Wildgoose Chase Moto Guzzi

General Category => General Discussion => Topic started by: Chuck in Indiana on July 31, 2018, 10:56:04 AM

Title: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on July 31, 2018, 10:56:04 AM
We're getting some much needed rain, so I thought I'd take a day and have a look at the new to me G5. I know there is a school of thought that says, "If it ain't broke, don't fix it." I don't subscribe to that one.  :smiley: Before taking it on some longer trips, I like to know what I have. The records from the anal  :thumb: previous owner say:
7-5-17    97867
Spark plugs
New exhaust gaskets
New o rings in heads
New head gaskets
adjust valves
oil and filter.
I changed the oil when I brought it home, and have ridden it 3 or 400 miles. It's time for head torque.
(https://farm2.staticflickr.com/1833/29893990968_1644985d73_k.jpg) (https://flic.kr/p/MxCw2o)2018-07-31_11-37-12 (https://flic.kr/p/MxCw2o) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Valves are at .004" If I had just set them back at .009" there would be a blown head gasket in our future.. :grin:
When I pulled the tank, I saw this:
(https://farm2.staticflickr.com/1771/42860522985_448d7b15ee_k.jpg) (https://flic.kr/p/28irofe)2018-07-31_11-36-28 (https://flic.kr/p/28irofe) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
where the tank had started to eat into the throttle cable. I'll have to reroute that at the very least.
Probably ought to have a look here..
(https://farm2.staticflickr.com/1837/43716164372_883e04bd02_k.jpg) (https://flic.kr/p/29B3LBW)2018-07-31_11-35-58 (https://flic.kr/p/29B3LBW) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
I'm going to spend the rest of the day doing an "annual inspection" on the old G5. If anyone is interested, I'll document it.
Title: Re: rainy day maintenance (G5 content)
Post by: Old Jock on July 31, 2018, 10:59:24 AM
Ahh Chckee

It's not only me Eh?

The things you find when you dig  :grin:

Hope that's all you find
Title: Re: rainy day maintenance (G5 content)
Post by: RinkRat II on July 31, 2018, 11:14:02 AM

 We're all patiently waiting for your tutorial, however, if you get too distraught on your findings, don't fear one of us here will take it off your hands :evil:

       Paul B :boozing:
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on July 31, 2018, 11:19:32 AM
We're all patiently waiting for your tutorial, however, if you get too distraught on your findings, don't fear one of us here will take it off your hands :evil:

       Paul B :boozing:

Sorry, Paul.. not much chance of that.  :smiley: I gave up the Monza to get it.
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on July 31, 2018, 11:23:09 AM
Just came up for lunch, and checked out the most excellent info that LeRoy sent me  :thumb: to refresh my memory on the torque pattern, valve clearances, etc.
Back in a bit..
Title: Re: rainy day maintenance (G5 content)
Post by: Zoom Zoom on July 31, 2018, 12:11:24 PM
My rainy day project, although it has been ongoing for a few days, is prep on the 1.1 meter Stearman RC model. Getting the CG right, balancing a couple props, etc. (All the little stuff that makes you take more than the two hours that say it will take.) Don't want the maiden flight to be the last!

John Henry
Title: Re: rainy day maintenance (G5 content)
Post by: John A on July 31, 2018, 12:31:35 PM
preventative maintenance at its best! :thumb:
Title: Re: rainy day maintenance (G5 content)
Post by: Rick4003 on July 31, 2018, 12:39:45 PM
I would be very interested in reading about your annual inspection. Lasts ones was great info.
My buddy got a G5 not so long ago that surely could use a yearly inspection even if he has got it pretty reliable now.

