those mirrors are not worthy of such a beautiful bike.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 03, 2017, 04:14:05 PM
It would be an insult to ask and I would not expect an answer.
Put as tactfully as I can...
To produce a result as mouth wateringly beautiful as you have, do you have to spend more than the bike will be "worth" to the fortunate new owner, or is the money spent, reflected in the enhanced value of the finished machine ?

Huzo.

This is a tough question to answer, my long winded 2 cents;

I started restoring motorcycles about 15 years ago moving on from working on cars beside my father (an autobody mechanic) since I was old enough to hold the oxy/acet torch for him. Initially I worked on tiddlers, no money, few tools and little knowledge, Honda S65, S90, Yamaha YL1,  then moving up to Yamaha 350cc twins, and a stint with Yamaha 500 singles. I never kept a single bike I rebuilt, sold it as soon as I got it sorted to fund the next project. I never made any money, it would cost me a couple hundred bucks per bike it was and is my hobby. 

A lot of people have asked me how I can sell a motorcycle restoration at a loss!! My response every time is to question them how much they get paid to golf, or fish, or play baseball, or whatever they fancy in their free time.

Back in 2011 I was looking for something new and different, wanted a cruiser to rebuild but I don't care for the metric stuff, Harleys don't interest me and I can not afford an Indian, then I saw a picture of a Moto Guzzi Eldorado and I was smitten. I bought a basket case 72 Eldorado off Ebay, shipped the wreck from Florida to my home in western Canada and over the course of a year ended up sinking in more than $10K into it. I will never get my money put of the Eldorado but it is my favorite motorcycle, I love the ride, feel and look of it and it has been very reliable.

I got hooked on Moto Guzzi but realized if I was going to  drop that kind of money into a restoration I better start with a motorcycle that in the right market can demand top dollar, at present market values I think that limits the choices to the V7 Sport, 750S, 750 S3 and the Le Mans MK I and MKII and perhaps the much newer 1000S. Same analogy as restoring a 1965 Ford Falcon or a 1965 Ford Mustang GT, both will cost the same to restore but the Mustang is 2 to 3 times more valuable on the market.

I have only sold one of my Guzzi restorations to date and my goal in that case was to recover what cash I had into the bike and a couple bucks for my labour. I think if one is very lucky finding the right buyer and the workmanship is up to scratch then recovering ones cash is possible. Having gone through half a dozen nut and bolt restorations I can safely say that at least $8K will be spent on the restoration, probably more and then add in the purchase price of the bike and it should total less than current market value, if not then just realize that when it comes time to sell there will be a loss.

Given present market values of a top flight restored Le Mans MKI being in the $16 ~ $20K USD  range, the purchase price needs to be in the $8K range to make the restoration feasible. Any Le Mans MKI is at least 40 years old and regardless of how well it was looked after it needs to completely come apart and a lot of it will need rebuilding or replacing. I don't think one can realistically expect to get top dollar for a restoration unless every single component has been addressed and there are the receipts and photographs to prove it.

On this bike I am going to break the $16K USD investment and probably get close to $18K in the end, but I have really enjoyed saving this one and I have again learned a lot more about the brand and model.

I will likely rebuild another Guzzi but at present I am interested in Benelli and Moto Morini as well and have a couple restorations projects waiting.

Cheers

Jim
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 03, 2017, 04:15:53 PM
Do you mind telling me what the dayglo orange colour is on the fairing ?

I will ask my painter for the formula and post it here.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 03, 2017, 04:20:31 PM
Sorry to have to say this but those mirrors are not worthy of such a beautiful bike.

They are a 'particular' taste aren't they! :azn:

The bike came with a set of black bar ends,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P6290054_zpsldbrlyby.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P6290054_zpsldbrlyby.jpg.html)

I am loath to cut the handgrips though, and I  don't particularly like bar ends to begin with, need to keep looking.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Groover on December 03, 2017, 05:53:15 PM
Searched some mirror options in hopes to suggest something great, but turns out the lemans (any model) just look best without  :evil:

I spent a lot more than I was anticipating once I got into stuff when I restored my G5. I also obsessed over finding as many old stock OEM parts as I could, including many bolts, washers, rubber parts, etc. which added to the challenge of the hunt for parts and cost. I only did surface stuff to the engine though since it seemed to be still ok, and the thought of going deeper was overwhelming at that point. Decided that I�ll either never do that (lacking some confidence in that department), or save it for later on, or even let the next owner do that.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: swooshdave on December 03, 2017, 06:12:49 PM
If the bike is being built to sell I’d leave the mirrors off and let the new owner decide what they want. At the top dollar this bike deserves it may not see the road and mirrors would be superfluous.


Sent from my iPhone using Tapatalk
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Huzo on December 04, 2017, 12:46:40 AM
I will ask my painter for the formula and post it here.
Thank you very much for the paint info.
Also your response is not long winded, every word a gem and I will read it over several times to digest your meanings fully.
We are fortunate to have you here...
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Groover on December 04, 2017, 07:19:14 AM
If you want to touch up the side badges or any Moto Guzzi badge from that era, the best color match to the factory white I found that looked natural/factory was this:

Duplicolor BCC0407 Perfect Match Stone White

For the black, I used this:

Duplicolor BUN0100 Universal Black, but the black wasn't really hard to match anyway.

Top one is NOS OEM Moto Guzzi (not repro, the repros out there are too Arctic looking), the bottom is the BC0407 Stone White. I could have given it one more coat to thicken it up a bit looking at it again, or it would be best to find that same color in a non-aerosol can (less diluted), easier to brush on. I sprayed the paint in a cap, then brushed it on.

(http://thumb.ibb.co/nkbBnw/Moto_Guzzi_Badges_Top_is_OEM_bottom_Duplicolor_BCC0407.jpg) (http://ibb.co/nkbBnw)
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 04, 2017, 09:26:31 AM
If you want to touch up the side badges or any Moto Guzzi badge from that era, the best color match to the factory white I found that looked natural/factory was this:

Duplicolor BCC0407 Perfect Match Stone White

For the black, I used this:

Duplicolor BUN0100 Universal Black, but the black wasn't really hard to match anyway.

Top one is NOS OEM Moto Guzzi (not repro, the repros out there are too Arctic looking), the bottom is the BC0407 Stone White. I could have given it one more coat to thicken it up a bit looking at it again, or it would be best to find that same color in a non-aerosol can (less diluted), easier to brush on. I sprayed the paint in a cap, then brushed it on.

(http://thumb.ibb.co/nkbBnw/Moto_Guzzi_Badges_Top_is_OEM_bottom_Duplicolor_BCC0407.jpg) (http://ibb.co/nkbBnw)


Thanks!

Great information
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Antietam Classic Cycle on December 04, 2017, 12:39:22 PM
Mirrors: I think mirrors like these were what most mid-late '70s Guzzi came with, possibly installed at the dealer.

http://www.mgcycle.com/index.php?main_page=product_info&cPath=41&products_id=2370

(http://www.mgcycle.com/images/atrex/2029605.jpg)

I say "like" because those aren't as well made as the originals - the heads are much lighter and don't swivel the same. I put them on my Convert and couldn't see a bloody thing behind me, the mirrors shook so much. So, I used the stems from them with the heads off of the originals and *presto* a clear view.   :azn:

Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 04, 2017, 06:13:22 PM
Thanks Charlie, I put something like these on a KLR 650, shook real bad, I added the rubber isolator that Twisted Throttle sells and they are OK.

