Recall 99 Bassa Single Throttle Cable Bikes

[toukow]

This subject came up in my other post, but thought it worthy of a separate thread to ease searching. I contacted Moto International yesterday and there is indeed a recall for Bassa's (and I assume any other bike with single throttle cable throttle, but may be wrong) as many of you are aware. It was stated that this recall was precipatated by incorrect installation of the air box after removal, jamming the throttle operating mechanism.  Unfortunately you're out of luck after 10 years apparently, so have to incur the costs to fix it yourself.

As mentioned in the other thread, an additional cable and a special tap is required -I guess to tap the throttle cam to accept the additional cable. I'm away from my bike, but I'm unclear on how the additional cable is integrated to the existing handlebar throttle assembly. It's already setup to accept two cables, as there is no mention of changing this assembly? Thanks, Dean

http://wildguzzi.com/forum/index.php?topic=78660.30

[John A]

The drum already has the slot for the return cable, the tap is for the housing where the cable goes through it with a jam nut . It's been so long ago I did one I don't remember much else about it. I wonder if replacement parts would have the hole already there ? I also wonder how I located the hole

[twhitaker]

The hole is already there on my '96 Cali with a 'vent - drain' screwed in.

[Mark West]

I also had the recall for my 01 Cal Special. Had a flaky local dealer order the parts but they never came. Did some reading then pulled my tank, examined the setup and concluded there was no way my throttle was going to catch on the airbox. The parts had so much clearance between them I figure something had to be installed incorrectly in order to have the problem that was described. Over the next 10 years and 50k+ miles, never had a hint of that issue.

I would look it over first and you may find it's a non-issue.

[twhitaker]

What he said. Even if it does hang up the kill switch is right next to the throttle.

[Rich A]

I'd install the second cable. I agree that the chances of any problems arising are slim, but in the 1 to 2 seconds it would take to react and hit the kill switch, you might have gone 50 or more ft.

Rich

[rodekyll]

I have identical throttles, one with a single cable and one with both.  Neither have given me any problems that I haven't inflicted on myself.  I keep a spare cable threaded up beside the connected ones for quick change on the road.  Never had to use them though.  The one time I did need to use one, the spare I'd routed was for the fast idle cam.  For the record, it doesn't have the proper end for the TB side bellcrank.     It does work to pull the proper cable through the same route.   

[pat80flh]

http://archive.guzzitech.com/Files/ThrottleRecall.pdf

[pat80flh]

If I had to guess, They are talking about the throttle body assembly moving rearward due to "refusal phenomenon",  ie, backfire?  And then interfering with the air box.

[Chuck in Indiana]

If I had to guess, They are talking about the throttle body assembly moving rearward due to "refusal phenomenon",  ie, backfire?  And then interfering with the air box.

That's exactly what happens. Instead of being bolted to a proper bracket, the only thing locating the injector assemblies are the clamps and intake rubbers. A good lean sneeze or backfire can move the injector assemblies aft, fouling the balance rod on the air box. An engineering faux pas to be sure. The dual cables are a band aid instead of designing a proper mount.

[pehayes]

 :1: on the backfire causing the entire mechanism to move aft and thence jam the throttle.  I defy you to hit the kill switch when your throttle sticks WFO and you're heading toward a cliff or wall.  You're going to focus on braking.  How many people got whacked by 'sudden acceleration' Toyotas when all they had to do was press and hold the start button for 5 seconds?  Add the cable.  The tap is for the hole in the throttle handle mechanism.  Check further.  I just checked the NHTSA recall site and the issue is still posted.  However, I also dug into the FAQ area and found this:

"Are there any limitations on my right to have a recalled vehicle remedied at no charge?
Yes. There is a limitation based on the age of the vehicle. In order to be eligible for a free remedy, the vehicle cannot be more than 10 years old on the date the defect or noncompliance is determined. Under the law, the age of the vehicle is calculated from the date of sale to the first purchaser."

So, you need the cable and it will be on your dime.  There are plenty of old, wrecked, parted out EV's and Bassas around.  Surely you can buy a used cable from one of them.  The documents included in the NHTSA report also include the instructions for installation and the dimensions of the required tap.

Patrick Hayes
Fremont CA

[pat80flh]

The link I posted above has the instructions complete with pictures. I've got to change my cable anyway, just came in the mail yesterday. I'll put it on the list; " things I'd like to do this winter but will wait for spring because I'm lazy and the garage is cold". I need to sort out handlebars, I had changed them to suit the girl, but it doesn't look like she'll ever fit this bike. The stock bars are a bit too wide for my taste.
   Theoretically, I'm not sure a return cable would do a lot of good if the throttle body partially blew out of the seal, I think the resulting vacuum leak would cause a pretty high idle itself. Of course if the throttle is stuck open,the TPS would be telling the computer to dump fuel in it, not a good scenario anyway you look at it. 
    Safety wire? tether of some kind?
    Dang new-fangled stuff. I've managed to get by all these years without dual cable throttles, sidestand switches, and the like. But thinking worst case........

[pehayes]

   Theoretically, I'm not sure a return cable would do a lot of good if the throttle body partially blew out of the seal, I think the resulting vacuum leak would cause a pretty high idle itself. Of course if the throttle is stuck open,the TPS would be telling the computer to dump fuel in it, not a good scenario anyway you look at it. 

The throttle bodies are attached to the head via a short, rubber tubing intake manifold.  The rubber is attached to the head via hose clamp and similarly to the throttle body via hose clamp.  If those clamps were seriously tight, I doubt you could replicate this problem.  However, if not quite so tight, an internal backfire inside the manifold will balloon the rubber thinning its walls and easing whatever clamp pressure is available.  Then the entire throttle body moves aft and the cross linkage is at risk of abuting the face of the air box.  The one original cable is "pull open" only.  Even the slightest bit of contact binding will prevent the throttle from closing.  Back off the hand throttle and the cable just goes limp.  The second cable is in place to "pull closed" so that, regardless of binding contact, you have some chance to pull back past the bind point and close the throttle.

Here's what pisses me off.  Both the hand throttle and the lower mechanism were originally fabricated to allow for both "pull open" and "pull closed" cables.  I don't think Guzzi fabricated those parts.  They were commodity pieces sourced from some other manufacturer.   Every Japanese bike of this era has dual cables.  Whoever designed the original hand throttle and linkage pieces surely intended a dual cable installation.  Guzzi specifically excluded the second cable to save a few bucks.  They never anticipated the internal backfire issue.  Cheap bastards!

Patrick Hayes
Fremont CA