Sent from my SM-A520F using Tapatalk

Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on July 31, 2018, 01:33:12 PM
Ok, here we go. To get to the top cylinder head bolt, you have to remove the "blanking plug." Inspect the o ring underneath it. A bad one will cause a mystery oil leak. Torque in a cross pattern according to "the book" at 30 ft. lbs. As expected, the left head bolts were quite loose.
(https://farm1.staticflickr.com/938/28831030467_cddfa51166_k.jpg) (https://flic.kr/p/KVGyUc)2018-07-31_01-58-58 (https://flic.kr/p/KVGyUc) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Have a look at the rocker arm pins. This is the worst one.. about .001" wear.
(https://farm1.staticflickr.com/848/43718779322_51d3d5e03b_k.jpg) (https://flic.kr/p/29BhaXh)2018-07-31_01-59-28 (https://flic.kr/p/29BhaXh) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Proves the robustness (is that a word?)  :smiley: of the Guzzi powerplant.
I have ejector pins from my days as a mold maker, and one makes quick work of reinstalling the rocker pin. It's undersized, so just insert it, roll it around the bore to align the spring and washer.. slide the rocker pin home. Easy Peasey.
(https://farm1.staticflickr.com/938/28831067947_cf459c8803_k.jpg) (https://flic.kr/p/KVGL3p)2018-07-31_02-00-32 (https://flic.kr/p/KVGL3p) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
BTW, it's good practice to rotate the rocker arm pin 180 degrees at each valve adjustment to even out wear.
Once the valves are adjusted to .009" and .009, it's the perfect time to do a leak down test. Here is my home made (naturally)  :wink: leak down tester. You have to be *exactly* at TDC, or the air pressure will just push the piston down.
(https://farm2.staticflickr.com/1777/28831076197_f7cde9ab6f_k.jpg) (https://flic.kr/p/KVGNuD)2018-07-31_02-01-06 (https://flic.kr/p/KVGNuD) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Yeah, baby! 80/76. That means 80 psi in through a regulated orifice, and read the leakage on the second gauge. 10% leakage is a good used cylinder. This one is considerably better than that.  :thumb: Listening for the air leakage will tell you where the engine is worn. Out the carbs, intake valves, out the exhaust is exhaust valve, out the breather, rings. This cylinder has a little (not very much) ring wear.
The other cylinder reads 80/75. Rings, also.  :thumb: again. These small valve Guzzi engines will run a *long* time, if properly maintained.
How long did all this take? Considerably less than telling you about it. :grin: That Dusty fellow called, and wants pictures from Oshkosh.
While I'm here, we might as well see what is under this black thing..
(https://farm2.staticflickr.com/1835/28831083397_cc0d883d9e_k.jpg) (https://flic.kr/p/KVGQCM)2018-07-31_02-01-39 (https://flic.kr/p/KVGQCM) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Still waiting are some wires and connectors that obviously haven't seen the light of day in some time.
(https://farm1.staticflickr.com/853/29896610168_94842f884e_k.jpg) (https://flic.kr/p/MxRWC1)2018-07-31_02-02-13 (https://flic.kr/p/MxRWC1) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
(https://farm1.staticflickr.com/934/43051092774_3e4c53aafe_k.jpg) (https://flic.kr/p/28Ah71f)2018-07-31_02-02-49 (https://flic.kr/p/28Ah71f) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
This is the stuff that will have you standing by the side of the road. At night. In the rain.  :grin: Let's go through it.
To be continued..

Title: Re: rainy day maintenance (G5 content)
Post by: guzzisteve on July 31, 2018, 01:36:15 PM
Chuck,  Do a video and play it on the big sheet at WI Rally, then sell copies. Autographed copies of course!!
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on July 31, 2018, 02:05:41 PM
Chuck,  Do a video and play it on the big sheet at WI Rally, then sell copies. Autographed copies of course!!

 :grin: Riiiiight..
Title: Re: rainy day maintenance (G5 content)
Post by: normzone on July 31, 2018, 02:14:44 PM
I'll buy one, preordered to help defray the production expense, if you'll include an explanation about what rain is.
Title: Re: rainy day maintenance (G5 content)
Post by: pete roper on July 31, 2018, 03:41:25 PM
Of course it's raining Chuck. We are bloody rain gods. After we left yesterday it pissed down all the way to Terre Haute and followed us out again this morning. We seem to have finally shaken it off in Quincy but I reckon it'll find us again before we get to Kansas City! :grin:

Pete
Title: Re: rainy day maintenance (G5 content)
Post by: LeRoy on July 31, 2018, 04:13:03 PM
I'd be interested in seeing how the whole airbox and crankcase breather apparatus is working on your G5. I just learned (the hard way) the joys of an over-pressurized crankcase on my new-to-me 1000 SP. Shoulda' looked that whole system over more closely on my pre-flight check before I took the first long-ish ride. It all seemed so good on short around-town trips. But it was all so oily on the return from an afternoon ride. It gave a new perspective to the concept of a total-loss lubrication system.
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on July 31, 2018, 04:41:19 PM
I'd be interested in seeing how the whole airbox and crankcase breather apparatus is working on your G5. I just learned (the hard way) the joys of an over-pressurized crankcase on my new-to-me 1000 SP. Shoulda' looked that whole system over more closely on my pre-flight check before I took the first long-ish ride. It all seemed so good on short around-town trips. But it was all so oily on the return from an afternoon ride. It gave a new perspective to the concept of a total-loss lubrication system.