Searching the interweb for pictures of Le Mans MKI I see that most don't have mirrors, typical Italian I suppose,

" we a dona need no stinkin mirrah!"
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 04, 2017, 10:03:51 PM
HMB is advertising new slides machined to fit he PHF 36 carbs and the ones I modified don't seem to have a lot of range to raise the slide for idle,

this is the slide I machined fully raised

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2406_zpsdrhnt4bj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2406_zpsdrhnt4bj.jpg.html)

I ordered a new pair from HMB and this is the difference, just under 1mm more lift

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2407_zpshx23bxrb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2407_zpshx23bxrb.jpg.html)

I used a trick Greg Bender shows on his this old tractor site to static set an equal slide height using a tiny drill bit. with this diameter of drill I have +/- 1mm either way to adjust the slide height for idle

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2408_zpsolrgrtad.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2408_zpsolrgrtad.jpg.html)

I set a fine pin mark on the carb body and dab of red paint to show the static idle point on each carb

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2409_zpsdmees6pl.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2409_zpsdmees6pl.jpg.html)

A new distributor rotor came with the slides, it doesn't fit any better than the 1st one so I got out my heat gun and warmed the plastic up as much as I could

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2412_zpsfq6sub98.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2412_zpsfq6sub98.jpg.html)

Lots of heat later it 'just' fit over the distributor cam, not very well made IMHO

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2413_zpsvmfsswvv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2413_zpsvmfsswvv.jpg.html)

New choke cables arrived, something is not right, the cable is too long to be of any use

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2414_zps2jncehvg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2414_zps2jncehvg.jpg.html)

the choke cable end at the carb 90 degree pipe end

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2415_zpsmupnk1bl.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2415_zpsmupnk1bl.jpg.html)

There is no cable adjuster on the 90m degree pipe end

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2410_zpsbs8akydt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2410_zpsbs8akydt.jpg.html)

Something is not adding up, maybe the wrong cables were sent??

What an I missing here?

Title: Re: 1977 Le Mans Rebuild almost done
Post by: Antietam Classic Cycle on December 04, 2017, 10:48:00 PM
New choke cables arrived, something is not right, the cable is too long to be of any use

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2414_zps2jncehvg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2414_zps2jncehvg.jpg.html)

the choke cable end at the carb 90 degree pipe end

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2415_zpsmupnk1bl.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2415_zpsmupnk1bl.jpg.html)

There is no cable adjuster on the 90m degree pipe end

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2410_zpsbs8akydt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2410_zpsbs8akydt.jpg.html)

Something is not adding up, maybe the wrong cables were sent??

What an I missing here?

You're missing the adjuster and locknut.
http://www.mgcycle.com/index.php?main_page=product_info&cPath=62&products_id=1988
http://www.mgcycle.com/index.php?main_page=product_info&cPath=62&products_id=912
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 04, 2017, 11:21:09 PM
Does the adjuster and lock nut fit between the 90 degree pipe fitting and the cast aluminum cap that bolts down onto the carb?

The carbs came without adjusters so I am not sure where they go, but can't think of where else they would fit.

Thanks

Jim
Title: Re: 1977 Le Mans Rebuild almost done
Post by: jvb on December 05, 2017, 02:37:02 AM
The parts diagram show the adjuster, lock nut then elbow covered by a rubber sleeve.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Antietam Classic Cycle on December 05, 2017, 08:49:12 AM
Does the adjuster and lock nut fit between the 90 degree pipe fitting and the cast aluminum cap that bolts down onto the carb?

The carbs came without adjusters so I am not sure where they go, but can't think of where else they would fit.

Thanks

Jim

It screws into the upper end of the elbow. Check out the box with nos. 44-47 in the illustration below:

(http://www.dellorto.co.uk/wp-content/uploads/2015/11/phmdiag-734x1024.png)
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 05, 2017, 09:19:28 AM
It screws into the upper end of the elbow. Check out the box with nos. 44-47 in the illustration below:

(http://www.dellorto.co.uk/wp-content/uploads/2015/11/phmdiag-734x1024.png)

Thanks again Charlie!  I doubt I have any of those in my  stock, one more parts order for the LeMans coming up.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: SED on December 05, 2017, 08:43:40 PM
Looks great!

"I had to carefully bend the steel ends of the tach and speedo cables to turn 90 degrees and clear the headlight bucket"

How did you do that?!  all the tubing benders I've used bend further from the end.

You're patience and attention to detail are admirable.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 06, 2017, 06:48:42 PM
Looks great!

"I had to carefully bend the steel ends of the tach and speedo cables to turn 90 degrees and clear the headlight bucket"

How did you do that?!  all the tubing benders I've used bend further from the end.

You're patience and attention to detail are admirable.

I pulled the inner cable out, set the steel cable end into a vice and then fitted a small diameter tube over the cable steel end. I gently pulled the steel pipe towards me in increments moving the cable steel section. It actually bent quite easily.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: SED on December 06, 2017, 10:42:03 PM
 :thumb:
I pulled the inner cable out, set the steel cable end into a vice and then fitted a small diameter tube over the cable steel end. I gently pulled the steel pipe towards me in increments moving the cable steel section. It actually bent quite easily.

 :thumb:  Good job - I woulda kinked it!
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 14, 2017, 10:18:48 PM
fitted the new adjusters

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2429_zpsyid2r9ut.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2429_zpsyid2r9ut.jpg.html)


The choke cables also arrived today, unfortunate they are slightly different, one is slightly too long

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2430_zpsigdygbfm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2430_zpsigdygbfm.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2431_zps5gesjz0y.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2431_zps5gesjz0y.jpg.html)

I shortened an old adjuster and used it as a spacer on the 'long' cable

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2432_zpse9tbkuj8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2432_zpse9tbkuj8.jpg.html)

works fine

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2434_zpsh3bcx9sg.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2434_zpsh3bcx9sg.jpg.html)

I routed the right choke cable forward

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2435_zpswzj7ce9n.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2435_zpswzj7ce9n.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2436_zps9fxq0otp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2436_zps9fxq0otp.jpg.html)

Left cable facing rear and comes around the inside of the carb

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2437_zps6rl0gzge.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2437_zps6rl0gzge.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2438_zpscqiidtj8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2438_zpscqiidtj8.jpg.html)

fitted the fuel hose clamps

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2439_zpsydhbmjug.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2439_zpsydhbmjug.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2442_zpslfm7ewmh.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2442_zpslfm7ewmh.jpg.html)

and as I finished off the work and installed the side cover the weak fiberglass tab broke

I mixed up some epoxy and used a steel shim as reinforcing

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2443_zps5hsgkczp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2443_zps5hsgkczp.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2445_zpsvbknfogs.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2445_zpsvbknfogs.jpg.html)

Some filler, sanding and paint and hopefully its a good and stronger repair

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2446_zps7srglcpn.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2446_zps7srglcpn.jpg.html)

Title: Re: 1977 Le Mans Rebuild almost done
Post by: Les P on December 14, 2017, 10:29:25 PM
A truly inspiring thread and great workmanship also.
Writing the thread and stopping along the way to take all the photo's would be no small task either, a project in itself.
Thanks for another great read to date.  :thumb: :thumb:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Huzo on December 14, 2017, 10:35:42 PM
A truly inspiring thread and great workmanship also.
Writing the thread and stopping along the way to take all the photo's would be no small task either, a project in itself.
Thanks for another great read to date.  :thumb: :thumb:
Damn right.
He's re-set the standard for this type of stuff..
Double bastard on the broken tab, he doesn't deserve that sort of crap.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Groover on December 14, 2017, 11:05:05 PM
There are a lot of variants of Guzzi clhole cables from that era. I could never find the correct right side replacement for my G5 (2nd gen, rubber manifolds). Looks like you found a great solution to make yours work.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: TRw1 on December 15, 2017, 05:07:48 AM
Nice fixes!  Seems like the simplest things usually are the ones that turn into much more work than intended.

Agree with everyone else....this is a great thread to follow.  Thanks
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 15, 2017, 11:01:52 PM
I started to add the fluids, rear drive gear oil with a moly additive, transmission gear fluid and then starting to bleed the brakes.

I fitted speed bleeders to all six of the caliper bleed nipples. The rear master cylinder and left front / rear caliper bled OK, took some time but eventually I found a few leaks / loose fittings that needed tightening and  the air bubbles ended.

