Time to get serious - V7C engine out

[sign216]

Nice photos.  Interesting about the black paint.  I guess it serves a purpose. 

[Muzz]

When I have to do something with the gears, it will be a lot less daunting. Come to think of it, the 1100 Sport's clutch slips a little & it has that fifth gear whine ......

You're a tiger for punishment!

Funny that they paint the inside of the box on the later models when they never used to.

edit; Bondhus stuff is pretty good. It was the only brand I was allowed to stock in the retail side of the engineering place I worked at. The owners reasoning was that the apprentices were not tempted to go cheap and nasty when the bought hex keys. They wear quick and tend to chew out what they were used on.

[malik]

.........  Interesting about the black paint.  I guess it serves a purpose.

I have noticed  a lot less aluminium corrosion, or I haven't noticed any corrosion, or significant discolouration, of the motor, unlike some other unpainted engines. Probably a bit of a help in those places that like to salt their roads. Maybe the inside coat is in fear of what chemicals are "they" going to add to oils next week? Whatever, it works.

Productive day - clutch on - new sprung plate  (or whatever the italians call it - don't think I've found it called the same thing twice), new clutch disc, cup, rod & thrust bearing. The whole back half is now buttoned up to the engine. Move the frame back on it tomorrow.

[SmithSwede]

Thanks again for this.  I love these threads and study them obsessively, no doubt hoping that one day my future self will have the courage to do similar work on my high-mileage Stone. 

Please don't hesitate to post more pictures, pictures of the tools, links to other sources of info, etc.  you have an audience here!

[Muzz]

I did a slightly different take on the "clutch" tool I made. I found a short piece of pipe offcut (cheap = Guzzi content) that happened to be just the right size and welded the clutch centre on to that, then welded a bit of flat on to the other end and bolted the handle on to that. Just meant that I did not put a crank in that particular handle and the business end could be easily shipped somewhere if someone else needed it.

[malik]

That was thinking ahead. Well done.

A few shots from yesterday:-

the sprung plate before torque



The "slot" (I'd call it a notch) on the "engine flywheel" on the sprung plate/driven plate that the chain ring aligns to. Yes, I had trouble too - it's in the middle of the photo at the edge of one of the plates.



the sanded chain ring



the mounted clutch



pushrod & gubbins in, all set to go



And joined. (That's the holed Nevada in the background - its frame is destined for the Breva).

[Muzz]

Lookin' good Mal. The black c/case & gearbox look good. Mine of course is the silver paint.

[malik]

Very frustrating day yesterday! Mating the frame to the engine block, all went well until we got to the throttle body manifolds! Haven't been able to get the airbox manifolds on. Pushed, shoved, help & poked, sqeezed & swore. Nothing doing. A little rubber grease on the lip of the airbox manifolds enabled them to be pushed into the airbox past the big concertina. Found the trick in getting the throttle bodies to line up to the inlet manifolds - put on the small rubbers on the metal inlet ports - lower the throotle body assembly to the block, putting the rod under the overhang of the airbox and come up from the bottom  (otherwise the throttle bodies appear to overhang the manifolds by a good inch or 2). But try as we might, we can't deform the rubber on those airbox manilds enough to get the big concertina out of the airbox & onto the lip.

So we gave up. Decided to leave it for Ron (Later on) & proceeded to do stuff we could. You CAN get the neutral light sender clip over its contact. You CAN get the blade connector onto the oil pressure sensor, but you do need two sets of hands working from each side of the bike, and long fingers. And patience.

Clutch is connected & adjusted. Gearshift linkage is connected to its spline (Just re-read some stuff and may have missed the thrust washer). The swing arm is now on, but not tightened up - I thought there should have been instructions on this - and found them last night.

So at least we have some progress. But the manifolds await.

[malik]

The saga continues.