LeRoy, my SP's Distinguished Previous Owner made up a Mickey Mouse arrangement with a cobbled up copper thing (tm) run up to the front of the bike on a rubber hose with a roughly 2 inch diameter air filter on it. Get the picture? It made a *very* fine oil mist that totally covered everything aft of it. Dust would settle in it and then the whole process would be started over on the next ride.  :evil: :grin:
After scraping about 1/4" off everything, I binned that and used a LeMans breather hooked up in the conventional way. My new old G5 apparently uses the same thing. I'll get a picture tomorrow..
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on July 31, 2018, 05:04:42 PM
I only have records for the last 15000 miles or so, and no mention has been made of the points.
Had a look, and gapped them .014" Both were around .018-.020.
(https://farm2.staticflickr.com/1780/42866619665_b4d32591c7_k.jpg) (https://flic.kr/p/28iYCzp)2018-07-31_05-42-31 (https://flic.kr/p/28iYCzp) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Started putting the valve covers back on, and the screws apparently are stainless. You need to use anti seize with stainless/aluminum. A little dab will do ya, as the old saying goes.  :smiley:
(https://farm2.staticflickr.com/1815/43054666234_04c40c583e_k.jpg) (https://flic.kr/p/28AAqgC)2018-07-31_05-42-48 (https://flic.kr/p/28AAqgC) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
I'd be remiss if I didn't tell you how I was turning the engine over. Just put an allen wrench in the bolt that holds the alternator on. Turn the engine clockwise, viewed from the front.
(https://farm1.staticflickr.com/860/41962314790_4860bd5bbb_k.jpg) (https://flic.kr/p/26W4Qf3)2018-07-31_05-43-22 (https://flic.kr/p/26W4Qf3) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
While we're there..
(https://farm2.staticflickr.com/1837/28834556247_502f7e96d2_k.jpg) (https://flic.kr/p/KW1CZv)2018-07-31_05-43-39 (https://flic.kr/p/KW1CZv) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
is the best stuff for electrical gizmos I've ever used. I've lost track of the things I've "fixed" with it. For instance, we were leaving for the Oshkosh fly in, and I plugged in the camper lights. Nothing. Nada. "Crap." Unplugged, replugged, wiggled it around.. nothing. Went to the Guzzi Garage (tm) got my can of DeOxit, sprayed the connector, plugged it in, and had lights. Just like new.
At any rate, take off the connectors off the alternator and give em a spray/wiggle.
(https://farm1.staticflickr.com/928/28834559357_ce70748629_k.jpg) (https://flic.kr/p/KW1DV8)2018-07-31_05-44-04 (https://flic.kr/p/KW1DV8) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
The three yellow wires are about 45 volts AC, and go to the diode board. More on that later. Have a look at the brushes, springs, too. An electrical failure is the most common breakdown on these old Tontis.
Title: Re: rainy day maintenance (G5 content)
Post by: John A on July 31, 2018, 05:21:08 PM
There is a service bulliten to clock the stator 90 degrees from what that one is. Supposed to help keeping brush bounce to a minimum.
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on July 31, 2018, 05:24:46 PM
Starting from the front.. here are the coils. You know the drill.  :grin:
(https://farm2.staticflickr.com/1776/42866657135_4ea046dc0c_k.jpg) (https://flic.kr/p/28iYPHr)2018-07-31_05-44-23 (https://flic.kr/p/28iYPHr) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Power to/from the key switch. they are not waterproof. The tendency is to just let them be. As the old ad says, "Just do it." :smiley:
(https://farm2.staticflickr.com/1776/42866660095_53bfb25238_k.jpg) (https://flic.kr/p/28iYQAt)2018-07-31_05-44-38 (https://flic.kr/p/28iYQAt) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Now, we are getting into the nitty gritty. The last guy that has seen these was Luigi.
(https://farm2.staticflickr.com/1772/43054683694_5b8bfac8fb_k.jpg) (https://flic.kr/p/28AAvsE)2018-07-31_05-44-56 (https://flic.kr/p/28AAvsE) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
This is the connector to the voltage regulator. It is *very* difficult to get to on the G5 for whatever reason.
(https://farm2.staticflickr.com/1799/29900309008_c3c8b02be8_k.jpg) (https://flic.kr/p/MybUa7)2018-07-31_05-45-12 (https://flic.kr/p/MybUa7) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
The temptation is to think, "Oh, no problem, I'll just remove it from the bracket, DeOxit the connections, and reinstall.
*Avoid that temptation.*  :smiley: Luigi assembled all that stuff before he put the engine in.  :evil: It's been an hour and a half, and I still don't have it back together. Just do whatever you have to do to get the plug out, squirt it, and put it back in. Trust me.
"Tweeeet." Quitting whistle. Beer o'clock. *maybe* more tomorrow.
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on July 31, 2018, 05:31:38 PM
There is a service bulliten to clock the stator 90 degrees from what that one is. Supposed to help keeping brush bounce to a minimum.