The front master cylinder / right front caliper has been another storey, the rebuilt master cylinder will not hold enough pressure to bleed out the front caliper. I stripped it down twice and can't find anything wrong but it just won't hold. I assume the bore was just too worn and the seal kit won't do its job. I order an new Brembo master cylinder this evening to replace the old original one/
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 16, 2017, 05:49:22 PM
A couple more passes of epoxy filler

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2542_zpsvp97iz7h.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2542_zpsvp97iz7h.jpg.html)

Genuine Moto Guzzi Le Mans touch up paint :grin:

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2540_zpsjwjgbvw2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2540_zpsjwjgbvw2.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2541_zpspbxi6rrs.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2541_zpspbxi6rrs.jpg.html)

several coats over the repair and its presentable

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2546_zpsy0wzd6gb.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2546_zpsy0wzd6gb.jpg.html)

Luckily the tab is hidden for the most part by the brake arm and the shadow of the cover

The tab seems to be much stronger now with the steel shim and the epoxy filling in the whole of the back side.

Now waiting on a new Master Cylinder to come from MG Cycle. I am giving up on rebuilding master cylinders, not worth the trouble on 40 year old precision parts.

Title: Re: 1977 Le Mans Rebuild almost done
Post by: balvenie on December 16, 2017, 06:02:01 PM
Thanks Jim for that Nail polish tip. Would never have thought of it :grin:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 16, 2017, 07:39:04 PM
Thanks Jim for that Nail polish tip. Would never have thought of it :grin:

My painter recommended it, he says touch up paint is usually too thin and does not adhere that well.

He swears by nail polish, another reason to stick with shades of red on all of one bikes! :smiley:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Bucky on December 17, 2017, 02:54:01 PM
Been lurking this thread for awhile, and have learned a lot. The detail in this rebuild is outstanding, a great resource for future reference, at least for those who have the skills which doesn't include me.
Way beyond my abilities, but certainly appreciate the time and effort put into this labor of love.

Jim, you sir, are a craftsman. Excellent work :thumb:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 19, 2017, 03:21:16 PM
Thanks for the kind words Bucky!

I am trouble shooting the electrical, the original Le Mans switch gear is poor quality, the electrical contact surfaces and the soft plastic that supports them warp and make for problematic contact. I have the switches apart, again, and am trying to improve on the function of the sliding mechanism and supplementing the wee ground tabs that make contact with the handlebars for a dedicated hard wire ground to the frame. I would abandon the switch gear if it were a regular rider but for the sake of originality I am going to try and make this 40 year old Italian stuff work, hopefully reliably.

I had installed and original starter relay, its crap as well and I have given in to stock and fitted a modern 5 tab relay that Greg Bender supplied, same for the light relays. At least now the signal lights flash, the park lights work and the brake light functions as it should, horns are nice and loud. Headlights are a no show, again I suspect its the crappy ground tab on the inside of the switch failing to make contact to ground through the handlebars.

Starter button is intermittent, the push button starter completes a ground circuit, again through the handlebars, same problem as the left hand switches and the engine stop slide hardly locks into a neutral position.

Back to basics, provide a dedicated ground wire to every component (as I did for the signal lights), ensure continuity of ground to frame, replace old relays with sealed new ones, and makes sure the switches actually switch.

Getting the electrical to be trouble free is the least desirable part of a rebuild for me. If I could farm out this step I would, trouble is the one time I did send a bike to a local 'expert' I found he knew less than I did about Guzzi electrical. This is when I wish I lived in Vancouver or Kiwi Roy lived in Edmonton!!!
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Groover on December 19, 2017, 04:09:53 PM
I've been examining my recently acquired LM4s and their switches to see what can be done to fix them and/or make them better; I thought the factory G5 ones (Lego switches) were crappy, but by comparison those seem rock solid now. The repros the LM4/5 are not being made yet (or ever?), so replacements is not really an option. Like you, I'm sure there are good solutions (use something else) but the intent in my case is also to do a restoration and keep as much as factory as possible.

My point, really none  :azn:

Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 20, 2017, 09:47:41 AM
Le Mans switch gear, on top of being ergonomically challenged, made of both soft and hard plastic components that tend to deform have the wires elegantly run through the handlebars, looks good but the wires have to make some sharp bends and removal / replacement can wear the wire insulation, case in point the head light switch which is just strange to begin with

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2563_zpshbqpofsy.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2563_zpshbqpofsy.jpg.html)

This rocker switch locks into the clutch perch and the wires from the switch exit under the base of the fixed plastic center, are 5 wires wide and the wires must bunch up to the width of two wires and turn 90 degrees into the handlebar, then the wires must remain centered while the switch slides into the clutch perch recess, sounds plausible  but in practice it's asking a lot. Then there is the switch mechanism itself, the rocker has a thumb release lock that pushes and slides to allow the rocker to rotate, the metal contacts have to align with the connector tabs and so on....

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2564_zps8mtibbj8.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2564_zps8mtibbj8.jpg.html)

I got the lights to work for a few flicks of the switch and back to nothing again. I have had the switch and wires out three times, back to the work bench and try and figure out where the wires may be broken, contacts not contacting etc.

This is why so few Le Mans have their original switch gear.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Groover on December 20, 2017, 10:35:30 AM
Wish I had taken photos of the G5 one. Though different that that, I'm thinking it functions similarly. In my case, I popped off a brass slider plate connected to the light switch lever, which is pressured by a tiny ball and spring to make the contact on the "rivets" where the wires terminate. The plate was worn, so to fix it in my case, I sanded the plate flat (to removed the worn-in grooves), then I added a spacer plate under the factory slider plate, above the tiny ball to add a little more pressure. Seemed to work, but I also don't really trust it to last...
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 20, 2017, 09:54:13 PM
After a lot more head scratching I think I have the lights figured out. When Luigi designed the Le Mans wire harness he had only so many colours of wire to work with and in this case the white with black stripe wire is used for two different purposes at the main block couplers, there is a white/black stripe wire that connects to a ground tab on the frame and then works its way through the headlight harness as a ground for the headlight. In the same bundle is another white / black stripe that ends up at the starter button coming from the starter relay. Both of these wires come out of the same big bundle and both have female connectors, on my harness the starter and ground white / black stripe were mixed up.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2566_zpstycidptq.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2566_zpstycidptq.jpg.html)

The headlight was being fed with the wire heading back to the starter relay and the starter had the headlight ground, simple huh! So often the solution is so simple but the pursuit so complicated.

To my relief the headlight works both low and high beam, signal lights flash and the gauge lights work, hurrah!

Now just to get the starter button working consistently.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Bucky on December 21, 2017, 08:30:49 AM
 :thumb:

Good catch!  I would have never thought that original wiring would use a same color wire for two different purposes.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 23, 2017, 12:38:24 PM
My Christmas present from MG Cycle came just in time, a new Brembo front master cylinder and brake lever

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2585_zpsc8ba7heu.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2585_zpsc8ba7heu.jpg.html)

MG Cycle states to only use DOT3 on these, don't know why that would be but I purged the Dot 4 out of the brake line and caliper and charged up the system. Brake bled easily with the new master cylinder.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2586_zpss6vvejbd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2586_zpss6vvejbd.jpg.html)

I took your advice Groover and added a small section of rubber sheet under the brass contact of the OFF switch, it now has a positive side to side click.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2588_zpsvivf8z04.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2588_zpsvivf8z04.jpg.html)

I needed to order some new MOLEX pins, after swapping the white / black wires they will not lock into the plug so they need to be replaced. I have a short to chase on the right rear signal.

The Le Mans will be shown at the International Motorcycle Show when it comes to Edmonton on January 12th and after that I will fire it up and go through the tuning.

Merry Christmas to everyone! and wishing you all the very best in 2018.

Cheers

Jim
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Bucky on December 23, 2017, 12:55:39 PM
 :drool:

......and a Merry Christmas to you!
Title: Re: 1977 Le Mans Rebuild almost done
Post by: TRw1 on December 25, 2017, 05:39:28 AM
I'll second that....

