Guzzi Hydro . . . doing the recall myself

[Dnaj]

OK, Got this 2003 Guzzi Aluminum. Nice folks here sold me the parts kit and lent me the tools to do the recall! Thank you. My Guzzi dealer did the steering recall check but Piaggio said, see ya, on the hydro valves. Read through the instructions. Doesn't look horrible but the local dealer quoted 15 hours, at my cost, so I said, see ya. Now starting at home and sharing my experience. Here goes!

Sump is off. The interior is coated with a film of grey gunk, which is probably ground up cam. I cleaned it in the parts cleaner then dumped the pan in the ultrasonic. There were definitely some metal fragments, particularly around the oil valve in the sump.

Someone was inside there before. (This bike had only 1250 documented miles). One sump bolt was missing a washer and another had an extra lock washer. and STP oil filter was inside. Also found an extra washer inside the sump. I'm guessing it was the missing sump pan washer and sure looks it, but there are two similar washers inside the oil pressure relief valve, look to be designed to seat the internal spring. Doubt it needs more then two so am I correct to assume, maybe the guy dumped all is pan bolts in the pan and lost one of the washers in the pan?



The oil pressure valve inside, gee the case is machined raggedly. Is this normal? The unit was really really tight! I needed a breaker bar to remove it from the pan.



My rectifier says "DUCATI" and had electrical tape over the bullet connectors. Is this normal?

Next I am to remove both ignition coils. Is there removal simple as the two mounting bolts or must I remove the whole mounting plate?

[guzzisteve]

What you found is the norm from what I have found. Normal on regulator wiring. Take off coil either way.

[Muzz]

Wayne Orwig may be the man to help you in your efforts, runs a very well sorted hydro.

[Dnaj]

What you found is the norm from what I have found. Normal on regulator wiring. Take off coil either way.

Ok, thanks! I'll keep going!

[Wayne Orwig]

The two bullet connectors on the rectifier/regulator are a common point of failure. Keep them clean and tight. Also make sure the regulator is grounded VERY well.

The oil pressure relief valve that you have disassembled MUST have the exact same washer stack put back in it to keep the oil pressure regulated properly. Or you need a jig to recalibrate it. Yes, the shroud over the relief valve is a simple stamped metal affair. I believe Loctite is recommended on this.

When you have the front off to pull out the old cam, also pull and inspect the oil pump. If you see metal bits in the regulator, it has been through the pump.

I can't recall if or why the coils need to come off. Maybe they do, but I can't think why. Maybe they interfere with the top cam chain cover. There are tiny nuts in the back of those long screws through the coils. Maybe lock washer too if I recall.

[stick]

If you pull the coils, be sure to straighten out the speedo cable.  On the V11 Lemans, it takes a crazy "S" bend under there.  No need for the bend, other than to wear out the cable.

Also give a good look at the breather hose that comes up off the block, in the vee, near the bell housing (and up to the bottom of the spine frame).  Make sure this bugger looks healthy.  If it looks cracked at all, get a replacement.  Hate to have you go in there twice!  MG Cycles sells an aftermarket one.

Stick

[Wayne Orwig]

Most hydraulic lifter bikes have a new style breather hose.

From the photo above it appears that it has the old style breather hose. The new style one would be in front of the right cylinder in that photo.

Also give a good look at the breather hose that comes up off the block, in the vee, near the bell housing (and up to the bottom of the spine frame).  Make sure this bugger looks healthy.  If it looks cracked at all, get a replacement.  Hate to have you go in there twice!  MG Cycles sells an aftermarket one.

[Dnaj]

Well yes, Ive got no breather hose where the instructions say it should be, so I guess I just skip that part, unless Im missing something.


Looks like someone was in the rotor cover, one bolt was missing. Rotor came off fine. Next question. How do I pull the stator off without damaging it?


Still going! Thanks all!

[Chuck in Indiana]

It should pop right off, it's not a taper shaft or anything. Just a little leverage behind it? Once it comes off, store the rotor and stator together. It can lose it's magic ju ju if you don't.

[Wayne Orwig]

It should pop right off, it's not a taper shaft or anything. Just a little leverage behind it? Once it comes off, store the rotor and stator together. It can lose it's magic ju ju if you don't.

Plus a bunch on this....


When reinstalling, make sure you route the wire so it does not get damaged.... I had a shop damage a couple of them that I had to repair.