Thanks for that, John. I remember that, now that you have jogged my (failing) memory.  :embarrassed:
Title: Re: rainy day maintenance (G5 content)
Post by: twodogs on July 31, 2018, 07:11:38 PM
This is good stuff Chuck, please document everything you do and send it to me for my winter project because I don't have a clue what I'm doing on mine, your pics are going to show me the way on my g5, looking toward winter for the first time in a long time  :boozing:
Bruce
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on July 31, 2018, 08:01:59 PM
This is good stuff Chuck, please document everything you do and send it to me for my winter project because I don't have a clue what I'm doing on mine, your pics are going to show me the way on my g5, looking toward winter for the first time in a long time  :boozing:
Bruce
Glad to see it will be of some value.  :smiley: I'll continue as I get time. Thought I'd get mostly through it today, but ran into a snag with the voltage regulator. Pay attention to that..  :evil:
Normally, a guy can spend a day and be pretty sure he won't have a breakdown in BF Utah.   :boozing: :wink: At night. In the rain..
What are you going to do for the rest of the Winter?  :grin:
Title: Re: rainy day maintenance (G5 content)
Post by: Guzzistajohn on July 31, 2018, 08:24:24 PM
Good stuff Chuck! Thanks for sharing your "skills" If we had a like button I'd be tearing that sucker up right now  :wink:
Title: Re: rainy day maintenance (G5 content)
Post by: twodogs on August 01, 2018, 06:08:00 AM
Between the beer and honey do list and so on, you know how it goes  :boozing: seriously though the pics and specs you listed are priceless to me, I look at a wrench and my knuckles start bleeding. LOL
Bruce
Title: Re: rainy day maintenance (G5 content)
Post by: brider on August 01, 2018, 06:38:36 AM
[img width=600 height=800]This is the stuff that will have you standing by the side of the road. At night. In the rain.  :grin: Let's go through it.
To be continued..
 (https://flic.kr/p/KVGL3p)

Chuck: What's your position on using dielectric grease? I read a bunch of recent and very interesting threads here on this forum about it's use, and your attention to the elec connections makes me think they would be a good candidate for it's use.

My Cal 2 is about at the same stage as your G5 right now, and I think I'm going to apply it after a quick spritz with contact cleaner.
Title: Re: rainy day maintenance (G5 content)
Post by: chuck peterson on August 01, 2018, 06:40:09 AM
Nice details, thanks. Would you go with the adjustable vr?
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 01, 2018, 06:48:16 AM
Nice details, thanks. Would you go with the adjustable vr?

Only if I was running in town all the time. I put one on the AeroLario. I'd been watching the voltmeter, and it had been trending lower. You could see the voltage regulator doing it's regulating.  :smiley: Thought a preemptive strike might be in order, so looked at Cheesehead and Gordon's website. Even though it cost $2 more <snapping suspenders> I ordered the adjustable one, just in case. It comes set at 14.3 volts, and is perfect. Dang! Wasted $2.. :grin:
Title: Re: rainy day maintenance (G5 content)
Post by: nobleswood on August 01, 2018, 11:12:42 AM
 :popcorn:

There's a few Rallies coming up, Ohio & Kentucky, are you thinking of riding the G5 to them ?
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 01, 2018, 12:17:14 PM
I'd be interested in seeing how the whole airbox and crankcase breather apparatus is working on your G5. I just learned (the hard way) the joys of an over-pressurized crankcase on my new-to-me 1000 SP. Shoulda' looked that whole system over more closely on my pre-flight check before I took the first long-ish ride. It all seemed so good on short around-town trips. But it was all so oily on the return from an afternoon ride. It gave a new perspective to the concept of a total-loss lubrication system.