Merry Christmas Jim and to all those following this thread.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: timmythecop on December 25, 2017, 05:12:14 PM
Are you not worried about using the blinker stalks for your tie downs?
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Huzo on December 25, 2017, 05:15:19 PM
Are you not worried about using the blinker stalks for your tie downs?
Closer inspection will reveal, that the metal hooks loop into fabric straps that go up and around the top clamp.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: twowings on December 25, 2017, 08:25:35 PM
What a sweetheart! Congrats and hope your New Year is bright with promise... :thumb:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: timmythecop on December 25, 2017, 10:52:56 PM
Closer inspection will reveal, that the metal hooks loop into fabric straps that go up and around the top clamp.
Check. I should have known you would be doing that right, judging by everything else.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Huzo on December 25, 2017, 11:58:16 PM
Check. I should have known you would be doing that right, judging by everything else.
yeah it would have been unusual to say the least.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Psychopasta on December 26, 2017, 01:44:37 PM
Getting the electrical to be trouble free is the least desirable part of a rebuild for me.

Hey Canuck,

I'm really getting a lot out of watching your rebuild. Your attention to detail and desire to attain restoration nirvana are an inspiration!

But...  :boozing:

Getting a Guzzi's switchgear and other electricals to work well is a serious challenge. IMHO, Guzzi makes great engines and frames, and even the suspension can be upgraded while still looking stock, but they seem to have just wired the bike up with spaghetti and lego. Which is unfair to both spaghetti and lego: both are excellent products, but never intended for electrical duty on a motorcycle.

My personal preference is to gut the original electrics and rewire completely, with Japanese switchgear, solid state reg/rectifiers and nowadays an m-Unit to handle all the flashing/honking/starting utilities.

So my hat's off to you for persevering with the originals. Self-harm never looked so good  :bow:


- Pasta
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on December 27, 2017, 10:12:40 AM
Hey Canuck,

I'm really getting a lot out of watching your rebuild. Your attention to detail and desire to attain restoration nirvana are an inspiration!

But...  :boozing:

Getting a Guzzi's switchgear and other electricals to work well is a serious challenge. IMHO, Guzzi makes great engines and frames, and even the suspension can be upgraded while still looking stock, but they seem to have just wired the bike up with spaghetti and lego. Which is unfair to both spaghetti and lego: both are excellent products, but never intended for electrical duty on a motorcycle.

My personal preference is to gut the original electrics and rewire completely, with Japanese switchgear, solid state reg/rectifiers and nowadays an m-Unit to handle all the flashing/honking/starting utilities.

So my hat's off to you for persevering with the originals. Self-harm never looked so good  :bow:


- Pasta

You nailed the Guzzi electrical, very apt description.
Rebuilding my Laverda SF1 was a treat with its Japanese switch gear and instruments that actually work as intendeded. The Moto Morini 500 I am working on has a miss mash of CEV components that make the Le Mans electrical look modern.

I have the original switch gear on to show the bike. If I were to ride it regularly I think  I would put on modern switch gear.

Cheers

Jim

Title: Re: 1977 Le Mans Rebuild almost done
Post by: Antietam Classic Cycle on December 27, 2017, 08:40:45 PM
Getting a Guzzi's switchgear and other electricals to work well is a serious challenge. IMHO, Guzzi makes great engines and frames, and even the suspension can be upgraded while still looking stock, but they seem to have just wired the bike up with spaghetti and lego. Which is unfair to both spaghetti and lego: both are excellent products, but never intended for electrical duty on a motorcycle.

My personal preference is to gut the original electrics and rewire completely, with Japanese switchgear, solid state reg/rectifiers and nowadays an m-Unit to handle all the flashing/honking/starting utilities.


All of the original switches on my Convert worked perfectly, but they're an ergonomic nightmare, so I sold them for $300 and bought a pair of K&S switches instead.

IMO, there's really nothing wrong with the wiring itself, but time and the environment take their toll. I replaced a bunch of the terminals, but most of the original wire was retained. Only that from the alternator to the diode board was replaced. I did use a solid-state regulator.

My Morini K2 has all of it's original electrics except for the headlight/horn/signal switch. The original was busted, so I used a "Minda" switch from Stucchi that someone gave me. The electrics have been flawless - impressive considering the hard life the bike lead previously. 
Title: Re: 1977 Le Mans Rebuild almost done
Post by: timmythecop on December 28, 2017, 01:40:57 AM
IMO, there's really nothing wrong with the wiring itself, but time and the environment take their toll.

In the mid 80's my V65 Lario was doing strange stuff. Like left blinker when you hit the horn, hi beam flash when you hit right blinker, etc.  I though, "no problem, I'll get a manual and slowly and carefully go through the wires and figure it out"

So I open up the area behind the clocks and NO JOKE, all the wires were black.  It was like my bike was made at 4:45 on a Friday and they were out of different colour wires.  I did end up fixing it. It was the ignition switch, if I remember correctly.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on January 15, 2018, 11:16:22 AM
I showed the Le Mans I the travelling International Motorcycle Show at our local Canadian Vintage Motorcycle Group (CVMG) display of 20 motorcycles on the weekend. We had an eclectic cross section of bikes from a 1938 BSA single to a Honda Transalp.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2701_zps1vvrtwxf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2701_zps1vvrtwxf.jpg.html)

Most people who come buy have little or no knowledge of Moto Guzzi, typical of the crowd that is at least 50% into the 'Life Style brand"

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2700_zpsjkflh4rz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2700_zpsjkflh4rz.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2703_zpsxrjtmsux.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2703_zpsxrjtmsux.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2704_zpssvx1qlrm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2704_zpssvx1qlrm.jpg.html)

Now to get back to getting the bike started and tuned. I am waiting on a batch of replacement molex connectors to finish the switch gear repairs.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Groover on January 15, 2018, 11:30:05 AM
Great job making the show deadline. The bike looks great! I do see one major problem with the venue though..... those bikes should all be on the red carpet!  :grin:

Title: Re: 1977 Le Mans Rebuild almost done
Post by: TRw1 on January 15, 2018, 05:38:17 PM
The bike looks outstanding!  Good luck with those switches.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on January 18, 2018, 09:22:14 PM
A bag of replacement molex pins and connectors arrived today, I got them on Ebay in the UK, pretty fast shipping

Pulling the switches apart over and over left the pins ragged and it was just easier to cut the ends off and re-crimp new pins and fit new connectors

I bought the removal and insertion tools as well

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2716_zpshkkt4lng.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2716_zpshkkt4lng.jpg.html)

These are the crimpers that are used, they have a ridge in the recess that folds he pin tabs over the insulation and wire

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2719_zpspsxqwsit.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2719_zpspsxqwsit.jpg.html)

New pins crimped on

Old connectors cut off, new ends fitted

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2720_zps3wiqpeyd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2720_zps3wiqpeyd.jpg.html)

These new connectors are just like the originals

All back in one piece, almost like Greg Bender assembled it in the first place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2721_zps4o7c6ajj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2721_zps4o7c6ajj.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2724_zpsy6txqbkv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2724_zpsy6txqbkv.jpg.html)

This supplier has all the Guzzi style connectors for the Tonti era, two pin, three pin, etc.

Title: Re: 1977 Le Mans Rebuild almost done
Post by: twowings on January 18, 2018, 09:27:04 PM
Congratulations!  :bow:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: TRw1 on January 19, 2018, 05:59:52 AM
Nice work!http://wildguzzi.com/forum/Smileys/default/bow.gif
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Don G on January 19, 2018, 09:46:51 AM
Jim: Next time try B&E Electronics for the Molex supplies, they have a Warehouse in Calgary and one in Saskatoon, way faster and cheaper as well.  DonG
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on January 19, 2018, 12:23:39 PM
Jim: Next time try B&E Electronics for the Molex supplies, they have a Warehouse in Calgary and one in Saskatoon, way faster and cheaper as well.  DonG

Thanks for the lead Don, good to know.

Title: Re: 1977 Le Mans Rebuild almost done
Post by: Antietam Classic Cycle on January 19, 2018, 12:40:43 PM
I just buy mine from Greg Bender. <shrug>
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on January 19, 2018, 03:20:54 PM
I just buy mine from Greg Bender. <shrug>

Now why didn't I think of that!

I just never thought of looking for individual components from Greg. :thewife:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Antietam Classic Cycle on January 19, 2018, 04:15:10 PM
Now why didn't I think of that!