You may be familiar with the problems had with the rubber manifolds (http://wildguzzi.com/forum/index.php?topic=82444.0), that was solved. Well, from there the bike went back together pretty swiftly & was ready to ride Friday. OoPs, difficult to get into third gear. That wasn't right. Tinkered a bit & attended to cosmetics on Saturday. While adjusting the gearshift linkage, I saw the the selector shaft that pokes out of the gearbox had play in it - moved up & down with the gear lever. That didn't look right at all. Sought advice on Sunday, found that adjusting the eccentric cam could tighten it up a little, but still not rigid enough. Something wrong in there. "Did you move up & down through the gears before you bolted it back onto the engine?"" I didn't know you could, or how to do it". Though it now seems obvious.

So  later Sunday afternoon, it looked like this







Today, we get to use the special tools again & find out what we did wrong - "who is this WE, Kemo Sabe?".

At least we are getting a lot quicker at taking down the bike - an afternoon, instead of three days. Augurs well for the future projects.

[Muzz]

"Did you move up & down through the gears before you bolted it back onto the engine?"" I didn't know you could, or how to do it". Though it now seems obvious.

That is actually quite difficult to do. Spring is quite strong. I tried before I threw mine together but could not do it reliably.

Not quite sure how you could get movement on the shaft by doing something wrong.

[malik]

Thought I'd take a short-cut, there's an unused gearbox in the holed Nevada, isn't there. And all the gears worked at standstill. So yesterday we stripped the Nevada, cleaned the gearbox, then tried shifting the gears - not much resistance & hard to isolate the gear changes, BUT spinning the shaft produced strange noises & notchy feelings. Feels like the bearings are suspect. Will try to get an expect opinion, but not looking good. So much for short-cuts. It seemed a decent idea at the time. The written off Breva may have been a better choice - at least it runs OK.

[Muzz]

I seem to remember that there are three bearings in the box that are not particularly standard, though two of them were not hard to find. the one that 5th gear runs on is a particular Guzzi one; held me up for a year trying to locate it. Everyone was out, and Guzzi refused to even sell Pete R. one! Work that out! The rest of them are run-of-the-mill.

[malik]

Going to take a raincheck on examining the insides of the suspect gearboxes -



now that the gearbox borrowed from the Breva (2007 model with 23.000km) is installed (but not yet tested).

After a couple of frustrating days putting the V7C back together - this time things did not go as smoothly as last time - we are almost there



Another frustrating annoyance - put the rear wheel back on, and found the rear brake would no longer work! Worked fine a couple of days ago. Flushed the fluid, replacing it with new & still not working if the caliper is mounted. Works while disconnected though, but not while on the rotor. A mystery! The only explanation I can come up with at present is that perhaps the rotor is too worn? More investigation is required.

An observation: the Breva bits were surprisingly clean & shiny. The drive shaft was pristine - unlike those in the V7C, the Nevada or the V7S. O the Breva, the gap in the spring that holds on the rubber boot over the uni joint on the swingarm was positioned at 12 o'clock, rather than at 4 or 8 o'clock. Perhaps that makes a difference. Or maybe the Breva never saw rain or wet roads.

The plan today is to solve the rear brake mystery, change the oils & try out the new gearbox.

[malik]

Adjusted the clearance on the brake rod to the master cylinder, cleaned up the caliper, pistons & pin, and voila! She works. Fitted the remaining muffler changed the oils.

The Breva gearbox doesn't look out of place



Took it for a ride around the block - all OK. Rode it home - all OK.



Yesterday took it out for a 240k test ride. Nothing fell off. The neutral light occasionally dims & cuts out, only to return. It did that before - may be a poor connection in the wirining. The accessory power take off at the front doesn't work, but when I tidied up the accessory wiring with a Termin8 from Powerlet, I didn't check out that circuit. The clutch is working well, the gearbox is fine - the linkage less sloppy as I've upgraded the standard studded rod end, to modern plan rod ends. A real pleasure to ride.

Some tweaking to do before setting off on the trip (proposed for a Thursday departure); suspension sag, handlebar & footpeg position, check that the heated glove liners work, that sort of thing. I don't think the metal tank conversion will be sorted in time - in at the painters at present, but a fuel pump has yet to be sourced.

It's been a great experience, couldn't have done it without the assistance of sterling friends (and a relative, cuz). And I'd do it again.

[Muzz]

I love it when a plan comes together.

Fine effort Mal. Enjoy your trip.