Ok, Bob.. I haven't been slackin.. the guys from Centroid were here this morning finishing the retrofit of the latest stuff to my ancient (naturally) CNC mill.
Here's the breather box the G5 is using.
(https://farm2.staticflickr.com/1811/29916671698_6f967e345b_k.jpg) (https://flic.kr/p/MzCLds)2018-08-01_12-58-40 (https://flic.kr/p/MzCLds) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
You can see the two lines from the heads here. It is apparently working fine. If you need more pix, just say so.
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 01, 2018, 12:24:00 PM
This is good stuff Chuck, please document everything you do and send it to me for my winter project because I don't have a clue what I'm doing on mine, your pics are going to show me the way on my g5, looking toward winter for the first time in a long time  :boozing:
Bruce

Bruce, one of the things I'm not going to address is rebuilding the ignition switch. This one, unfortunately, has a new switch, so I'm not going to mess with it at this time. I have to have two keys because of the unnecessary new switch.  :evil:
The switches are easy to take apart, clean off the old hardened grease, wire brush the contacts, apply fresh Vaseline.. not dielectric grease.. :evil: and reassemble.  :smiley: You *need* to do this to your "survivor."
I did a tutorial on the switch, among other things,  on the Monza annual inspection thread.
http://wildguzzi.com/forum/index.php?topic=89034.0
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 01, 2018, 12:27:43 PM
Chuck: What's your position on using dielectric grease? I read a bunch of recent and very interesting threads here on this forum about it's use, and your attention to the elec connections makes me think they would be a good candidate for it's use.

My Cal 2 is about at the same stage as your G5 right now, and I think I'm going to apply it after a quick spritz with contact cleaner.

Wayne, who knows a brazillion per cent more about this stuff than me, is adamant about not using dielectric grease on your Guzzi, except for the spark plug boots. I could tell you the story of my barn find Strada that someone thought it was a good idea to pack every connector with dielectric grease. I'll just say, not a good idea.
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 01, 2018, 12:30:36 PM
:popcorn:

There's a few Rallies coming up, Ohio & Kentucky, are you thinking of riding the G5 to them ?

Kentucky.. Ohio is during the National Antique Airplane meet in Iowa.
Title: Re: rainy day maintenance (G5 content)
Post by: John A on August 01, 2018, 12:47:21 PM
I was surprised at how many old aviation mechanics didn't understand that DC-3 [dielectric grease] is an insulator, not a conductor. the sort of thing that will have you spend a night 40 miles south of East Jesus, South Dakota either on a bike or your new Light Sport airplane :sad:
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 01, 2018, 12:56:20 PM
Let's see now, where were we? Oh, yeah. Remember the three yellow wires that come from the alternator? They terminate here at the diode board, where the AC is converted to DC. I'm convinced that many of the problems with the Bosch alternator are here. It's sort of hidden, and not serviced. The contacts get corroded, create heat, and havoc.(I've actually seen this connector melted)
(https://farm1.staticflickr.com/934/43738983922_d7d8dfcf45_k.jpg) (https://flic.kr/p/29D4J5s)2018-08-01_12-59-19 (https://flic.kr/p/29D4J5s) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
So.. unhook it, get your points file or diesinker's Swiss file set  :grin: and clean those connectors up.
(https://farm1.staticflickr.com/857/42884064335_93288a2515_k.jpg) (https://flic.kr/p/28kw3gz)2018-08-01_01-35-25 (https://flic.kr/p/28kw3gz) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Some DeOxit, wiggle it around.. oh, you know.
Austin came down this morning and helped me put the voltage regulator assembly back together. It takes 3 hands. Forewarned is forearmed.  :evil: It's one of Luigi's most diabolical tricks.
When I pulled off another wire on the diode board, there was almost no tension at all. Hmmm. Told Austin to take the duckbills and tighten the female connector.
(https://farm2.staticflickr.com/1832/42884083845_999a50e0cf_k.jpg) (https://flic.kr/p/28kw94X)2018-08-01_01-36-10 (https://flic.kr/p/28kw94X) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
It snapped as soon as a little pressure was put on it. No doubt, it was ready to fail.. that's why I don't subscribe to the "don't fix nothin that ain't broke" theory. Put a new one on, tightened the matching very loose one, and moved on to the fuse box.
Austin took it off
(https://farm1.staticflickr.com/862/28851247127_293c876d60_k.jpg) (https://flic.kr/p/KXubBi)2018-08-01_01-36-31 (https://flic.kr/p/KXubBi) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
so we could get to the connectors.
(https://farm1.staticflickr.com/938/43739746562_0c8c31ac7d_k.jpg) (https://flic.kr/p/29D8CMq)2018-08-01_01-36-57 (https://flic.kr/p/29D8CMq) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
We'll clean up all the connectors, take a stainless toothbrush to the fuse holders, and put new fuses in them.
There is an important power and ground lead to the diode board, but I'll have to pull the battery to get to them.
Stay tuned..
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 01, 2018, 06:06:03 PM
Here are the connections that are generally ignored. Power on the left, ground (barely seen) on the right. There are a couple more that aren't shown.
(https://farm2.staticflickr.com/1780/43790764271_ae15333bf4_k.jpg) (https://flic.kr/p/29HD7z6)2018-08-01_04-52-03 (https://flic.kr/p/29HD7z6) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Clean and put Vaseline on the battery cables and battery, and the heavy lifting is done. Sure, there are some minor things.. lights, etc. but doing this will keep you going down the road for a long time.
Thanks for following along.. and I hope it has been of value to someone.
Title: Re: rainy day maintenance (G5 content)
Post by: BikeMike on August 01, 2018, 07:07:48 PM
Thanks for posting Chuck.  This is very useful (practical) maintenance information.