I just never thought of looking for individual components from Greg. :thewife:

Greg probably tires of me bugging him about misc. bits and pieces.  :wink:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Huzo on January 20, 2018, 02:34:37 AM
A bag of replacement molex pins and connectors arrived today, I got them on Ebay in the UK, pretty fast shipping

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2715_zpsxuwhif0x.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2715_zpsxuwhif0x.jpg.html)

Pulling the switches apart over and over left the pins ragged and it was just easier to cut the ends off and re-crimp new pins and fit new connectors

I bought the removal and insertion tools as well

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2716_zpshkkt4lng.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2716_zpshkkt4lng.jpg.html)

These are the crimpers that are used, they have a ridge in the recess that folds he pin tabs over the insulation and wire

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2719_zpspsxqwsit.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2719_zpspsxqwsit.jpg.html)

New pins crimped on

Old connectors cut off, new ends fitted

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2720_zps3wiqpeyd.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2720_zps3wiqpeyd.jpg.html)

These new connectors are just like the originals

All back in one piece, almost like Greg Bender assembled it in the first place

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2721_zps4o7c6ajj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2721_zps4o7c6ajj.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_2724_zpsy6txqbkv.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_2724_zpsy6txqbkv.jpg.html)

This supplier has all the Guzzi style connectors for the Tonti era, two pin, three pin, etc.
Jim Carey (Carrey)!!!
Well alllrrriggghhhttyyy y then !
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on January 22, 2018, 09:46:50 PM
Starter working now thanks to Kiwi Roy, bypassed the press to start button and the starter does what it should!

I checked the compression (new rings and honed iron pistons) and its an even 150 psi per side, I am happy with that, should go up to 160 psi with running on of the rings.

I tried a separate ground wire to the handlebars where I scrapped the paint off for the switch ground tabs and ran the ground back to the frame, press to start still won't start, same for the horn, grounding is not a problem, its still in the damn switches.

I am going to strip the switches one more time before I replace them with modern universal switches, fingers crossed.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on January 24, 2018, 09:37:03 PM
FINALLY !!!! I have both the left and right hand switches working, reliably too (or so it seems).

For the right it was a poor ground from the switch ground tab making contact with the bare clip-on bar face, more paint scraping, tab bending and 'springing' of the push to start tab until contact was regular and strong. I was so relieved I wore the battery down pressing the starter button while checking for a good strong spark on both cylinders.

The left hand switch horn button was a bear to trace, same ground check, spring tab check, trace the power through the relay back to the fuse panel. Every wire showing continuity and then the penny dropped, the brown power lead into the fuse box had not made contact with the powered fuse box lug, duh!! Well at least I eventually found it and its so satisfying to have all the lights, brake light signals and horn working as they should.

With a good spark and compression its time to fill the tuning gas bottle and connect the fuel to the carbs, hold my breath, cross all digits and press start ..... stay tuned for the big bang :evil:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: TRw1 on January 24, 2018, 10:55:54 PM
Great news!  We all knew you would figure it out.  Look forward to the next chapter.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Bucky on January 25, 2018, 08:31:59 AM
 :thumb:s

Maybe video the initial start and post it...

And good work on solving the electrical gremlins!
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Rick4003 on January 26, 2018, 11:15:58 PM
+1 for the start up video :grin:

As always good job with the problem solving and great that you got those pesky switches sorted out.

-Ulrik

Sent from my SM-A520F using Tapatalk

Title: Re: 1977 Le Mans Rebuild almost done
Post by: Stephen Hill on January 28, 2018, 12:44:02 AM
Jim, I noticed earlier in the thread that the headlight rim stuck out past the fairing about an inch or so.  In your final photos the headlight rim is about flush with the fairing.  The stock US sealed headlight sticks out.  The European non-sealed headlight sits flush.  What did you do to make it flush?

Stephen Hill
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on January 28, 2018, 06:20:33 PM
Jim, I noticed earlier in the thread that the headlight rim stuck out past the fairing about an inch or so.  In your final photos the headlight rim is about flush with the fairing.  The stock US sealed headlight sticks out.  The European non-sealed headlight sits flush.  What did you do to make it flush?

Stephen Hill

The European headlight is also smaller in diameter. MG Cycle sells a reproduction fiberglass faring with the smaller diameter headlight opening, this is what I mounted on the 77 Le Mans. I then found a matching diameter all black headlight on UK Ebay to fit the opening. In my opinion the US version with the headlight sticking out past the fairing looks like a Minion from the movie Despicable Me!
Title: Re: 1977 Le Mans Rebuild almost done
Post by: 73eldorado on January 28, 2018, 06:54:58 PM
 :1:
The European headlight is also smaller in diameter. MG Cycle sells a reproduction fiberglass faring with the smaller diameter headlight opening, this is what I mounted on the 77 Le Mans. I then found a matching diameter all black headlight on UK Ebay to fit the opening. In my opinion the US version with the headlight sticking out past the fairing looks like a Minion from the movie Despicable Me!
I agree 100 %!!
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on January 29, 2018, 03:00:00 PM
I need to wait for some warmer weather to move the bike onto the driveway and start it up, I think that won't be for another month!
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Stephen Hill on January 30, 2018, 01:29:14 AM
The previous owner of my 1976 LeMans modified the bracket that mounts the fairing, so the headlight does not stick out.  Looks fine, but it makes adjusting the headlight a bit tricky.  Is there another headlight rim and or reflector that fits into the stock bucket and uses the stock fairing?

Stephen Hill
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on January 30, 2018, 07:32:37 PM
The previous owner of my 1976 LeMans modified the bracket that mounts the fairing, so the headlight does not stick out.  Looks fine, but it makes adjusting the headlight a bit tricky.  Is there another headlight rim and or reflector that fits into the stock bucket and uses the stock fairing?

Stephen Hill

Not that I know of, measure the diameter of the opening on the bikini fairing and check Ebay for a new universal headlight that may fit.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: swooshdave on January 31, 2018, 10:50:39 AM
I intentionally put the lego switch on my 850-T so you know I have serious mental problems. It took a lot of work tracing wires and emails to Greg but I finally figured it out. It's oddly almost as satisfying to sort out Italian electrics as it is to get an engine running for the first time.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Antietam Classic Cycle on January 31, 2018, 12:33:19 PM
I intentionally put the lego switch on my 850-T so you know I have serious mental problems. It took a lot of work tracing wires and emails to Greg but I finally figured it out. It's oddly almost as satisfying to sort out Italian electrics as it is to get an engine running for the first time.

Legos are quite a bit better than what Jim's dealing with.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on January 31, 2018, 04:33:32 PM
It's oddly almost as satisfying to sort out Italian electrics as it is to get an engine running for the first time.

True. But I think it’s easier to get an engine running for the 1st time than getting the Guzi electionics working !!
I do share your sense of satisfaction with beating a gremlin.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: 10doh on February 02, 2018, 01:46:46 PM
Nice project looking good, doing a California to Cafe project and wanted to ask if you could help me out with a couple of measurements so I can get my ride height set... What is the fork length top to center of the axel and the rear shock length, if you could share those numbers it would be a huge help. Going to start posting a thread once I start getting things back together in the mock up phase. 
Title: Re: 1977 Le Mans Rebuild almost done
Post by: swooshdave on February 02, 2018, 09:32:39 PM
Legos are quite a bit better than what Jim's dealing with.

Quite a bit? We are still talking about degrees of horrible here.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Rick4003 on February 03, 2018, 12:13:39 AM
Nice project looking good, doing a California to Cafe project and wanted to ask if you could help me out with a couple of measurements so I can get my ride height set... What is the fork length top to center of the axel and the rear shock length, if you could share those numbers it would be a huge help. Going to start posting a thread once I start getting things back together in the mock up phase.

Hi 10doh, Your California doesn't have the same height of the steering head as the Lemans have, so the measurement will not be the same. For the California and most models after 1985 the steering head height on the BB tonti is 220mm vs the 170mm on the models up to 1985. You can check out my thread in the build sections also. I had the same issues when I changed the frame.

And Jim, wonderful work as always. I really enjoy following along in your progress :grin: Still looking forward to that video :grin:  :bike-037:

-Ulrik
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on February 04, 2018, 09:52:10 AM
The ‘start-up’ awaits Mother Nature’s cooperation, it has snowed at least 25cm (10”) in the past two days and daytime high temperatures around -20C. On top of not wanting to open the garage door and let the heat out I have been fighting a lousy flu for a week and shivering any harder is not in the cards. The LeMans is itching to show me what it’s got and I know it won’t disappoint. Let’s hope Spring comes in March!!
Title: Re: 1977 Le Mans Rebuild almost done
Post by: SED on February 21, 2018, 11:43:27 PM
Get well soon!  And may spring come early for you.  Beautiful work.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on February 24, 2018, 11:19:27 AM
Get well soon!  And may spring come early for you.  Beautiful work.

Thanks Sed, still fighting the bug, bronchitis and now a big dose of antibiotics, slowing me down on my projects!
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on March 12, 2018, 10:19:26 AM
My painter finished the paint repair to the gas tank that got chipped transporting the bike to and from the bike show in January, looks great

I removed the exhaust and painted over the easily scratched ceramic coating with a very high heat black low-gloss rattle can, I think the ceramic will work as a great primer and dissipate the heat while the top coat will be more durable to scratches and can be recoated if necessary

(http://i249.photobucket.com/albums/gg217/canuck750/1978%20Moto%20Morini%20500/IMG_3177_zps7ep0wn8y.jpg) (http://s249.photobucket.com/user/canuck750/media/1978%20Moto%20Morini%20500/IMG_3177_zps7ep0wn8y.jpg.html)

Weather is starting to get better, spring may actually be on the way and I will be out of excuses for not firing the bike up ....
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on March 14, 2018, 10:43:24 PM
I painted the exhaust with very high temperature paint, reinstalling the exhaust I wrapped the parts with rags to prevent scratches,

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_3184_zpsokpn2adp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_3184_zpsokpn2adp.jpg.html)

The low gloss paint over the ceramic coating looks much better to me

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_3189_zpszxwaxyrr.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_3189_zpszxwaxyrr.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_3190_zpsekdsxg3f.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_3190_zpsekdsxg3f.jpg.html)

Title: Re: 1977 Le Mans Rebuild almost done
Post by: balvenie on March 15, 2018, 12:29:53 AM
Looks very Good :grin:
Title: Re: 1977 Le Mans Rebuild almost done
Post by: TRw1 on March 15, 2018, 08:56:02 AM
Yes, very nice look!
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on March 18, 2018, 05:42:31 PM
Today was the day the bike was to start .... except it didn't

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_3192_zpshatby5ca.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_3192_zpshatby5ca.jpg.html)

The kill switch is intermittent, just trouble, spark, then no spark, I think I need to give up on this switch and install a universal start / kill switch.

Carbs float heights and perhaps my test gas bottle is too high in the air with too much head pressure feeding the carbs, but I was not getting fuel past the float needle. Lowered the gas bottle to reduce head pressure and fiddled with the float heights but then the battery was just too weak to crank the engine over so back on the charger.

I need to read up on the electronic ignition and start over with static timing again just to be sure I got that right.

Fiddling .....
Title: Re: 1977 Le Mans Rebuild almost done
Post by: swooshdave on March 18, 2018, 07:18:29 PM
So is that a Harbor Freight (or Canadian equivalent) with an air cylinder? Is that a mod?
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on March 18, 2018, 08:03:56 PM
So is that a Harbor Freight (or Canadian equivalent) with an air cylinder? Is that a mod?

Yes its a Harbor Fright / Princess Auto - air over hydraulic bench, I bought it used a couple years ago for $300, pretty happy with it.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Antietam Classic Cycle on March 19, 2018, 12:20:28 PM
The kill switch is intermittent, just trouble, spark, then no spark, I think I need to give up on this switch and install a universal start / kill switch.

Have you checked with Harper's for the kill/start switch? I bought a NOS signal switch from them a while back, maybe they have that one too.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on March 19, 2018, 12:51:44 PM
Have you checked with Harper's for the kill/start switch? I bought a NOS signal switch from them a while back, maybe they have that one too.

Thanks for this

I will check

Jim
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on May 06, 2018, 10:10:40 PM
I have had the LeMans carbs returned following an inspection by Wolfgang Haerter, the Laverda and Dellorto guru, other than resetting the floats all was OK.

Installed the carbs, re set the valve gap and hooked up a battery. 1st trial was a no show, I struggled to get the bike to fire, it really wanted to but no ignition. So in frustration I pulled out the Dyna III (it was a used one I had laying around so I can't be certain it was functioning) and installed another distributor with a fresh set of points and condensers.

It fire right up and idled fairly smooth. I balanced the carbs and set the timing. I let it run through about a half gallon of gas. It was quite hard to start when hot, mixture screws out 1 1/24 turns, choke cable have slack, all stock carb setting and jets, plugs are fouled. Fresh pugs and it restated just fine.

I went at it again on Sunday and once again it fired right up but when hot it was hard to re start. I retorqued the heads once more and re set the valve gap, changed out the oil and filter. After a lot of balancing and strobe timing I think I have it as good as I can get it but the plugs are still quite black and the mixture screws are out 1 turn.

I am guessing the idle jets are too big??

Here are some poor videos I took today, I apologize for the quality.

https://youtu.be/Nx1ELCo7kQ0

https://youtu.be/Gn8fN5kEejM
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Groover on May 07, 2018, 07:44:56 AM
I have had the LeMans carbs returned following an inspection by Wolfgang Haerter, the Laverda and Dellorto guru, other than resetting the floats all was OK.

Installed the carbs, re set the valve gap and hooked up a battery. 1st trial was a no show, I struggled to get the bike to fire, it really wanted to but no ignition. So in frustration I pulled out the Dyna III (it was a used one I had laying around so I can't be certain it was functioning) and installed another distributor with a fresh set of points and condensers.

It fire right up and idled fairly smooth. I balanced the carbs and set the timing. I let it run through about a half gallon of gas. It was quite hard to start when hot, mixture screws out 1 1/24 turns, choke cable have slack, all stock carb setting and jets, plugs are fouled. Fresh pugs and it restated just fine.

I went at it again on Sunday and once again it fired right up but when hot it was hard to re start. I retorqued the heads once more and re set the valve gap, changed out the oil and filter. After a lot of balancing and strobe timing I think I have it as good as I can get it but the plugs are still quite black and the mixture screws are out 1 turn.

I am guessing the idle jets are too big??

Here are some poor videos I took today, I apologize for the quality.

https://youtu.be/Nx1ELCo7kQ0

https://youtu.be/Gn8fN5kEejM

It's alive! I thought the hard to start when hot is typically because it may be running hot and the fuel vaporizes from the intake path. I know you are seeing it rich after checking the plugs, so that doesn't match. Will it start quicker when hot if you activate the choke(s). Also, valve gaps may be too tight? Be sure they are set at the correct TDC interval.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on May 07, 2018, 09:32:50 AM
It's alive! I thought the hard to start when hot is typically because it may be running hot and the fuel vaporizes from the intake path. I know you are seeing it rich after checking the plugs, so that doesn't match. Will it start quicker when hot if you activate the choke(s). Also, valve gaps may be too tight? Be sure they are set at the correct TDC interval.

It will start when hot with a quick use of the choke, valves are set at TDC compression. Its running real nice, no hesitation on throttle, carb balance sticks tracking evenly throughout throttle range. Problem is sooty plugs even with mixture screws turned out only 1 turn from full stop.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Rick4003 on May 07, 2018, 10:47:56 AM
Hi Jim, great to hear that you have gotten it up and running. How is the weather now? Are you able to do some test rides on it?

I'm going to give myself a lambda analysis system for my birthday here on Sunday. It takes a lot of the guess work out of the carb tuning. You will have to weld some bungs in the exhaust or use it with an bracket for the end of the exhaust pipe. Could be a solution to fine tuning your carbs. I know you can read the plugs the old way, smell the exhaust, check the pipe for soot and probably many other tricks to tell if it is rich or lean. In my mind a lambda probe is going to take out much of the guess work and speed up the process. And you can also read the mix all way way up the rev/throttle range under load.