Mike
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 11, 2018, 11:02:35 AM
Thanks for posting Chuck.  This is very useful (practical) maintenance information.

Mike

Thanks, Mike..
Ok, let's get this bad boy back on the road. Haven't had time to finish it up. Wisconsin rally  :thumb: and a 4 day Cad/Cam school. The oil pressure gauge was flaky, so ordered one from Cheesehead and Gordon while I was gone. It uses a different terminal, though  :sad: .. but.. an automotive bullet connector will fit right on.  :smiley:
(https://farm2.staticflickr.com/1818/43261494664_363904916b_k.jpg) (https://flic.kr/p/28USta3)2018-08-11_11-34-36 (https://flic.kr/p/28USta3) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Crimp that sucker on there..
(https://farm2.staticflickr.com/1798/43980113351_e9308038b9_k.jpg) (https://flic.kr/p/2a1nzsp)2018-08-11_11-34-53 (https://flic.kr/p/2a1nzsp) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
(should have gotten a new boot, too) a little anti seize, and we now have a reliable oil pressure light.
A very good indicator of engine condition (besides the leak down test) is what the spark plug looks like. This one looks a little cold. The book calls for a BP7ES, but Guzziology sez a BP6 (hotter) ES is better.
(https://farm2.staticflickr.com/1816/29042151167_4bb0c80b20_k.jpg) (https://flic.kr/p/LfmBJg)2018-08-11_11-35-18 (https://flic.kr/p/LfmBJg) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
So.. had MGC throw a couple of those in the box, too. Gapped .023" a *little* anti seize on the threads.. don't let it get past the first thread, or you will be wondering what is causing the "mystery miss" before long. Anti seize is a conductor. Run it in until it's snug on the new gasket, and then turn the wrench 3/4 of a turn. No torquing necessary.
As an aside, I was talking to Jim at Rose Farm one day and he told me that whenever a plug comes out, a new one goes in. I agree. They are cheap, and are the cause of many vexing problems.
"Tweeeet." Lunch whistle. Back later.
Title: Re: rainy day maintenance (G5 content)
Post by: Stevex on August 11, 2018, 12:46:30 PM
Chuck: What's your position on using dielectric grease? I read a bunch of recent and very interesting threads here on this forum about it's use, and your attention to the elec connections makes me think they would be a good candidate for it's use.

My Cal 2 is about at the same stage as your G5 right now, and I think I'm going to apply it after a quick spritz with contact cleaner.

When I carried out my LM2 refurb I had the wiring loom off the bike. After cleaning every last inch of every wire, connector and component and removing any corrosion I Silicone greased (dielectric) every connection on the bike. I've never had a problem since doing this. As for it being an insulator, well of course it is, who would use conducting grease?
Its the metal to metal contact that provides the electrical connection, the grease prevents moisture or water getting to the contact.
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 11, 2018, 01:31:26 PM
When I carried out my LM2 refurb I had the wiring loom off the bike. After cleaning every last inch of every wire, connector and component and removing any corrosion I Silicone greased (dielectric) every connection on the bike. I've never had a problem since doing this. As for it being an insulator, well of course it is, who would use conducting grease?
Its the metal to metal contact that provides the electrical connection, the grease prevents moisture or water getting to the contact.

On these old bikes *without any relays* you can probably get by with it. Use Vaseline to do the same job on a new bike.
Title: Re: rainy day maintenance (G5 content)
Post by: Antietam Classic Cycle on August 11, 2018, 02:01:17 PM
Crimp that sucker on there..
(https://farm2.staticflickr.com/1798/43980113351_e9308038b9_k.jpg) (https://flic.kr/p/2a1nzsp)2018-08-11_11-34-53 (https://flic.kr/p/2a1nzsp) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr

I'm surprised to see that you use the insulated, single crimp type terminals. I figured a perfectionist like you would only use the double crimp, strain relief type.

(http://vintageconnections.com/Content/images/products/19/1.jpg)
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 11, 2018, 02:03:30 PM
Remember that rusty pin on the front brake?
(https://farm1.staticflickr.com/933/29042156217_87ad180211_k.jpg) (https://flic.kr/p/LfmDek)2018-08-11_11-35-41 (https://flic.kr/p/LfmDek) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
I know this is basic stuff, but there are all levels of wrenching experience on this list.. so let's replace the worn out pads. There is a millimeter to a millimeter and a half of pad material left. Just in the nick of time.  :grin:
The reason these pins are rusty is because over the years someone has just grabbed them with pliers an worn off the plating. They may be frozen in there, so take a copper drift and break them loose from the back side.
(https://farm2.staticflickr.com/1796/29042174587_6e4da8efe4_k.jpg) (https://flic.kr/p/LfmJG4)2018-08-11_11-36-55 (https://flic.kr/p/LfmJG4) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Once they are loose, a long 1/8" diameter punch will peck them out. There is a flat spring that will catch on the pin. Carefully pull it up on the big diameter and the pins will come out easily. No cave manning required or wanted..
(https://farm1.staticflickr.com/937/43261521134_9beefc68db_k.jpg) (https://flic.kr/p/28USB2q)2018-08-11_11-37-21 (https://flic.kr/p/28USB2q) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
You can clean off the rust with fine emery paper in the lathe, or drill chuck. It doesn't hurt anything, really, but looks like crap.
(https://farm1.staticflickr.com/934/42171116580_52eab65b0f_k.jpg) (https://flic.kr/p/27fvZJU)2018-08-11_11-37-42 (https://flic.kr/p/27fvZJU) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Spritzing some of this airplane stuff on the pins will keep that rust thing from reoccurring. Pretty much, anyway. :cool:
(https://farm2.staticflickr.com/1773/29042190637_1c7fb890e9_k.jpg) (https://flic.kr/p/LfmPsM)2018-08-11_11-37-54 (https://flic.kr/p/LfmPsM) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Once the pins and spring retainer are out, "carefully" lever the pistons back into the caliper using a big hunker screwdriver between the old pads and rotor. One side, then the other. Again, no cave manning required. There's really no need to warp the rotor, right?  :wink: The pistons will have to be almost flush for new pads to go in.
Once that's done, pull the pins (including the center pin) and retaining spring. If you didn't notice, the curved end goes to the front.
(https://farm2.staticflickr.com/1798/43980167771_5c261ab553_k.jpg) (https://flic.kr/p/2a1nRCF)2018-08-11_11-38-41 (https://flic.kr/p/2a1nRCF) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Put the new pads in, slide the front pin into pad, then the flat spring. Do the same thing on the rear. The inside pad has fallen down now.. just push it up with your hand, locate the holes and push the pins in. The flat spring will want to hang up again, but can easily be maneuvered into the correct position with a screwdriver.
Tap the pins home.
(https://farm2.staticflickr.com/1815/29042198447_53adb733c4_k.jpg) (https://flic.kr/p/LfmRMr)2018-08-11_11-38-20 (https://flic.kr/p/LfmRMr) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
Snap the cover back on, and you're done.  Don't forget to pump up the lever and foot pedal before moving the bike.. :shocked: :grin:
(https://farm2.staticflickr.com/1799/42171134800_63cf5f55fa_k.jpg) (https://flic.kr/p/27fw6a3)2018-08-11_11-38-56 (https://flic.kr/p/27fw6a3) by Charles Stottlemyer (https://www.flickr.com/photos/107188298@N06/), on Flickr
That's all there is to it. No removing calipers, etc. Total time? Considerably less than telling about it.  :grin:
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 11, 2018, 02:11:49 PM
I'm surprised to see that you use the insulated, single crimp type terminals. I figured a perfectionist like you would only use the double crimp, strain relief type.