I'm planning to stick some tape on my throttle handle and mark out all the positions from zero to full throttle in 1/8 steps. It should give some idea on which circuit of the carbs that is in operation at that moment.

I think I'll go with the AFR500v2 as it has gotten some good reviews and has scored well in tests. C5 ignition also uses and recommends that model.

Oh and your Lemans looks great! Hope you'll make some riding videos of it [emoji4]
Hope you get the mix figured out!

-Ulrik

Sent from my SM-A520F using Tapatalk

Title: Re: 1977 Le Mans Rebuild almost done
Post by: Groover on May 07, 2018, 10:52:35 AM
Sounds like it's pretty close to me, I wouldn't be too concerned with the plugs like that. Plug chops are done at high engine speed, so they'll always be a little wet I think when running in the garage setting. Though, I could be very wrong on that!

Anyway, just to get by for now, I would shut down the bike pulling the choke right before turning off the key/switch, that way it should start up right away even if shut down hot as it would leave a rich path.

If you want to mess with it more, then I would lower needle #2 a notch to reduce your low/mid fuel, and open/unscrew #58 another half turn, making 1.5 turns out to richen your idle path. Maybe that will help. Of course, wait for someone else to jump in here, but that's what I would try as a starting point from this point before going too deep into atomizers and such.


(https://thumb.ibb.co/iwYzyn/PHM.jpg) (https://ibb.co/iwYzyn)


(https://thumb.ibb.co/ecF9W7/PHM_1.jpg) (https://ibb.co/ecF9W7)


(https://thumb.ibb.co/c9HOr7/PHM_2.jpg) (https://ibb.co/c9HOr7)
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on May 07, 2018, 05:49:26 PM
Hi Jim, great to hear that you have gotten it up and running. How is the weather now? Are you able to do some test rides on it?

-Ulrik

Sent from my SM-A520F using Tapatalk

Summer has finally arrived, going to get the Le Mans out on the road this week, its not registered so I have to sneak around the block ain the evenings!

Sounds like you are on the right tool for tuning, please keep me posted.
Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on May 07, 2018, 05:52:19 PM
Sounds like it's pretty close to me, I wouldn't be too concerned with the plugs like that. Plug chops are done at high engine speed, so they'll always be a little wet I think when running in the garage setting. Though, I could be very wrong on that!

Anyway, just to get by for now, I would shut down the bike pulling the choke right before turning off the key/switch, that way it should start up right away even if shut down hot as it would leave a rich path.

If you want to mess with it more, then I would lower needle #2 a notch to reduce your low/mid fuel, and open/unscrew #58 another half turn, making 1.5 turns out to richen your idle path. Maybe that will help. Of course, wait for someone else to jump in here, but that's what I would try as a starting point from this point before going too deep into atomizers and such.


(https://thumb.ibb.co/iwYzyn/PHM.jpg) (https://ibb.co/iwYzyn)


(https://thumb.ibb.co/ecF9W7/PHM_1.jpg) (https://ibb.co/ecF9W7)


(https://thumb.ibb.co/c9HOr7/PHM_2.jpg) (https://ibb.co/c9HOr7)


I spoke with Wolfgang Haerter today, he tells me the same carbs on the Laverda 750 acted similar and were typically hard to start hot without a dab of choke. He suggested dropping the idle jet down to a 58 or 56 and give it a try, jets are on order. I like your idea about shutting down with the choke on, will try that as well. I may try dropping the needle if these first steps don't sort it out.

Thanks

Jim
Title: Re: 1977 Le Mans Rebuild almost done
Post by: Rick4003 on May 07, 2018, 09:20:11 PM


Summer has finally arrived, going to get the Le Mans out on the road this week, its not registered so I have to sneak around the block ain the evenings!

Sounds like you are on the right tool for tuning, please keep me posted.

Sounds good, how much do you need to go through to register it up there? Would be more fun to take it out on some proper rides [emoji4]

I will order the afr500 this week and hopefully I can get some time in dk to work on the bike next month or so. I will keep my build thread updated.

- Ulrik

Sent from my SM-A520F using Tapatalk

Title: Re: 1977 Le Mans Rebuild almost done
Post by: canuck750 on May 07, 2018, 10:29:34 PM
I found a pair of 57 idle jets in my Dellorto stash, swapped out the 60's

I installed the gas tank seat and side covers, poured a gallon of gas in he tank and hit the road for the 1st time with a plate off another of my bikes. I road around the neighbourhood for about 20 minutes, got it up to 3rd and hit the brakes hard a couple times, it sure stops better than my V7 Sport.

I pulled back into the shop and pulled the plugs, much better. I think it was a bit too lean and maybe the timing just off a bit on full advance, seemed to lug a bit on full throttle, re set the timing with the strobe and went for another spin. Better, opened up the mixture screws a wee bit, plugs look pretty good. Went over the bike fasteners tightening everything again.

Only thing that went amiss was the fairing came loose and began to rattle, got that fixed.

I think its about a close I will get it without a dyno run.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_3391_zps28c6mijx.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_3391_zps28c6mijx.jpg.html)
Title: Re: 1977 Le Mans running and on the road
Post by: balvenie on May 08, 2018, 04:03:47 AM
Well done Jim :grin: :thumb:
Title: Re: 1977 Le Mans running and on the road
Post by: Groover on May 08, 2018, 08:12:54 AM
Sounds like you have completed a successful restoration!  :bow:
Title: Re: 1977 Le Mans running and on the road
Post by: Psychopasta on May 08, 2018, 09:18:07 PM
Congratulations Jim! This has been a real pleasure to follow  :bow:

- Mark
Title: Re: 1977 Le Mans running and on the road
Post by: canuck750 on May 10, 2018, 10:03:16 AM
Congratulations Jim! This has been a real pleasure to follow  :bow:

- Mark

Thanks Mark

I have been riding around the neighbourhood at night as I continue to fine tune it. Sorting out the usual little niggles, no leaks from the engine or transmission or final drive, it is much more responsive than my V7 Sport and the brakes are much better than the 4LS on the Sport. The clip on riding position gets some getting used to but its actually not too aggressive a riding position. I got it up to 4th gear on a long stretch of road in the light commercial district roads around my shop, great fun! I now realize why these are so popular.
Title: Re: 1977 Le Mans running and on the road
Post by: Bucky on May 11, 2018, 08:02:46 AM
 :bow:

Congrats on the final product! Impressive.

Your detailed build threads are so enjoyable to read, and very informative for this Geezer Noob.
Thanks so much for putting the effort in posting these threads. You have no idea how valuable they are to noobs like me. Again, thanks for taking the time to document this build. I learned a lot.
Title: Re: 1977 Le Mans running and on the road
Post by: canuck750 on May 11, 2018, 06:16:56 PM
Thanks Bucky!

I was having a heck of a time getting the LH cylinder to time properly. Greg Field wrote a great article on modifying the Tonti dual point distributor points plate.

http://www.thisoldtractor.com/moto_guzzi_tonti_distributor_dual_points_plate_modification_so_you_can_time_both_cylinders_properly.html

Once I carried out the mod I could get the LH points adjusted to open at static timing mark kike they should. Amazing amount of very useful information on Greg's wonderful site.

A leak out of the front caliper was a bit of a mystery, one of the new Brembo piston seals was leaking, the system is filled with DOT3, this is what the flat O ring looked like when I removed it, only one of them in the pair of front calipers is doing this, strange!!

I fitted another rebuilt caliper, re-bled the system and its all good to go (er. stop).

Snag list is getting shorter, stubborn tach not working, may need to pull it apart.
Title: Re: 1977 Le Mans running and on the road
Post by: canuck750 on May 12, 2018, 01:11:02 PM
Final snag resolved, I had bent the steel tube at the end of the tach drive cable thinking all was fine as the cable did move and rotate. After removing the cable I find it is sheared off at the instrument, cable was binding. Off came the fairing and headlight shell, after a couple 'adjustments' with a section of pipe and hammer the headlight bucket is now formed to accept the unbent tach cable.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_3400_zpsqgk3eawt.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_3400_zpsqgk3eawt.jpg.html)

And the tach does what it should

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_3401_zpsz3wzptcf.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_3401_zpsz3wzptcf.jpg.html)

I started the bike this morning after modifying the points plate and setting the timing, starter on the first stab of the starter button, choke off in a minute and then it settled into a smooth idle, thank you Mr. Field!!

Here is video of the bike restarting after running up to temperature for 15 minutes, one stab of the starter button and it lights, no choke!

https://www.youtube.com/watch?v=mbgucEyB9yg&feature=youtu.be
Title: Re: 1977 Le Mans running and on the road
Post by: TRw1 on May 12, 2018, 07:24:52 PM
Jim - great job getting the bike done and in top shape.  It's been a long process.  Thanks for documenting so thoroughly as you went along.
Title: Re: 1977 Le Mans running and on the road
Post by: Rick4003 on May 12, 2018, 09:14:06 PM
Looks great on the video Jim!

Now your indicators flash a bit fast? Too low bulb wattage? Wrong flasher relay? It usually happens when people put on new indicators with smaller bulbs than original.

Can't praise your build and your build threads enough. I think everybody is learning a bunch from them! It is like how to build a LM1, V7 sport, V7S3 and so on. They are great.! Thank you for taking the time to post it all.

-Ulrik

Sent from my SM-A520F using Tapatalk

Title: Re: 1977 Le Mans running and on the road
Post by: canuck750 on May 13, 2018, 12:47:29 PM
Ok I can really claim this build is done!

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060001_zpssaozw6qj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060001_zpssaozw6qj.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060002_zps3ljgdpgi.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060002_zps3ljgdpgi.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060003_zpsgjx8kl6v.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060003_zpsgjx8kl6v.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060004_zps98rsw5ld.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060004_zps98rsw5ld.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060005_zpsldapgov2.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060005_zpsldapgov2.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060007_zpsyou1vh4z.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060007_zpsyou1vh4z.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060008_zpsjammy1a3.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060008_zpsjammy1a3.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060011_zpsvhp09jtj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060011_zpsvhp09jtj.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060012_zpszvbmx9ai.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060012_zpszvbmx9ai.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060013_zpsruiy97vm.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060013_zpsruiy97vm.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060014_zps7zpwzgod.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060014_zps7zpwzgod.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060015_zpsfqvecgbz.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060015_zpsfqvecgbz.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060016_zpsajxw3znp.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060016_zpsajxw3znp.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060018_zpstytzmbzj.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060018_zpstytzmbzj.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060019_zpsohpjgcqo.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060019_zpsohpjgcqo.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060020_zpszjv4nsh0.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060020_zpszjv4nsh0.jpg.html)


The Le Mans is pointing in the direction it will soon be leaving me, yes I am selling it on to a new home where it will be loved and ridden, I have too many bikes and I must choose which ones to keep, the V7 Sport won out in the decision. The new custodian, who I  will not identify, is an enthusiast and will no doubt love it. This bike must be ridden and I can't give her the seat time it deserves.

Now its on to getting some damage repaired on my Laverda, some workers carrying out renovations in my shop knocked her over and broke the front brake master cylinder, fractured the carb manifold and broke a horn, and who knows what else.

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/P7060024_zps15aqygnk.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/P7060024_zps15aqygnk.jpg.html)
Title: Re: 1977 Le Mans running and on the road
Post by: vintage53 on May 13, 2018, 03:03:39 PM
Congratulations Sir! :thumb: :thumb: :thumb:
Title: Re: 1977 Le Mans running and on the road
Post by: Rick4003 on May 14, 2018, 03:12:05 AM
Big congratulations on getting the licenseplates for it! That is a big milestone to get past that. Sorry to hear you´re selling it, but that is the way it is with the hobby. I don´t know if I could restore it so nicely and sell it afterwards. Maybe it helps having too many bikes in the shop :grin:

Very sorry to hear about the damage to your Laverda. Hope those builders got told off well!

Looking very much forward to follow your next restoration! Which bike is in the pipeline? Benelli or perhaps a Bimota? How about going Spanish and going for a Bultaco or Montesa? ;)

-Ulrik
Title: Re: 1977 Le Mans running and on the road
Post by: Groover on May 14, 2018, 08:07:19 AM
Congrats on the sale. Having too many bikes is indeed a problem, and hard to maintain even the little annual things, batteries, fluids, it can get out of control. Bummer on the Laverda being knocked over like that  :violent1:
Title: Re: 1977 Le Mans running and on the road
Post by: canuck750 on May 14, 2018, 09:47:14 AM
Big congratulations on getting the licenseplates for it! That is a big milestone to get past that. Sorry to hear you´re selling it, but that is the way it is with the hobby. I don´t know if I could restore it so nicely and sell it afterwards. Maybe it helps having too many bikes in the shop :grin:

Very sorry to hear about the damage to your Laverda. Hope those builders got told off well!

Looking very much forward to follow your next restoration! Which bike is in the pipeline? Benelli or perhaps a Bimota? How about going Spanish and going for a Bultaco or Montesa? ;)

-Ulrik

I am waiting on engine machine work to finish my 1978 Moto Morini 500, it needed a crank grind, big end shells, valve guides and valves, parts were on back order from NLM but should arrive this week. I am going to get back onto  my 74 Benelli 9650 Tornado after the Morini. I don't like to sit still .....

Cheers

Jim
Title: Re: 1977 Le Mans running and on the road
Post by: canuck750 on May 23, 2018, 09:54:45 AM
Its officially no longer in may care, eventually they all need to leave home and find their way in the world, going to miss you 1977 Le Mans!

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_3434_zpsscgtk8z7.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_3434_zpsscgtk8z7.jpg.html)

(http://i249.photobucket.com/albums/gg217/canuck750/1977%20Moto%20Guzzi%20le%20Mans/IMG_3436_zpsleapye4d.jpg) (http://s249.photobucket.com/user/canuck750/media/1977%20Moto%20Guzzi%20le%20Mans/IMG_3436_zpsleapye4d.jpg.html)

 :sad:
Title: Re: 1977 Le Mans running and on the road
Post by: Antietam Classic Cycle on May 23, 2018, 10:00:29 AM
 :cry:
Title: Re: 1977 Le Mans running and on the road
Post by: Psychopasta on May 26, 2018, 01:17:45 PM
Somebody has got a great bike. Thank you so much for this thread, it has been great to watch your progress.
Title: Re: 1977 Le Mans running and on the road
Post by: oldbike54 on June 05, 2018, 12:15:41 AM
 Kinda like watching a favorite puppy go to a new home . Nice work Jim  :bow:

 Dusty
Title: Re: 1977 Le Mans running and on the road
Post by: Rick4003 on June 17, 2018, 02:28:49 AM
You did a great job on the bike Jim, must be hard to see it go. But I'm happy that it is going to a good home, the new owner couldn't get a better bike.

I'm looking forward to follow your new adventures in the restoration of the next bikes :)

-Ulrik
Title: Re: 1977 Le Mans running and on the road
Post by: balvenie on June 17, 2018, 04:21:07 AM
Kinda like watching a favorite puppy go to a new home . Nice work Jim  :bow:
 Dusty

Funny you should mention that subject. A looong time ago I thought of raising sheep and cattle dogs for sale but the thought of how they might be treated put me off, after recollecting how many bad owners I've seen............... ....... :angry:
Title: Re: 1977 Le Mans running and on the road
Post by: jas67 on September 21, 2018, 11:08:59 AM
I'll be reading all 18 pages of this thread before I proceed with the 1977 Le Mans I just bought.
Title: Re: 1977 Le Mans running and on the road
Post by: canuck750 on September 21, 2018, 02:28:02 PM
I'll be reading all 18 pages of this thread before I proceed with the 1977 Le Mans I just bought.

Happy reading, I hope there is some useful information in there.