(http://vintageconnections.com/Content/images/products/19/1.jpg)

Charlie, all I'm going to say about that is this is what I had in my "good junk" box that would work..  :smiley: You are absolutely right, of course, and it is going to get treated to all new good terminals this Winter when I'm needing a project. I had two of the OEM terminals come apart when I was just cleaning and DeOxiting them. I thought, "Note to self. Replace all the terminals when you get time. It hasn't been sitting in suspended animation these last 39 years."
Title: Re: rainy day maintenance (G5 content)
Post by: Antietam Classic Cycle on August 11, 2018, 04:54:29 PM
 :thumb:

I replaced a lot of terminals and some of the alternator wiring on my Convert, to the point that I probably should have just bought a new harness from Greg Bender. I did buy his "relay solution" for the headlight high/low, horn and ignition circuit.
Title: Re: rainy day maintenance (G5 content)
Post by: bad Chad on August 11, 2018, 05:23:28 PM
Does it still rain in Indiana???
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 11, 2018, 05:59:11 PM
Does it still rain in Indiana???

Good point. All the rain seems to have moved elsewhere. Maybe I shouldn't worry about it?
Title: Re: rainy day maintenance (G5 content)
Post by: Unkept on August 12, 2018, 07:37:18 AM
I'm having fun following along Chuck.  :thumb: Thanks for sharing.
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 12, 2018, 09:01:25 AM
I'm having fun following along Chuck.  :thumb: Thanks for sharing.

Thanks, Joe.. that's about it.
Oh, forgot.. when it gets hot, the clutch is grabby. I may look into that.
Title: Re: rainy day maintenance (G5 content)
Post by: Chuck in Indiana on August 13, 2018, 09:32:42 AM
Thanks, Joe.. that's about it.
Oh, forgot.. when it gets hot, the clutch is grabby. I may look into that.

Sometimes, you *do* get the bear.  :smiley: :smiley: The Previous Owner told me about the clutch problem. I thought, probably the transmission input hub.  :sad: Oh well, the price reflected the problem..
Had a look this morning, and the spring behind the clutch actuating arm was off it's pin, but trapped behind the arm. <scratching head> No pix, I couldn't get my phone in there to take one. At any rate, fixed that, adjusted the arm.. that is a fussy adjustment. One turn makes a lot of difference.. adjusted the cable and the lever.
Works like new. :grin: I'm a happy camper. Hopefully it hasn't been loading the throwout bearing for thousands of miles.
That does it. I'll ride it the rest of the season without worrying about breaking down.  :thumb: Maybe I can get it to roll over 100, 000..
Title: Re: rainy day maintenance (G5 content)
Post by: Unkept on August 13, 2018, 09:48:50 AM
Sometimes, you *do* get the bear.  :smiley: :smiley: The Previous Owner told me about the clutch problem. I thought, probably the transmission input hub.  :sad: Oh well, the price reflected the problem..
Had a look this morning, and the spring behind the clutch actuating arm was off it's pin, but trapped behind the arm. <scratching head> No pix, I couldn't get my phone in there to take one. At any rate, fixed that, adjusted the arm.. that is a fussy adjustment. One turn makes a lot of difference.. adjusted the cable and the lever.
Works like new. :grin: I'm a happy camper. Hopefully it hasn't been loading the throwout bearing for thousands of miles.
That does it. I'll ride it the rest of the season without worrying about breaking down.  :thumb: Maybe I can get it to roll over 100, 000..

 :thumb: Glad to hear you found the culprit! You still have plenty of riding time before Winter. :)
Title: Re: rainy day maintenance (G5 content)
Post by: twowings on August 13, 2018, 02:53:06 PM
 :thumb: